Owner's Manual 2006

OWNER’S MANUAL 2006

125 SX, EXC 200 EXC, XC, XC-W 250 SX, EXC, XC, XC-W 300 EXC, XC, XC-W ART. NR. 3.211.72EN ENGLISH

KTM Group Partner

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at IMPORTANT b theuseofvehicleaftersuchdeviceorelementdesignhasbeenremovedrendered inopera- (b) Theremoval orrenderinginoperativebyanypersonotherthanforpurposesofmaintenance,repair (a) Owners arewarnedthatthelawmayprohibit: Tampering withnoisecontrolsystemprohibited COMSUMER INFORMATION FORAUSTRALIAONLY please payparticularattentiontonoticesthataremarkedasfollows: of informationandadvicewhichwillhelpyouusehandleyourbikeproperly. Inyourowninterest, Please readthismanualcarefullyandcompletelybeforegoingonyourfirstride.Itcontainsagreatdeal extracts, withwrittenallowance ofKTM-SPORTMOTORCYCLE AG,Mattighofenonly. © 2004byKTM-SPORTMOTORCYCLE AG,MattighofenAUSTRIA;Allrightsreserved; Reprint,alsoin partly containextraequipment, whichisnotappliedtostandardmodels. ity and/orabilitytodeliver, illustrations,descriptions, printingand/orothererrors.Theillustratedmodels ing certainmodelswithoutprevious notice.KTMshallnotbeheldliableforanydeviations ofavailabil- above items,allwithoutprevious announcementandwithoutgivingreasons.KTMmaystop manufactur- constructions, equipmentandthelikesoastoadaptthem tolocalconditionsorcancelanyofthe to modifyanyequipment,technicalspecifications,prices,colors, shapes,materials,services,servicework, All informationcontainediswithoutobligation.KTM-Sportmotorcycle AGparticularlyreservestheright Stamp ofdealer Key number Engine number Frame number Please inserttheserialnumbersofyourmotorcycleinboxesbelow tive byanyperson. noise controlpriortoitssaleordeliverytheultimatepurchaser orwhileitisinuse;and replacement, ofanydeviceorelementdesignincorporated intoanynewvehicleforthepurposeof IGNORINGTHESEINSTRUCTIONSMAY DAMAGEPARTS OFTHEMOTORCYCLEORIMPAIR THEMOTOR- – IGNORINGTHESEINSTRUCTIONSCANBEDANGEROUSTOLIFEANDLIMB! – CYCLE’S TRAFFICSAFETY! »

1 ENGLISH Before you go for your first ride, be sure Before you go for your At the time this manual was typeset, it was up-to-date with the latest state of was typeset, it was up-to-date with At the time this manual » Attachments: Spare parts manual chassis & engine KTM-SPORTMOTORCYCLE AG KTM-SPORTMOTORCYCLE AUSTRIA 5230 MATTIGHOFEN, this production series. It cannot be completely ruled out, however, that minor discrepancies may exist It cannot be completely ruled out, however, this production series. manual is an important part of your motor- design upgrades of these motorcycles.This resulting from further you decide to sell it. passed on to any subsequent owner in case bike and should be work on the chas- expressly point out that work marked with an asterisk in the chapter "Maintenance We KTM workshop. If maintenance work should become necessary sis and engine" must be performed by a by a trained mechanic. during a competition, it must be performed KTM is not liable for damage that parts and accessories only. use KTM-approved For your own safety, products. arises in connection with the use of other intervals. Heeding special care to follow the recommended run in, inspection, and maintenance Take the life of your motorcycle. Have services carried out by a KTM these guidelines will significantly increase intact. dealer so that your warranty claim remains sport and we hope that you will be able to enjoy it to the full. Off-road motorcycle driving is a wonderful for the environment or lead to conflicts with others. These involve potential problems however, It may, safeguard the future of To the motorcycle is used responsibly. problems or conflicts can be avoided if show that you are the motorcycle in accordance with the law, motorcycle sports, make sure that you use rights of others. environmentally conscious and respect the wish you a lot of fun when driving ! We We would like to congratulate you on your purchase of a KTM motorcycle. of a KTM motorcycle. you on your purchase like to congratulate would We to bring you lots of fun and state-of-the-art sports motorcycle that guarantees are now the owner of a You that you clean and maintain it appropriately. enjoyment, provided new yourself with how to operate your carefully and thoroughly in order to familiarize to read this manual your that you will have to dedicate some of its characteristics, even if this means motorcycle and with how to tune your motorbike to your specific task. Only by doing so will you learn valuable time to this on this manual contains important information Besides, yourself against injury. needs and how to protect motorcycle maintenance. INTRODUCTION INTRODUCTION

ENGLISH 2 IMPORTANT WARRANTYANDGUARANTEEINFORMATION not on publicroads. this performancerestriction(i.e.dethrottled),thesemodelsareonlyallowedtobedrivenoff-roadbutnot The EXCmodelsareonlyallowedonpublicroadsintheoriginalhomologated(throttled)version. THE SX/SXSANDXCMODELSAREPROHIBITEDONPUBLICROADS. schedule hasbeenreached. become necessarytoserviceorreplacewearpartsbeforethelimitspecifiedinmaintenance to higherthanaveragewearoncomponentssuchasthedrivetrainorbrakes.Inthiscaseitmay The useofthemotorcycleunderextremeconditions,e.g.onextremelymuddyandwetterrain,canlead or conversionstothemotorcycle. No claimscanbefiledunderthewarrantyfordamageorconsequentialcausedbymanipulations tions mustbeusedinaccordancewiththemaintenanceschedule. The fuelsandlubricantsspecifiedintheOwner'sManualorautomotivefluidswithequivalentspecifica- workshop andrecordedintheservicemanualotherwiseclaimsunderwarrantyshallbecomevoid. The serviceworkspecifiedinthe"LubricationandMaintenanceSchedule"mustbeperformedbyaKTM checking thebasicchassissetting). improperly tunedchassiscanleadtodamageandbreakageofthecomponents(seechapteron the Owner'sManualisaprerequisiteforfaultlessoperationandavoidanceofprematurewear. An Observance oftheservice,maintenanceandtuninginstructionsforenginechassisspecifiedin tional motorcycleassociations. The motorcyclescomplywiththeregulationsandcategoriescurrentlyineffectleadinginterna- competitions. KTM sportsmotorcyclesaredesignedandconstructedtoresisttheusualweartearofnormalusein Ask yourKTMdealerformoreinformation. on publicroadsandmustbeadaptedtotheseoperatingconditions. public roadstoacertainextent.Theengineissubjectedcompletelydifferentperformancedemands KTM EXCandXC-Wmodelsweredesignedforoffroaduseonlyaresuitablelongerrideson 2-STROKE OFFROADMOTORCYCLESONPUBLICROADS suitable forpredominantmotocrossuse. The EXCmodelsaredesignedforoff-roadsportsendurancecompetitions(enduro)and quality assuranceprocessesthatleadtothehighestpossible productquality. In accordancewiththeinternationalqualitymanagementISO 9001standard,KTMuses » Without

3 ENGLISH Page Checking and adjusting the steering head bearingand adjusting the steering Checking .29 . . position the handlebar How to change ...... 30 ...... tensionCheck chain . . . . .30 ...... tensionCorrect chain ...... 31 ...... Chain maintenance ...... 31 ...... Chain wear.31 ...... about KTM disc brakesGeneral information ...... 32 at the hand brake leverAdjusting the free travel . . .33 . . fluid level - front brakeChecking the brake ...... 33 fluid reservoirRefilling the front brake ...... 33 . padsChecking the front brake ...... 33 brake padsReplacing the front ...... 34 position of the foot brake pedalChanging the basic . .34 fluid levelChecking the rear brake ...... 34 fluid reservoirRefilling the rear brake ...... 34 Checking the rear brake pads ...... 35 Replacing the rear brake pads ...... 35 . . . Dismounting and mounting the front wheel ...... 35 Dismounting and mounting the rear wheel ...... 36 air pressureTires, ...... 37 Checking spoke tension ...... 37 . Replacing the battery of the digital speedometer . . . .37 Check/set distance of the magnetic sensor ...... 38 lampReplacing the headlight lamp/parking light . . . .38 Cooling system ...... 39 ...... Radiator cover for the cold season ...... 39 Checking the coolant level . .39 ...... Refilling/Bleeding the cooling system ...... 40 Cleaning the air filter ...... 40 Checking the oil level of the hydraulic clutch . .41 . . . . . Exhaust system ...... 41 leverChanging the original position of the clutch . . . .41 Bleeding the hydraulic clutch ...... 42 Carburetor adjustment ...... 43 Draining the float chamber of the carburetor ...... 44 Checking the float level ...... 44 Engine characteristic 250/300 SX/XC/EXC ...... 45 Check transmission oil level (125/200) ...... 46 Changing the transmission oil (125/200) ...... 46 Check transmission oil level (250/300) ...... 46 Changing the transmission oil (250/300) ...... 46 CLEANING ...... 47 ...... 47 FOR WINTER OPERATION CONSERVATION STORAGE ...... 47 / 200 – CHASSIS 125 . . .48 TECHNICAL SPECIFICATIONS / 200 – ENGINE 125 TECHNICAL SPECIFICATIONS . . .50 / 300 – CHASSIS 250 . . .52 TECHNICAL SPECIFICATIONS / 300 – ENGINE 250 TECHNICAL SPECIFICATIONS . . .54 INDEX . . . .56 ...... WIRING DIAGRAM, CARBURETOR TABLE . . . . .APPENDIX Page . .24 » Pivot bearing ...... 24 Basic suspension setup for the weight of the driver . . .25 Checking the shock absorber and spring ...... 25 Determining the static sag of the shock absorber . . . .25 Determining the riding sag of the shock absorber . . . .25 Changing the spring preload on the telescopic fork . . .26 Checking the basic setup of the telescopic fork . . . . .26 Replacing fork springs . . .27 ...... Breather plug front fork ...... 27 Cleaning the dust sleeves of the telescopic fork . . . . .27 Changing the fork offset (caster) (SX / XC) ...... 28 Changing the spring preloading of the shock absorber What you should check before each start ...... 17 Starting when the engine is cold ...... 18 Starting when the engine is warm ...... 18 What to do when the engine is „flooded“ ...... 18 Starting off ...... 18 Shifting/Riding ...... 18 Braking ...... 19 Stopping and parking ...... 19 Refueling, fuel ...... 19 ...... Instructions for your first ride ...... 16 Running in...... 16 ...... Clutch lever ...... 5 ...... Hand brake lever ...... 5 . . . Electronic speedometer...... 6 . . . . Indicator lamps (EXC). . . .10 ...... (SX)Short circuit button ...... 11 . . . . (EXC)Combination switch ...... 11 ...... Headlamp switch (XC-W)...... 11 ...... Flasher switch...... 11 . . . . (Australia)Emergency OFF switch ...... 11 . . . . Filler cap ...... 12 ...... Filler cap (XC, XC-W) ...... 12 ...... Fuel tap...... 12 ...... Choke knob ...... 12 Shift lever ...... 12 Kickstarter ...... 13 Foot brake pedal ...... 13 Side stand ...... 13 Steering lock ...... 13 Compression damping of fork ...... 14 Rebound damping of fork...... 14 ...... Damping action during compression of shock absorber (SX) ...... 14 EXC) (XC-W, Compression damping of shock absorber .15 EXC) .15 XC-W, Rebound damping of shock absorber (SX, Chassis number...... 5 ...... engine type Engine number, .5 ...... TABLE OF CONTENTS CONTENTS OF TABLE MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .24 PERIODIC MAINTENANCE SCHEDULE ...... 20 DRIVING INSTRUCTIONS ...... 17 GENERAL TIPS AND WARNINGS FOR STARTING THE FOR STARTING GENERAL TIPS AND WARNINGS MOTORCYCLE. . . . .16 ...... OPERATION INSTRUMENTSOPERATION ...... 5 . . . SERIAL NUMBER LOCATIONSSERIAL NUMBER ...... 5 ......

ENGLISH 4 OPERATION INSTRUMENTS SERIAL NUMBERLOCATIONS 1 A B 2 » » engine belowthesprocket.Enterthisnumberonpage1. The enginenumberandthetypearestampedintoleftsideof Engine number,enginetype Enter thisnumberinthefieldonpageno1. The chassisnumberisstampedontherightsideofsteeringheadtube. Chassis number The handbrakelever Hand brakelever The clutchlever Clutch lever ates thefrontwheelbrake.Theadjustingscrew ing screw The clutchishydraulicallyactuatedandadjustsitselfautomatically. maintenance workonchassisandengine). and engine). the basicpositionofhandbrakelever(seemaintenance workonchassis [A] is usedtochangetheoriginalpositionofclutchlever(see [1] is locatedontheleftsideofhandlebars.Theadjust- [2] is mountedonthehandlebarsrightandactu- [B] can beusedtochange

5 ENGLISH (odometer) (service hours) button changes to the next display mode | buttons are used to control various functions. buttons are used to – button 3 secs. changes to the next display mode button is used to change between display modes. display modes. to change between button is used and | (wheel size) | + button no function button no function The SPEED/ODO mode displays the speed and the total distance traveled. The display automatically changes to the SPEED/H display mode when the front wheel stops turning. + – briefly press The display changes and the circumference of the front wheel is briefly dis- The display changes and the circumference to a front wheel circumference played in millimeters (2205 mm corresponds of 21" with production tires). previous display mode. Afterwards the display will return to the SPEED display mode / H Only the SPEED / H and SPEED / ODO display modes are activated in the SPEED/H is displayed whenever the display is activated condition at delivery. and the front wheel is not turning. It automatically changes to the SPEED/ODO display mode as soon as the front wheel starts turning. SPEED displays the speed. H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motorcycles, making the service hour counter a very practical function. SPEED / ODO display mode The display in the electronic speedometer is activated as soon as you press as soon as you is activated in the electronic speedometer The display sen- from the wheel or an impulse is received the speedometer a button on is running. lights up when the engine The display sor. is 1 minute or no impulse is pressed for is cleared if no button The display the wheel sensor. received from The The TEST test. briefly light up for the display function All of the display segments WS Electronic speedometer Electronic The electronic speedometer has a number of display modes (functions) that you can also activate (reveal) (see: Activating and deactivating display modes). hold » OPERATION INSTRUMENTS INSTRUMENTS OPERATION

ENGLISH 6 OPERATION INSTRUMENTS » SPEED/TR1, SPEED/TR2,SPEED/A1,SPEED/A2,SPEED/S1,SPEED/S2 maximumspeed SPEED/H, SPEED/CLK,SPEED/LAP, LAP/LAP, SPEED/MAX,SPEED/ODO, laptime following order: displayinkilometersormiles(see:Kilometersmiles) clock If youhaveactivatedallofthedisplaymodes,theywillbedisplayedin stopwatch2 stopwatch1 KMH/MPH averagespeed2 MAX averagespeed 1 LAP tripmaster2 CLK tripmaster1 S2 S1 A2 A1 TR2 TR1 The followingdisplaymodescanbeactivated: hold briefly press – + cally andthedisplaywillreturntoSPEED/Hmode. If nobuttonispressedfor20seconds,thesettingwillbestoredautomati- Press andholdthe briefly press – pressing the In thedisplaymodeSPEED/H,pressandhold Activating anddeactivatingdisplaymodes + LAP displaysthelaptimesinhours,minutesandseconds. which youcanviewintheLAP/LAPdisplaymode(seebelow). You canusethemanualstopwatchtoandstoreup10laptimes, SPEED /LAP briefly press – + CLK displaysthetimeinhours,minutesandseconds. SPEED /CLK ing functioncanbeactivatedbypressingthe access theSETUPmenu.Theactivefunctionswillbedisplayed.blink- hold hold To settheclock, see„Settingtheclock“. utndeactivatestheblinkingdisplay button button utnnofunction button utnactivatestheblinkingdisplay button utnStartsandstopsthestop watch,laptimeisnot button nofunction button | | | utn3sc.startstheSETUP button 3secs. utn3sc.Clears allLAP figures button 3 secs. utn3sc.settheclockmenu button 3secs. | | | – button. (lap time) (time) utnchangestothenextdisplaywithoutchangingany button utnChangestothenextdisplay mode.Ifnolaptimeis button utnchangestothenextdisplaymode button | button 3secondstostorethesettings. display mode mode stores thesettingsandchangestoSPEED/H settings in thisway. SPEED/LAP mode.Upto10lap timescanbestored lap times,holdthe ory locationsareoccupied.To clearallofthe stored tinues torunafteryoupressthe -button,all10mem- of 10laptimescanbestored. Ifthelaptimecon- the stopwatchagain.Thetimeisresetto0.Atotal Stops thestopwatch,storeslaptimeandrestarts reset to0 mode willbeskipped. stored orthemotorcycle isdriving,theLAP/LAP display mode | + button for3secondsinthe button anddeactivatedby | button for3secondsto

7 ENGLISH button to access + buttons. This is a very use- button for 3 seconds in the button for – | and + (maximum speed) (maximum speed) (tripmaster 2) (tripmaster 1) (average speed 1) (to view lap times) (to view button changes to the next display mode button mode changes to the next display button changes to the next display mode button the next display mode changes to button changes to the next display mode | | | | | button 3 secs. clears the TR1, S1, A1 figures button 3 secs. clears the MAX figure button 3 secs. clears the TR1, S1, A1 figures button 3 secs. display mode changes to the next button 3 secs. clears the TR2 figure | | | | | button no function button no function button no function button time to the next lap changes button increases the TR2 figure button no function button no function button no function button no function button decreases the TR2 figure A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (stop watch 1) figures. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received. + – briefly press SPEED / TR2 display mode The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the displayed figure can be changed using the SPEED / A1 display mode The LAP/LAP display mode will only be shown if lap times have been stored times have been only be shown if lap display mode will The LAP/LAP the the lap number and It will display wheel has stopped. and the front the and seconds. Press time in hours, minutes stopped lap time. the next lap hold the the stored lap times, clear all of To mode SPEED / MAX display speed traveled and is always active. MAX displays the maximum + – briefly press SPEED / TR1 display mode counts to 999.9. It is used to meas- The TR1 tripmaster is always active and 2 refueling stops. ure the length of a trip or the distance between calculation of these figures is acti- TR1 is linked to A1 (average speed 1). The wheel sensor (when the front wheel vated by the first impulse received from the the last impulse is received (when starts to turn) and stops 3 seconds after the front wheel has stopped). cleared after passing 999.9. The TR1, A1 and S1 figures are automatically + – briefly press LAP / LAP display mode LAP / LAP mode. SPEED/LAP + – briefly press hold hold hold hold ful function for trips taken according to a roadbook. + – briefly press hold » OPERATION INSTRUMENTS INSTRUMENTS OPERATION

ENGLISH 8 OPERATION INSTRUMENTS » hold briefly press – + to theSPEED/S2modeandpress the othermodesifS2continuestoruninbackground.To stopS2,return hold hold briefly press – SPEED /S2displaymode briefly press – + onds afterthelastimpulseisreceived. vated bythefirstimpulsereceivedfromwheelsensorandstops3sec- receives impulsesfromthewheelsensor. Thecalculationofthisfigureisacti- S1 showsthetravelingtimebasedonTR1andcontinuestorunwheneverit SPEED /S1displaymode briefly press – + figure waschangedmanuallyorifS2notstoppedafterthetrip. The displayedfigurecandeviatefromtheactualaveragespeedifTR2 watch 2)figures. A2 showstheaveragespeedbasedonTR2(tripmaster2)andS2(stop SPEED /A2displaymode To selectthe unit,selecttheSPEED/Hmodeandhold will becleared. retained andconvertedaccordingly. TheTR1,A1,S1,TR2andA2figures The unit(kilometersormiles)canalsobechanged.ODOfigurewill Kilometers ormiles S2 isamanualstopwatch.Startthewatchbypressing + cally andthedisplaywillreturntoSPEED/Hmode. If nobuttonispressedfor20seconds,thesettingwillbe stored automati- play returnstotheSPEED/Hmode. To set,brieflypressthe function blinks.Pressthe Press the press againtohold.Presscontinuetiming. onds toaccesstheSETUPmenu.Press hold + utnnofunction button utntoactivatetheMPHdisplay button utnnofunction button nofunction button utnstartsandstopsthestopwatch button utnnofunction button nofunction button utntoaccessthemenu button button forKMHorthe | | | | utn3sc.clearstheS2figure button 3secs. utn3sc.storesandclosestheSETUPmenu button 3secs. utn3sc.clearstheTR1,S1,A1figures button 3secs. utn3sc.changestothenextdisplay mode button 3secs. | button tochangethenextmode.TheS2displaywillblinkin | | | | utnchangestothenextdisplaymode button utnchangestothenextmode button utnchangestothenextdisplaymode button utnchangestothenextdisplaymode button | – changes fromthemenutoSETUP to activatetheKMHdisplay + button forMPH. button 1xandholdfor3secondsuntilthedis- button brieflytomovetheoptions.Press (stop watch2) (stop watch1) (average speed2) + button. | button untiltheKMH/MPH | button for3sec- + button,

9 ENGLISH ty

button 3 secs. clears S2 clears TR2 clears MAX | next display mode next display mode next display mode clears TR1, S1, A1 clears TR1, S1, A1 clears TR1, S1, A1 clears all LAP figures hold setting the clock menu displays the SETUP menu button to move to the next digit. 0- move to the next digit. button to button | | flashes in the same rhythm as the lights up when the high beam is on. [1] [2] next display mode next display mode next display mode next display mode next display mode next display mode next display mode next display mode next display mode next display mode next display mode next display mode stores the time and changes to the SPEED/CLK dis- stores the time and changes play mode briefly press button for 3 seconds to store the settings. 3 seconds to store the button for | buttons. Press the buttons. Press button for 3 seconds. The blinking digits can be changed digits can be 3 seconds. The blinking button for – button to the next digit changes | | button and – + button 3 secs. starts the SETUP menu The green control lamp flashing indicator when the indicator is working. The blue control lamp | no function no function no function no function no function no function no function no function no function no function button time + button – time hold Indicator lamps (EXC) To set the clock, switch the ignition off and select the SPEED/CLK mode. Press off and select the SPEED/CLK switch the ignition set the clock, To and hold the Setting the clock Setting the using the in the 24-hour mode. mode, 0-24 the time in the 12-hour 12 will show hold the Press and stored automati- for 20 seconds, the settings will be If no button is pressed will return to the SPEED/CLK mode. cally and the display + – briefly press briefly press stops LAP, stores LAP stops LAP, figure, resets LAP to 0 reduces the TR2 figure » button + 1 OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS OVERVIEW OF THE ELECTRONIC SPEEDOMETER next figure no function no function no function no function no function no function no function no function starts - stops S2 clearing LAP figure briefly press starts/stops LAP without increases the TR2 figure display 2 LAP / LAP SPEED / H

SPEED / A2 SPEED / S1 SPEED / S2 SPEED / A1

SPEED / CLK SPEED / LAP SPEED / TR1 SPEED / TR2 SPEED / ODO SPEED / MAX Motorcycle is driving is Motorcycle

X X X X X X X X X X Motorcycle is standing standing is Motorcycle X X X X X X X X X X X If the CLK, LAP, MAX, TR1, TR2 A1, A2, S1 and S2 figures are suddenly cleared, the battery in the electronic speedometer is emp If the CLK, LAP, A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar. A tripmaster switch is available as an accessory that lets you control the electronic and must be replaced (see: Replacing the battery in the electronic speedometer). OPERATION INSTRUMENTS INSTRUMENTS OPERATION

ENGLISH 10 OPERATION INSTRUMENTS 3 5 C B A 1 2 4 » the ignitioncircuitisshort-circuited. Headlamp switch(XC-W) The redshortcircuitbutton You mayusebutton [C] [B] [A] The lightswitchhas2,respectively3positions. Combination switch(EXC) The shortcircuitbutton Short circuitbutton(SX) The emergencyOFFswitch Emergency OFFswitch(Australia) affecting thefunctionofremainingelectricalsystem. bike off-road,youcandismounttheentireturnindicatorsystemwithout The wireharnessisdesignedinawaythatwheneveryouwanttouseyour handlebar. The flasherswitchisaseparateunitandmountedontheleftportionof Flasher switch In thismodeltheheadlampisswitchedonwithpullswitch switch presseduntiltheenginestops. activated state. designed assafetyoremergencyOFFswitch,itshouldnormally notbeinits = Highbeamon = Lightoff(thisfunctionisnotavailableinallmodels) = Lowbeamon Flasher right Flasher left In thisposition,theignitioncircuit isenabled;theengineshouldstart. it willstallimmediately, ifitisatstandstill,willnotstart. In thisposition,theignitioncircuit isshorted;iftheenginerunning, [2] to actuatethehorn. [1] [5] turns offtheengine.Whenpressingthisbutton, [3] is locatednexttothethrottlegrip.Primarily serves toswitchofftheengine.Leave [4] .

11 ENGLISH counter-clockwise. ° fully towards the top, a bore is opened in [2] Turn the filler cap 45 Turn Put the filler cap on and turn it 45 ° clockwise. Put the filler cap on without kinks. [1] turn filler cap counter-clockwise. turn filler put filler cap back on and tighten it by turning it clockwise. Install it by turning it clockwise. back on and tighten put filler cap In this position the fuel tap is closed. No fuel can flow to the carbure- tap is closed. No fuel can flow to the In this position the fuel tor. that twist grip must be turned to ON. This means During operation the the twist grip in this position With the fuel can flow to the carburetor. is left. the tank will be emptied until only the reserve the rotating handle is turned The reserve tank cannot be tapped until as possible and remember to to the RES position. Fill the tank as soon position so that you will have turn the rotating handle back to the ON backup fuel next time, too. (0.32 USReserve of the 8.5 l tank ...... 1.3 l gallons) USReserve of the 10 l tank ...... 1.7 l (0.45 gallons) The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. Choke knob When pulling the choke knob Through this bore the engine can take in additional fuel. This the carburetor. results in a rich fuel-air mixture, that is needed for a cold start. the bore is closed When pressing the choke knob downward in the carburetor, again. Shift lever To open it: open To (XC, XC-W) Filler cap To open the filler cap: Fuel tap OFF ON RES Filler cap it: close To hose tank breather To close the filler cap: » RES 2 ON 1 1 OFF N 2,3,4,5, (6) XC EXC SX OPERATION INSTRUMENTS INSTRUMENTS OPERATION

ENGLISH 12 OPERATION INSTRUMENTS 1 » Side stand tion canbeadjustedtoyourseatposition(seemaintenancework). The footbrakepedalisdisposedinfrontoftherightrest.Itsbasicposi- Foot brakepedal be swivelled. The kickstarterismountedontheleftsideofengine.Itsupperpartcan Kickstarter DLEBAR TOTHELEFTKEYCOULDGETDAMAGED. NEVER LEAVE THEKEYINSERTED INTHESTEERINGLOCK.IFYOUTURNHAN- turn ittotheleft,pressin,tehright,andremoveit. head. To lock it,turnthehandlebarallwaytoright,insertkey, The handlebarcanbelockedbymeansofthelocklocatedonsteering Steering lock tion. Foroff-roadriding,youcanusetherubberband cycle. Makesurethatyouputyourbikeonsolidgroundandinasecureposi- Push thesidestandtogroundwithyourfootandloaditmotor- the centerstandinitsfolded-upposition. [1] to additionallysecure

13 ENGLISH . [1] , damping of the the degree of [3] CONNECTION (24MM). [6] to the limit in a counterclockwise direction to the limit in a clockwise direction using a [5] [4] clockwise to increase damping, turn it counterclockwise to increase damping, clockwise [2] using a box wrench. in a clockwise direction. screwdriver . absorber in a counterclockwise direction. – screw clockwise as far as it will go turn adjusting – by as many clicks as are specified for the relevant type of fork turn it back – Unscrew the respective number of turns for the specific type of shock absorber – as far as it will go turn adjusting screw clockwise – fork as are specified for the relevant type of turn it back by as many clicks – screw the adjusting Turn – type of shock Unscrew the respective number of clicks for the specific – screw the adjusting Turn rebound can be adjusted. Turn the knob clockwise to increase damping, turn the knob clockwise to increase damping, Turn rebound can be adjusted. rebounding. it counterclockwise to reduce damping during ADJUSTMENT: STANDARD WP Suspension 14187B01 Typ . . . . .20 clicks WP Suspension 14187B02 Typ . . . . .21 clicks WP Suspension 14187B03 Typ . . . . .20 clicks WP Suspension 14187B04 Typ . . . . .21 clicks Typ WP Suspension 12187B01Typ turns . . . . .2.5 WP Suspension 12187B03Typ turns . . . . .2.5 to reduce damping during compression. to reduce ADJUSTMENT: STANDARD WP Suspension 14187B01Typ . . . . .18 clicks WP Suspension 14187B02Typ . . . . .20 clicks WP Suspension 14187B03Typ . . . . .18 clicks WP Suspension 14187B04Typ . . . . .20 clicks THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRES- OR TO DO THE SHOCK ABSORBER APART TO TAKE SION NITROGEN. NEVER TRY SEVERE INJURIES COULD BE THE RESULT. ANY MAINTENANCE WORK YOURSELF. NEVER UNSCREW THE BLACK SCREW Turn the screw the screw Turn synchronize the compression The shock absorber on the SX models can separately (Dual Compression damping in the low and high-speed range Control). of the shock absorber during com- Low and high speed refers to the movement pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. slow to normal shock absorber The low-speed setting is primarily for is effective at fast compression compression rates.The high-speed setting in a clockwise direction will increase the damping, turning coun- rates.Turning terclockwise will decrease the damping. SETTING: LOW-SPEED STANDARD Hydraulic compression damping determines the reaction when the fork is com- when the fork is determines the reaction compression damping Hydraulic adjusted with adjusting can be The degree of compression pressed. protecting cap legs.Remove the the bottom of the fork screws at of fork Rebound damping the fork is damping determines the reaction when Hydraulic rebound the adjusting screw rebound. By turning of shock absorber (SX) Damping action during compression Compression damping of fork Compression Typ WP Suspension 12187B01Typ . . . . .15 clicks WP Suspension 12187B03Typ . . . . .15 clicks HIGH-SPEED SETTING: STANDARD » 2 1 6 4 3 3 5 2 OPERATION INSTRUMENTS INSTRUMENTS OPERATION

ENGLISH 14 OPERATION INSTRUMENTS 1 3 2 4 » y PSseso 1170 ..22clicks Typ WPSuspension 12187B04 ..22clicks Typ WPSuspension 12187B03 ..22clicks Typ WPSuspension 12187B02 ..22clicks Typ WPSuspension 12187B01 STANDARD ADJUSTMENT: the leftsidetoreducedampingduringrebounding. be adjusted.Turn theknobtorightsideincreasedamping,turnit Rebound dampingofshockabsorber(SX,XC-W,EXC) NEVER UNSCREWTHEBLACKSCREW ANY MAINTENANCEWORKYOURSELF. SEVEREINJURIESCOULDBETHERESULT. SION NITROGEN.NEVERTRY TOTAKE THESHOCKABSORBERAPART ORTODO THE DAMPINGUNITOFSHOCKABSORBERISFILLEDWITHHIGH-COMPRES- The degreeofdampingcanbeadjustedbyturningadjustingscrew W andEXCshockabsorbers(MonoCompressionControl). The compressiondamping(duringcompression)canbeadjustedfortheXC- Compression dampingofshockabsorber(XC-W,EXC) NEVER UNSCREWTHEBLACKSCREW ANY MAINTENANCEWORKYOURSELF. SEVERE INJURIES COULDBETHERESULT. SION NITROGEN.NEVERTRY TOTAKE THESHOCKABSORBERAPART ORTODO THE DAMPINGUNITOFSHOCKABSORBERISFILLEDWITHHIGH-COMPRES- By usingtheadjustingscrew y PSseso 1170 ..15clicks Typ WPSuspension12187B04 ..15clicks Typ WPSuspension12187B02 STANDARD ADJUSTMENT: ing inacounterclockwisedirectionwilldecreasethedamping. a screwdriver. Turning inaclockwisedirectionwillincreasethedamping,turn- Thenturntheadjustingscrew counterclockwise, countingthenumberof – Turn theadjustingscrewclockwisetostop. – Thenturntheadjustingscrewcounterclockwise,countingnumberof – Turn theadjustingscrewclockwiseto stop. – clicks thatcorrespondstotherespectivetypeofshockabsorber. clicks thatcorrespondstotherespectivetypeofshockabsorber. [3] , thedegreeofdampingreboundcan [2] [4] CONNECTION (24MM). CONNECTION (15MM). [1] with

15 ENGLISH » KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES, AND A GLOVES, AND BOOTS, WEAR A HELMET, ALWAYS KTM DRIVERS OR JUST DRIVING ALL DAY OF WHETHER REGARDLESS JACKET, BE CLOTHING SHOULD THE PROTECTIVE RIDE. GO FOR A SHORT OF THE ROADS CAN OTHER USERS SO THAT COLORED BRIGHTLY PASSENGER AS POSSIBLE. OF COURSE YOUR SEE YOU AS EARLY PROTECTIVE CLOTHING. WILL ALSO NEED SUITABLE AS POSSIBLE. OF YOU AS EARLY ERS BECOME AWARE THE DRIVING CHARACTER- CAN IMPAIR PLE, FRONT PANELLING CAN ETC. CASES, EXTRA TANKS ISTICS OF THE MOTORCYCLE. THE IMPAIR THE WEIGHT DISTRIBUTION AND THUS ALSO ALTER CHARACTERISTICS. VEHICLE’S DRIVING TYPE. THE SAME PROFILE HAVE WITH TIRES THAT ON TENSION WILL DECREASE QUICKLY NING TIME. THE SPOKE CONTINUE TO DRIVE WITH LOOSE SPOKES, NEW WHEELS. IF YOU HANDLING (SEE UNSTABLE CRACK AND LEAD TO THE SPOKES MAY "CHECKING THE SPOKE TENSION"). YOU RECOG- AS POSSIBLE SO THAT TO LOOK AHEAD AS FAR TRY AS POSSIBLE. NIZE ANY HAZARDS AS EARLY DRIVING SKILLS. TERRITORY. YOU CAN HELP SO THAT MOTORCYCLE TO KEEP YOU COMPANY, ARISE. EACH OTHER SHOULD DIFFICULTIES VISOR OR GOG- ON A SCRATCHED WHEN LIGHT SHINES DIRECTLY BLIND. GLES, YOU WILL BE PRACTICALLY LONG AS THE ENGINE IS RUNNING. ALLOWED! PASSENGER - NO ADDITIONAL SON ONLY USING THEM ON PUB- STANDARDS. AND SAFETY REGULATIONS ETC. IS AGAINST THE LAW. FREEWAYS, LIC ROADS, HIGHWAYS, BY EXCESSIVE NOISE. FEEL MOLESTED OTHER PEOPLE MAY – SMART DRIVING A MOTORCYCLE. CLOTHING WHEN WEAR SUITABLE – DRIV- OTHER TO MAKE SURE THAT TURN ON THE LIGHT ALWAYS – CONSUMED ALCOHOL. DO NOT DRIVE AFTER HAVING – BY KTM. FOR EXAM- RECOMMENDED PARTS USE ACCESSORY ONLY –WHEEL ARE ALLOWED TO BE FITTED ONLY THE FRONT AND REAR – RUN- THE SPOKE TENSION AFTER 30 MINUTES' BE SURE TO CHECK – AND DRIVE DEFENSIVELY THE TRAFFIC REGULATIONS, OBSERVE – YOUR DRIVING SPEED TO THE CONDITIONS AND YOUR ADJUST – OR IN UNKNOWN ON UNKNOWN ROADS DRIVE CAREFULLY – ON A SECOND A FRIEND HAVE DRIVING OFF-ROAD, ALWAYS WHEN – ENOUGH. VISOR OR GOGGLE GLASSES EARLY REPLACE THE HELMET – AS YOUR MOTORCYCLE WITHOUT SUPERVISION NEVER LEAVE – FOR ONE PER- ABOVE MODELS WERE DESIGNED AND BUILT THE – DO THESE MODELS MEET THE APPLICABLE STATUTORY NEITHER – RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT WHEN formed by your authorized KTM workshop. The DELIVERY CER- workshop. The DELIVERY your authorized KTM formed by over when you MANUAL will be handed SERVICE and TIFICATE vehicle. pick up your your first tour. starting for position. pedal to the most comfortable going for a longer ride. Also try to ride or open space, before while standing upright, to improve your as slowly as possible feeling for the vehicle. and experience. foot rests while driving. the brake pads braking. If the foot brake lever is not released is overheated. rub continuously and the braking system the ride, the pas- ted and registered for such purposes. During with his feet driver, senger must hold on to the straps or to the on the passenger footrests. ORIGINAL KTM SPARE Spare parts from other man- PARTS. ufacturers can impair the safety of the motorcycle. it should be secured weight. If you are taking luggage with you, vehicle; distribute the as close as possible to the middle of the rear wheel. Never weight evenly between the front and the weight and the axle exceed the maximum permissible laden weight is made up weights. The maximum permissible laden of the following components: full - Motorcycle ready for operation and tank - Luggage and helmet. - Driver and passenger with protective clothing – inspection" was perfor the "pre-delivery Make sure the work – manual before read the whole instruction Thoroughly – controls. Familiarize yourself with the – lever and the foot brake the hand brake Adjust the clutch lever, – on an empty parking lot Get used to handling the motorcycle – which go beyond your ability Do not drive along off-road trails – hands and leave your feet on the Hold the handlebar with both – brake lever when you are not Remove your foot from the foot – a passenger along if your motorcycle is fit- may only take You – any alterations to the motorcycle and always use Do not make – are sensitive to alterations in the distribution of Motorcycles – to running-in procedure. Pay attention GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE MOTORCYCLE THE STARTING FOR WARNINGS AND TIPS GENERAL DO NOT DRIVE AT FULL LOAD FOR THE FIRST 500 KILOMETERS (300 DO NOT DRIVE AT MILES) OR 5 HOURS! Running in engine components have Even very precisely machined sections of have been sliding across rougher surfaces than components which every engine needs to one another for quite some time. Therefore, 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. Instructions for your first ride Instructions

ENGLISH 16 DRIVING INSTRUCTIONS » 5 BRAKES 4 TIRES 3 CHAIN 2 FUEL CHECKTRANSMISSIONOILLEVEL 1 The followingchecksshouldbeperformed: your motorcyclebeforeeachstart. For safetyreasons,youshouldmakeitahabittoperformanoverallcheckof When youstartoff,themotorcyclemustbeinaperfecttechnicalcondition. What youshouldcheckbeforeeachstart 9 LUGGAGE 8 ELECTRICAL SYSTEM 7 COOLING FLUID 6 CABLES FIRST HAVING THEBRAKESYSTEMLOOKEDOVERBYAKTMDEALER. WITH THEBRAKESYSTEM.DON’TRIDEYOURMOTORCYCLEANYMOREWITHOUT „SPONGY“ (TOOMUCHGIVE),THISISANINDICATION THAT SOMETHINGISWRONG IF THERESISTANCE INTHEHANDBRAKELEVERORFOOTPEDALFEELS Check freetravelofthehandbrakeleverandfootlever. linings. Also checkthestateofbrakehoseandthickness dealer, as complete failureofthebrakingsystemcanbeexpected. ized KTM brake pads.Arrangeforthebrakingsystemtobecheckedbyanauthor- value, thisindicatesaleakinthebrakingsystemorcompletelywornout brake padsareworn.Iftheleveloffluidfallsbelowminimum such awaythatbrakefluiddoesnotneedtoberefilledevenwhenthe ficient brakefluidinthereservoir. Thereservoirshavebeendesignedin Check correctfunctioningofthebrakingsystem.Verify thatthereissuf- driving performance. air pressure.Insufficienttreadandincorrectpressuredeterioratethe The treaddepthmustcomplywiththelegalregulations.Alsocheck Check fordamagedtires.Tires showingcutsordentsmustbereplaced. chain andwheels. tear, andinsufficientlubricationmayresultinunnecessarywearofthe A loosechainwasfalloffthewheels;anextremelywornmay check thatthetankventinghoseisfreeofkinks. Check thatthereissufficientfuelinthetank;whenclosingfillercap, gear wheelsandpartsoftheshiftmechanism. Too littletransmissionoilleadstoprematurewearandwillultimatelydestroy If youaretakingluggagewithyou,checkthatitissecurely fastened. indicators, indicatorlampsandhornwhiletheengineisrunning. Check correctfunctioningofheadlamps,tail-lights,brakelights,turn Check thelevelofcoolingfluidwhenengineiscold. Check correctadjustmentandeasyrunningofallcontrolcables.

17 ENGLISH SWUNG RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE FLOOR, YOU DRAGS IF THE STAND SWUNG RIGHT UP TO THE TOP. LOSE CONTROL OF YOUR MOTORCYCLE. MAY WITH THE RUBBER BAND ON THE AIR SECURE THE SIDE STAND TIONALLY BOX. FILTER YOU COULD SLIP OFF THE KICKSTARTER OR THE MOTOR COULD KICK BACK OR THE THE KICKSTARTER YOU COULD SLIP OFF UPWARDS. AND FLING YOUR FOOT LITTLE MOMENTUM AND AN WITH TOO A KICKSTART OPEN THE THROTTLE. THE KICKING BACK RISK. OPENED THROTTLE INCREASES IF YOU DEPRESS THE KICKSTARTER THE KICKSTARTER. BEFORE YOU ACTUATE TRANSMITTED. POWER IS NOT BEING RESISTANCE, WITHOUT FEELING ANY THIS COULD CAUSE INJURIES. CAUSE LOSS OF CONSCIOUS- EXHAUST FUMES ARE POISONOUS AND CAN WHILE THE VENTILATION PROVIDE ADEQUATE ALWAYS NESS AND DEATH. ENGINE IS RUNNING. starter vigorously all the way. starter vigorously all Start engine with full throttle. If necessary, unscrew spark plug and dry it. Start engine with full throttle. If necessary, – HAS BEEN THE MAIN OR SIDE STAND CHECK THAT OFF, BEFORE YOU START – TOUR, IT IS RECOMMENDED TO ADDI- FOR AN OFF-ROAD BEFORE STARTING – INJURIES. BOOTS TO AVOID PUT ON YOUR MOTORCYCLE ALWAYS FOR STARTING – AND DO NOT DOWN THE WHOLE WAY KICK THE KICKSTARTER FORCEFULLY – BELOW 0°C (32°F) TEMPERATURES AT CHECK FOR POWER TRANSMISSION –TO IDLE IN A CLOSED AREA. THE ENGINE AND ALLOW IT DO NOT START DO NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV UP THE DO NOT RIDE YOUR MOTORCYCLE WITH FULL THAN FASTER UP AND EXPANDS ENGINE WHEN COLD. SINCE THE PISTON WARMS CYLINDER, THIS MIGHT CAUSE ENGINE DAMAGE. ALWAYS COOLED THE WATER SPEEDS. LOW R.P.M. AT OR DRIVE IT WARM LET ENGINE IDLE UNTIL WARM Shifting/Riding Depending on referred to as the drive or uphill gear. are now in first gear, You down Turn the conditions (traffic, hill size, etc.), you can shift to a higher gear. the throttle, at the same time pull the clutch lever in and shift to the next Let the clutch lever go again and open the throttle. If you turned higher gear. on the choke, make sure you turn it off again as soon as engine is warm. turn throt- When you reach full speed through opening the throttle all the way, tle 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 shifting down, use the brakes if necessary and turn down at the same time. Pull the clutch Let the clutch lever go slowly and lever and shift down to the next lower gear. open the throttle or shift down again. Starting when the engine is warm 1 Open fuel tap 2 OFF switch on ignition or emergency Turn 3 Swing up the side stand 4 Put the gear in neutral 5 Open throttle to 1/2 and kick down kickstarter vigorously What to do when the engine is „flooded“ 1 Close fuel tap 2 3 open fuel tap again. Once the engine is running, Starting off slowly release the clutch Put the engine into first gear, Pull the clutch lever. lever and accelerate at the same time. 1 Open fuel tap 2 or emergency OFF switch on ignition Turn 3 up the side stand Swing 4 in neutral Put the gear 5 cold-starting aid (choke) Activate 6 than 1/3 and kick down kick- throttle closed or open it no more Leave NOTE: modern fuels volatilize if left stand- The highly inflammable components in has not been used for over ing for longer periods of time. If the motorcycle The engine will the float chamber. 1 week, the fuel should be drained from is filled with fresh, ignitable fuel start up immediately if the float chamber Starting when the engine is cold the engine Starting when » DRIVING INSTRUCTIONS INSTRUCTIONS DRIVING

ENGLISH 18 IT ANDGETBURNED. CARE TOPARK ITWHERE PEDESTRIANSARENOTLIKELY TOTOUCH OF THESEPARTS AFTER STARTING THEMOTORCYCLE,ANDTAKE AND SHOCKABSORBERSCANBECOMEVERY HOT. DONOTTOUCHANY RUNNING. THEENGINE,EXHAUSTPIPE,MUFFLER,BRAKEROTORS, MOTORCYCLE ENGINESPRODUCEAGREAT AMOUNTOFHEAT WHILE a curve. gear tomatchyourspeed.Alwaysapplythebrakesbeforeyou enter wheels cancausethebiketoskidorcrash.Shiftdowna lower wet orslicksurfaces.Alwaysapplythebrakesintuitively, locked ously. Beespeciallycarefulwhenyouapplythe brakesonsandy, Close thethrottleandapplyhandfootbrakesimultane- Stopping andparking ing onyourspeed. can causeyoutoskidorfall.Alsochangedownlowergearsdepend- the rearwheelbrake.Alwaysbrakewithfeeling,blockingwheels time. Whendrivingonsandy, wetorslipperyground,usemainly Turn offthegasandapplyhandfootbrakesatsame Braking DRIVING INSTRUCTIONS IFTHERESISTANCE INTHEHANDBRAKELEVERORFOOT – WHENYOUBRAKE,THEBRAKE DISCS,BRAKEPADS, BRAKE – DIRTY BRAKEDISCSCAUSEINCREASED TEAROFBRAKEPADS AND – RIDESON SALT-STREWED ORDIRTY ROADSCANALSODELAY THE – INCASEOFRAIN,AFTERWASHING THEMOTORCYCLE,AFTER – INTHEEVENTTHAT, WHILERIDINGONYOURMOTORCYCLE, YOU – IFTHEENGINERUNSWITHOUTTHROTTLEDURINGLONGER – NEVERHAVE THETHROTTLEWIDEOPENWHENCHANGINGDOWN – HIGHRPMRATES WHENTHEENGINEISCOLDHAVE ANADVERSE – ATWISTEDHANDLEBARMUSTALWAYS BEREPLACED.DONOT – AFTERFALLING WITHTHEMOTORCYCLE,CHECKALLITSFUNC- – NEVERPARK YOURMOTORCYCLE INPLACESWHERETHERE EXIST – CLOSETHEFUELTAP WHEN LEAVING YOURVEHICLE.OTHERWISE – BRAKE SYSTEMLOOKEDOVERBYAKTMDEALER. RIDE YOURMOTORCYCLEANYMOREWITHOUTFIRSTHAVING THE TION THAT SOMETHINGISWRONGWITHTHEBRAKESYSTEM.DON’T PEDAL FEELS“SPONGY”(TOOMUCHGIVE),THISISANINDICA- THE ENTIREBRAKINGSYSTEMCANFAIL. GET, THEWEAKERBREAKINGEFFECT. INEXTREMECASES, CALIPER ANDBRAKEFLUIDHEAT UP. THEHOTTERTHESEPARTS BRAKE DISCS. CLEAN. BRAKING EFFECT. THEBRAKESMUSTBEPULLEDUNTILTHEYARE OR CLEAN. ING EFFECT. THEBRAKESMUSTBEPULLEDUNTILTHEYAREDRY TRACKS, HUMIDORDIRTY BRAKEDISCSCANDELAY THEBRAK- RIDES THROUGHWATER ANDINCASEOFRIDES ONWETOFF-ROAD DEALER. KTM DIATELY, TURNTHEENGINEOFF, ANDCONTACT ANAUTHORIZED NOTICE ANYUNUSUALOPERATION-RELATED NOISE,STOPIMME- LUBRICANT WHICHISMIXEDINTHEFUEL. SIONALLY TOENSURETHAT ITISSUPPLIEDWITHSUFFICIENT DOWNHILL TRAVEL, THEENGINESHOULDBEACCELERATED OCCA- MOTORCYCLE CANEASILY GETOUTOFCONTROL. VALVES. INADDITION,THEREARWHEELWILLBLOCKSOTHAT THE TO ALOWERGEAR.THEENGINEWILLOVERREV, DAMAGINGTHE CAUTIONS INTHISRESPECTNEEDTOBETAKEN. ING ITACHANCETOWARM UP. AFTERTHAT NOFURTHER PRE- THE ENGINEINAMODERATE RPMRANGEFORAFEWMILESGIV- EFFECT ONTHELIFEOFYOURENGINE.WERECOMMENDYOURUN ADJUST THEHANDLEBAR,ITWILLLOSESTABILITY. TIONS THOROUGHLY BEFOREUSINGITAGAIN. BLE MATERIALS. FIRE HAZARDS DUE TODRY GRASSOR OTHER EASILY FLAMMA- THE ENGINE. THE CARBURETORMAY GETFLOODEDANDFUELWILLENTER » IMMEDIATELY. LOWED ORSPLASHEDINTHEEYES,SEEKADOCTOR’SADVICE THE ENGINEISHOT. WIPEUPSPILLSPROMPTLY. IFGASOLINEISSWAL- NOT TOSPILLGASOLINEONTHEENGINEOREXHAUSTPIPEWHILE ALWAYS SWITCHOFFTHEENGINEBEFOREREFUELING.BECAREFUL THE MOTORCYCLENEAROPENFLAMESORBURNINGCIGARETTES. TION SHOULDBEUSEDWHENHANDLINGGASOLINE.DONOTREFUEL GASOLINE ISHIGHLY FLAMMABLEANDPOISONOUS.EXTREMECAU- KTM recommendsMotorexCrossPower2T. Fuel andengineoilshouldonlybemixedimmediatelybeforeuse. grade twostrokeoil.Mixtureratio1:40-1:60 125-300: UnleadedpremiumgasolineRON95mixedwithhigh Refueling, fuel THESIDESTAND ISONLY DESIGNEDFORTHEWEIGHTOF – FUELEXPANDS WHENITSTEMPERATURE RISES.THEREFOREDO – IFYOURMOTORCYCLEISEQUIPPED WITHACATALYTIC CON- – NOTENOUGH OILORLOW-GRADE OILCANCAUSEEROSIONOF – NEVERMIXSYNTHETIC OILSANDMINERALOILS. – ONLY USEKNOWNBRANDSOFHIGH-GRADE2-STROKEENGINE – DONOTUSEGASOLINEANDOILMIXTURESTHAT ARE OLDER – DONOTUSEPREMIXEDTWO-STROKEOILS,OILSFOROUTBOARD – ONLY USEPREMIUM-GRADEGASOLINEROZ98RESPECTIVELY 95 – ON THESIDE. THE FRAMECANBEDAMAGEDORMOTORCYCLEMAY FALL ADDITIONAL WEIGHTONTHEMOTORCYCLE,SIDESTAND OR MOTORCYCLE. IFYOUGETONYOURMOTORCYCLEANDTHUSPUT NOT FILLTHETANK TOTHETOP. (SEE FIG.) THE CATALYTIC CONVERTER. VERTER, ALWAYS KEEPINMINDTHAT LEADEDFUELWILLDESTROY START SMOKINGANDFOULTHESPARK PLUG. THE PISTON.WHENUSINGTOOMUCHOIL,ENGINEMAY OIL (I.E.MOTOREXCROSSPOWER2T). STROKE OILSCANDETERIORATE VERY RAPIDLY. THAN ONEWEEK.THELUBRICATION PROPERTIES OFSOMETWO- ENGINES ORNORMALENGINEOILTOPREPARE THEMIXTURE. OF GASOLINECANCAUSEENGINEFAILURE. MIXED WITHHIGH-GRADETWO-STROKEENGINEOIL.OTHERTYPES 35 mm

19 ENGLISH

a year a

at least once once least at z z z z z z every 40 hours hours 40 every

z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z every 20 hours hours 20 every

z z z z z z z z z z z z z z

10 hours hours 10

1st service after service 1st z z z z z z z z z z z z z z z z z z z z z after every race every after z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z »

Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings Check spoke tension and rim joint Check tires and air pressure fitment and tension Check chain, rear sprockets and chain guides for wear, Check tightness of all chassis screws (triple clamps, fork leg axle passage axle nuts and screws, swing arm bearings, shock absorber) Bleed fork legs Check swing arm bearings Check/adjust steering head bearings Check the screws and guide bolts on the brake system for a tight fit Check the screws and guide bolts on the and function Check shock absorber and fork for leaks Clean dust bellows Check brake lines for damage and leaks travel of handbrake/foot brake lever Check/adjust smooth operation and free Check function of electric systems (low beam, high beam, break light, indicator, Check function of electric systems (low horn, emergency OFF switch or button indicator lamps, speedometer illumination, brake lining Check brake fluid level, lining thickness, Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check cables for damage, smooth operation, bends; adjust and lubricate Check cables for damage, smooth operation, of the hydraulic clutch Check the fluid level in the master cylinder Check that vent hoses are not damaged or bent Check that vent hoses of antifreeze Check cooling system for leaks, check quantity Check exhaust system for leaks and fitment Check the screws on the kick starter and shift lever for a tight fit the kick starter and shift lever for a tight Check the screws on cracks or leaks connection boot and intake flange for Check the carburetor Check idle speed setting Renew spark plugs connector and check for a tight fit Clean the spark-plug Check gear box oil level Change gear box oil distance between electrodes Check spark plugs, adjust

A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY CHECKED MORE QUICKLY CAN BE A CLEAN MOTORCYCLE 125/200 SX/XC/EXC/XC-W 2006 125/200 SX/XC/EXC/XC-W

WHEELS CHASSIS BRAKES ADD-ON-PARTS ENGINE CARBURETOR PERIODIC MAINTENANCE SCHEDULE SCHEDULE MAINTENANCE PERIODIC THE KILOMETER READING FOR INSPECTION INTERVALS SHOULD NOT EXCEED 5 HOURS. SHOULD NOT EXCEED 5 THE KILOMETER READING FOR INSPECTION INTERVALS IS NOT A SUBSTITUTE FOR CARE AND MAINTEN- MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP ANCE BY THE DRIVER!

ENGLISH 20 H C OE IFTHEINSPECTIONESTABLISHES THAT PERMISSIBLETOLERANCESAREEXCEEDED,THERESPECTIVECOMPONENTS NOTE: PERIODIC MAINTENANCESCHEDULE Check tiresforpressureandwear Clean airfilterandbox Clean andlubricatechain,checktensionadjustifnecessary Remove andcleandustbellowsregularly Bleed forklegsregulary Lubricate andadjustcablesnipples Check hornforfunction Check lightsforfunction Check brakepadsforwear Check brakefluidlevel Check gearboxoillevel IMPORTANT CHECKSANDMAINTENANCETOBECARRIEDOUTBYTHERIDER 125/200 SX/XC/EXC/XC-W2006 Change breakfluid Treat electriccontactsandswitcheswithcontactgrease Replace theglass-fiberyarnfillinginsilencer Replace thesealingcupforfootbrakecylinder Clean andgreasesteeringheadbearingsgasketelements Complete maintenanceofshockabsorber Complete maintenanceoffork Check theentiretransmission,shiftmechanismandbearings Replace theconrodbearings Replace thecrankshaftmainbearings Check pistonpinbearing Check functionofexhaustcontrol Check thecylinderandpistonforwear Check thewearonclutchdisksandlengthofsprings Check thereed-typeintakevalveforwear Clean andadjustcarburetor IMPORTANT RECOMMENDEDMAINTENANCEWORKTHATCANBECARRIEDOUTBYEXTRAORDER 125/200 SX/XC/EXC/XC-W2006 Check tightness ofscrews,nutsandhoseclamps regularly Treat ignitionandsteeringlocks andlightswitcheswithcontact spray with wax-basedanticorrosion agent Treat blankmetalparts(withtheexception ofbrakeandexhaustsystems) Check brakeperformance Check allcontrolelementsfor smoothoperation Remove, cleanandoilthethrottle slide Empty andcleanfloatchamber Check fuellinesforleaks Check coolingliquidlevel = FORCOMPETITIVEOFFROADRACING( = FOROFFROAD MUST BEREPLACED. H OBBY USE C OMPETITION) » C C C C C C C C C / Every 20 H hours C C C C C C C C z z z z z z z z z z C C before each / / / / / / / / Every 40 H H H H H H H H start hours C C C C C C C C C C C z z z z z z z z H C after every / / / / / / / / / / / Every 80 H H H H H H H H H H H cleaning hours C C C C C z z z z for cross / / / / / At least once H H H H H country use a year C C z z / / once a year H H Every 2 years

21 ENGLISH

a year a

at least once once least at z z z z z z every 40 hours hours 40 every

z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z every 20 hours hours 20 every

z z z z z z z z z z z z z z

after 10 hours hours 10 after

1st service service 1st z z z z z z z z z z z z z z z z z z z z z

race after every every after z z z z z z z z z z z z z z z z z z z z z z z z z z z z z z »

A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY CHECKED MORE QUICKLY CAN BE A CLEAN MOTORCYCLE 250/300 SX/XC/EXC/XC-W 2006 250/300 SX/XC/EXC/XC-W WHEELS CHASSIS BRAKES ADD-ON-PARTS ENGINE CARBURETOR PERIODIC MAINTENANCE SCHEDULE SCHEDULE MAINTENANCE PERIODIC THE KILOMETER READING FOR INSPECTION INTERVALS SHOULD NOT EXCEED 5 HOURS. SHOULD NOT EXCEED 5 THE KILOMETER READING FOR INSPECTION INTERVALS IS NOT A SUBSTITUTE FOR CARE AND MAINTE- MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP NANCE BY THE DRIVER!

ENGLISH 22 H C OE IFTHEINSPECTIONESTABLISHES THAT PERMISSIBLETOLERANCESAREEXCEEDED,THERESPECTIVECOMPONENTS NOTE: PERIODIC MAINTENANCESCHEDULE Check tiresforpressureandwear Clean airfilterandbox Clean andlubricatechain,checktensionadjustifnecessary Remove andcleandustbellowsregularly Bleed forklegsregulary Lubricate andadjustcablesnipples Check hornforfunction Check lightsforfunction Check brakepadsforwear Check brakefluidlevel Check gearboxoillevel IMPORTANT CHECKSANDMAINTENANCETOBECARRIEDOUTBYTHERIDER 250/300 SX/XC/EXC/XC-W2006 Change breakfluid Treat electriccontactsandswitcheswithcontactgrease Replace theglass-fiberyarnfillinginsilencer Replace thesealingcupforfootbrakecylinder Clean andgreasesteeringheadbearingsgasketelements Complete maintenanceofshockabsorber Complete maintenanceoffork Check theentiretransmission,shiftmechanismandbearings Replace theconrodbearings Replace thecrankshaftmainbearings Check pistonpinbearing Check functionofexhaustcontrol Check thecylinderandpistonforwear Check thewearonclutchdisksandlengthofsprings Check thereed-typeintakevalveforwear Clean andadjustcarburetor IMPORTANT RECOMMENDEDMAINTENANCEWORKTHATCANBECARRIEDOUTBYEXTRAORDER 250/300 SX/XC/EXC/XC-W2006 Check tightness ofscrews,nutsandhoseclamps regularly Treat ignitionandsteeringlocks andlightswitcheswithcontact spray with wax-basedanticorrosion agent Treat blankmetalparts(withtheexception ofbrakeandexhaustsystems) Check brakeperformance Check allcontrolelementsfor smoothoperation Remove, cleanandoilthethrottle slide Empty andcleanfloatchamber Check fuellinesforleaks Check coolingliquidlevel = FORCOMPETITIVEOFFROADRACING( = FOROFFROAD MUST BEREPLACED. H OBBY USE C OMPETITION) » C C C C C C C C C / Every 20 H hours C C C C C C C C C C C / / / / / / / / Every 40 H H H H H H H H hours C C C C C C C C C C z z z z z z z z z z C C C before each / / / / / / / / / / Every 80 H H H H H H H H H H start hours C C C C C C C C C z z z z z z z z H H C after every / / / / / / / / / Every 120 H H H H H H H H H cleaning hours C C C C C z z z z

for cross / / / / / At least once H H H H H country use a year C C z z / / once a year H H Every 2 years

23 ENGLISH . For this [1] [A] changes the spring pretension by , tighten it to 8 Nm (6 ft.lb) [1] [2] » and use the hook wrench contained in the and use the hook wrench contained in [2] for PDS suspension struts at the swinging fork is Teflon- [3] many threads are visible above the adjusting ring. many threads are visible above the adjusting approximately 1.75 mm (0.07 in). – the spring preload note down the basic setting, e.g. how Before changing – of the adjusting ring One rotation ADJUSTMENT VALUES – SPRING PRELOAD – SPRING PRELOAD ADJUSTMENT VALUES PRELOADSTANDARD . . .5 mm (0.20 in) vehicle tool set to turn the adjusting ring as desired. Turning it counterclock- as desired. Turning vehicle tool set to turn the adjusting ring will increase the preload. wise will reduce the preload, turning it clockwise After readjusting the clamping screw purpose, you should dismount the shock absorber and clean it thoroughly. purpose, you should dismount the shock NOTE: Loosen the clamping screw The pivot bearing The spring preload can be changed by turning the adjusting ring The spring preload can be changed by turning Pivot bearing Changing the spring preloading of the shock absorber Changing the spring preloading of coated and must not be lubricated with either grease or other lubricants. Grease dissolve, whereby the bearing’s coat to and other lubricants cause the Teflon lifecycle will be reduced dramatically. do not aim the high- When cleaning your bike with a high-pressure cleaner, pressure spray directly at the pivot bearing. 3 2 A 1 TOR, ETC. THE HIGH PRESSURE WILL CAUSE WATER TO PENETRATE INTO THE COMPONENTS AND CAN CAUSE THEM TO MALFUNCTION INTO THE COMPONENTS AND CAN CAUSE TO PENETRATE PRESSURE WILL CAUSE WATER TOR, ETC. THE HIGH WEAR. OR LEAD TO PREMATURE NO FUEL CAN LEAK FROM THE OVER, FALL OFF POSITION - IF THE MOTORCYCLE SHOULD IS IN THE THE FUEL TAP DEVICES AND THAT TANK CARBURETOR OR FUEL FLOW OUT. THROUGH WHICH FUEL CAN TANK SCREWS CAN CAUSE LEAKS IN THE OTHER SCREWS OR LONGER LOOSE. INSTEAD, USE SELF-LOCKING NUTS. AND KEEP WORKING IF THE THREAD IS SCREWS AND NUTS MUST BE REPLACED LOCTITE 243 TO THE THREAD. THE APPLY AVAILABLE, LOCKING NUTS ARE DAMAGED. GO OUT OF CONTROL WHILE YOU DRIVE. TIGHTENED, THEY CAN BECOME LOOSE AND CAUSE THE MOTORCYCLE TO ARE NOT ADEQUATELY CAN DAMAGE THE THREAD AND COMPONENTS. TIGHTLY TIGHTENING THE SCREWS AND NUTS TOO LITERS OF WATER. 1,000,000 OIL CONTAMINATES – CABLES, BEARINGS, CARBURE- THE ELECTRIC COMPONENTS, PLUGS, JET AT DO NOT POINT THE WATER IF USING A POWER WASHER, – FASTENING STRAPS OR OTHER MECHANICAL IT IS HELD UPRIGHT WITH RESTRAINING YOUR KTM, ENSURE THAT WHEN TRANSPORTING – USING TANK. BY KTM TO FIX THE SPOILERS ON THE THREAD LENGTH SUPPLIED SPECIAL SCREWS WITH AN APPROPRIATE USE ONLY – THE FRAME PARTS SCREWS, AS THESE WORK INTO THE ENGINE FASTENING OR SPRING RINGS WITH WASHERS DO NOT USE TOOTHED – WHEN MOUNTING. IF NO SELF- NUTS, THEY MUST BE REPLACED SCREWED CONNECTIONS WITH SELF-LOCKING IF YOU UNSCREWED ANY – A TORQUE WRENCH. IF SCREWS OR NUTS SCREWS AND NUTS MUST BE TIGHTENED TO THE SPECIFIED TORQUE FIGURES USING ALL – GETTING BURNED. IN ORDER TO AVOID YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK LET – DETERGENTS, ETC. PROPERLY. FUELS, WASHING FILTERS, MATTERS, OF OILS, FATTY DISPOSE – 1 LITER OF USED SYSTEM OR IN THE OPEN COUNTRYSIDE. USED OIL BE DISPOSED OF IN THE SEWAGE MAY NO CIRCUMSTANCES UNDER MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK * REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR TECHNICAL KNOW-HOW. SKILLS AND EXPERT AN ASTERISK * REQUIRES WORK MARKED WITH AND ADJUSTING MAINTENANCE SERV- WILL BE OPTIMALLY YOUR MOTORCYCLE KTM DEALER WHERE BY A SPECIALIZED WORK PERFORMED SUCH HAVE ALWAYS OWN SAFETY, SKILLED STAFF. QUALIFIED, ICED BY APPROPRIATELY

ENGLISH 24 MAINTENANCE WORKONCHASSISANDENGINE o xml 125SX for example RIDERS WEIGHT INCLUSIVEGEARSINKILOGRAM 50 SPRING RATE 69-250 55 60 72-250 65 70 Shock absorber A C B 76-250 75 80 Motorcycle onground,unloaded(dimensionB) ..600mm Motorcycle jackedup(dimensionA) EXAMPLE: Procedure: than 2mmcanstronglyinfluencethemotorcycle'sperformance. The staticsagshouldbeasclosepossibleto35mm.Deviationsofmore Determining thestaticsagofshockabsorber before theridingsagcanbedetermined. weight bycheckingtheridingsag.Thestaticslagmustbecorrectlyadjusted You canestablishwhetherornottheshockabsorberspringissuitableforyour Checking theshockabsorberandspring preload. Differentspringsmustbeinstalledforlargerdeviations. ingly. Minordeviationsinweightcanbecompensatedbyadjustingthespring you willneedtoadjustthebasicsetupforsuspensioncomponentsaccord- ing fullprotectiveclothing).Ifyourweightexceedsorfallsshortofthisrange, offroad motorcyclesaresettoaccommodateadriverweighing60-70kg(wear- suspension componentsmustbesuitableforyourweight.Atdelivery, KTM's absorber, swingarmandframefrombeingdamaged,thebasicsetupof To achievemaximumhandlingperformanceandtopreventthefork,shock Basic suspensionsetupfortheweightofdriver After installing a differentspring,readjustthe staticsagto35mm(±2mm). shown inboldprint . illustrations showwhichspring shouldbeinstalled.Thestandardspringis number oftheshockabsorberis embossedonthefrontofshockabsorber.The The springrateiswrittenonthe outsideofthespring(e.g.72-250).Thetype spring rateistoolow). too high).Iftheridingsagismore than105mm,thespringistoosoft(the If theridingsagislessthan90 mm,thespringistoohard(therate The ridingsagshouldliebetween90and105mm. ..90mm Riding sag Determining theridingsagofshockabsorber chapter "Changingthespringpreloadofshockabsorber." increased, ifthestaticsagisreduced,springpreloadmustbehigher. See If thestaticsagislower, thespringpreloadofshockabsorbermustbe ..35mm Static sag Motorcycle onground,loaded(dimensionC) ..600mm Motorcycle jackedup(dimensionA) EXAMPLE: Thestaticsagisthedifference betweendimensionsAandB. – Measurethedistance betweentherearaxleandfixedpointagainto – Askahelpertoholdthemotorcycle inverticalposition. – Placethemotorcycleonground again. – Measuretheverticaldistancebetweenrearwheelaxleandafixedpoint – Jackupthemotorcycleuntil therearwheelnolongertouchesground. – TheridingsagisthedifferencebetweendimensionsAandC. – Stayonthebikeandhaveanotherpersonmeasuredistancebetween – Haveahelperholdthemotorcyclewhileyousitonbikeinnormal – establish dimensionB. (e.g. amarkonthesidecover)andwriteitdownasdimensionA. the sametwopointsandwriteitdownasdimensionC. become level. bounce upanddownafewtimestoallowtherearwheelsuspension to seating position(feetonthefootrests)wearingfullprotectiveclothingand » . . – 510mm – 565mm

25 ENGLISH » . [1] 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 XC-W/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 different degrees of pretension. Fork springs and pretension spacers should always stay together. The precise riding sag of the telescopic fork cannot be determined for vari- The precise riding sag of the telescopic deviations in your weight smaller ous reasons. Similar to the shock absorber, if your tele- preload. However, can be compensated by adjusting the spring during compression), you should scopic fork bumps frequently (hard end stop the telescopic fork and frame. install harder fork springs to avoid damaging Changing the spring preload on the telescopic fork (SX models) The telescopic forks on the SX models are equipped with a preload adjuster. can easily adjust the spring preload by 10 mm by turning the adjusting You screw Changing the spring preload on the telescopic fork (XC-W/EXC models) Checking the basic setup of the telescopic fork Checking the basic setup of the telescopic the prestress, turning in a coun- in a clockwise direction will increase Turning terclockwise direction will decrease the prestress. Changing the spring preload will not affect the rebound damping adjustment. the rebound damping should also if the spring preload is higher, Generally, be set higher. SETTING: STANDARD Unscrew the adjusting screw to the limit and then back 2 turns. According to our experience, the damping rate of the compression stage can of the compression rate the damping experience, to our According stage can be reduced rate of the rebound The damping remain unchanged. harder a few clicks for a or increased by for a softer spring by a few clicks spring. 76-250 76-250 80-250 80-250 HARDER 76-250 76-250 1 72-250 72-250 76-250 76-250 STANDARD 72-250 72-250 69-250 72-250 72-250 69-250 69-250 SOFTER 69-250 12187B04 250/300 EXC, XC-W 12187B25 250/300 XC 12187B03 250 SX 12187B24 200 XC 12187B02 125/200 EXC, XC-W MODELL 12187B01 125 SX MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 26 MAINTENANCE WORKONCHASSISANDENGINE 14187B28 250/300XC 14187B04 250/300EXC,XC-W SX 14187B03 250 14187B27 200XC 14187B02 125/200EXC,XC-W 14187B01 125SX MODELL o xml 125SX for example RIDERS WEIGHTINCLUSIVEGEARSINKILOGRAM 50 SPRING RATE 4,0 N/mm 55 1 60 2 4,2 N/mm 65 70 4,4 N/mm 75 Front fork 4,0 N/mm 3,8 N/mm 4,2 N/mm 3,8 N/mm 3,6 N/mm 4,0 N/mm SOFTER 80 Breather plugfrontfork spring. by afewclicksforsofterspringorincreasedharder remain unchanged.Thedampingrateofthereboundstagecanbereduced According toourexperience,thedampingrateofcompressionstagecan If youareuncertainwhichspringtouse,contactyourKTMworkshop. embossed ontheinsideofforklegaxlepassage. dard springisshowninboldprint.Thetypenumberofthetelescopicfork tive forksprings.Thecorrectspringrateisshownintheillustrations.stan- If youweighlessthan60kgormore70kg,shouldinstalltherespec- Replacing forksprings THE FRONTBRAKE. CONSIDERABLY REDUCETHETIRE'SROADGRIPAND THEBRAKINGEFFECTOF NO OILMAY REACHTHE FRONTTIREORTHEBRAKEDISKSSINCETHISWOULD oil. Then,pushthedust-protectionbellowsintooutertubes byhand. oil themthoroughlywithUniversalspray(MotorexJoker 440)orengine Clean thedust-protectionbellows,outertubes,andforktubes thoroughly, and and slidethemdownward. Use ascrewdrivertoliftthedust-protectionbellowsoutofoutertubes behind itmaystarttoleak. dust-protection bellows.Ifthisdirtisnotremoved,theoilsealingringslocated from theforktube.However, aftersometime,dirtmayalsogetinbehindthe The dust-protectionbellows Cleaning thedustsleevesoftelescopicfork PLUGS BEFOREHAVING THESEALSREPLACED. FORK. IFYOURFORKISLEAKING,ITRECOMMENDEDTOOPENTHEBREATHER EXCESSIVE PRESSUREINTHEINTERIOROFFORKCANCAUSELEAKS plugs After every5hoursofuseforcompetitiveracing,slackenthebreather service. to havethisjobperformedinthecourseofperiodicalmaintenance off theground.Whenridingmotorcyclemainlyonroad,itwillsuffice fork. To dothis, placethemotorcycleonastandwithfrontwheellifted [1] a fewturnsinordertorelieveexcesspressurefromtheinsideof 4,2 N/mm 4,0 N/mm 4,4 N/mm 4,0 N/mm 3,8 N/mm 4,2 N/mm STANDARD [2] are toremovedustandcoarsedirtparticles » 4,4 N/mm 4,2 N/mm 4,6 N/mm 4,2 N/mm 4,0 N/mm 4,4 N/mm HARDER

27 ENGLISH is in [B] and the pro- [3] » from the upper triple clamp, loosen the clamp to see which offset is set. If the mark offset is set. If the to see which on the lower triple clamp 2 turns. [1] [1] [2] in the SX models (center fork legs - center steering head legs - center steering models (center fork in the SX is in the rear as illustrated, the offset is 20 mm. This setting is in the rear as illustrated, [A] . out of the bearing seat. Take the lower triple clamp with the steer- the lower triple clamp out of the bearing seat. Take [4] [B] [5] SCREW SELF-LOCKING. REPLACE IF THE COLLAR SCREW CAN BE SCREWED IN BY HAND. LAR SCREW IS SELF-LOCKING. – THREAD MAKES THE COLLAR IN THE COLLAR SCREW A PLASTIC INSERT – THE COL- DO NOT CONFUSE THE COLLAR SCREW WITH THE BLIND SCREW. screw and upper triple clamp on the seat. Remove the O-ring front, the offset is 18 mm. This setting will deliver more directional stability setting will deliver offset is 18 mm. This front, the on fast race courses. If the mark in curves. will deliver better handling mm in the condition at delivery. The offset is set to 20 the offset, dismount the front wheel and remove the front wheel adjust To fender. plate. Remove the clamp screws Remove the screw on the starting number hand brake cylinder to the left fork on the hand brake cylinder and fasten the from kinking (see illustration). leg with a cable tie to keep the brake line Loosen the clamp screws and take the fork legs out of the triple clamps. Loosen the collar screw Remove the blind screw tection ring Tap gently on the lower triple clamp with a rubber hammer to loosen the steer- gently on the lower triple clamp with a rubber Tap ing stem ing stem out of the steering head. Remove the collar screw from the lower triple clamp and pull out the steer- steering stem 180° and insert the ing stem. Thoroughly clean all parts. Turn it in the triple clamp, tighten the collar screw all the way to the stop. Grease the steering head bearing and sealing elements. The fork offset The fork offset Changing the fork offset (caster) (SX / XC) * (SX / XC) the fork offset (caster) Changing angle) can be set to either 18 or 20 mm. This allows you to optimize the han- you to optimize the 20 mm. This allows be set to either 18 or angle) can the race course. dling to match blind screw Remove the A 3 4 5 2 2 1 2 3 B 5 4 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 28 MAINTENANCE WORKONCHASSISANDENGINE 1 2 3 1 Checking andadjustingthesteeringheadbearing* Mount thefrontwheel(see:Dismountingandmountingwheel). Mount thestaringnumberplate. Mount thehandbrakecylinderandtightenscrewsto10Nm. Mount thefrontwheelfenderandtightenscrewsto10Nm. triple clampto17Nmin3stages. ing thesteeringheadsupport)andtightenclampscrewsonupper Adjust thesteeringheadbearingwithoutclearance(see:Checkingandadjust- to 12Nmin3stages. Mount theforklegsandtightenclampscrewsonlowertriple Tighten thecollarscrewonlowertripleclampto60Nm. O-ring, uppertripleclampandtheblindscrew. Mount thelowertripleclamp,uppersteeringheadbearing,protectionring, (e.g. MotorexLongTerm 2000). The steeringheadbearingsshouldberegreasedatleastonceayear fork forwardandbackward.To adjustthe5clampingscrews cle onastandsothatthefrontwheelisoffground.Nowtrytomove Check steeringheadbearingforplayperiodically. To check,putthemotorcy- the uppertripleclampandturnendscrew sion. Retightenthefivepinchboltsto15Nm(SX)/20(EXC,XC-W). aged. With aplastichammer, lightlytaponthe tripleclamptoreleaseten- tighten thesteeringstemboltallway, otherwisethebearingswillbedam- WILL BEDESTROYED. ODS, THEBEARINGSANDSUBSEQUENTLY THEBEARINGSEATS INTHEFRAME IF YOUDRIVEWITHPLAY INTHESTEERINGHEADBEARINGFORLONGERPERI- APLASTIC INSERT INTHETHREADOFCLAMPINGSCREW[3]MAKESIT – IFTHESTEERING HEADBEARINGISNOTADJUSTEDTOBEFREEOFPLAY, – TURNED INBYHAND. SELF-LOCKING. THECLAMPINGSCREWMUSTBEREPLACEDIFITCAN CAN GETOUTOFCONTROL. THE MOTORCYCLEWILLEXHIBITUNSTEADYDRIVINGCHARACTERISTICSAND » [2] until noplayisleft.Don’t [1] and [3] , loosen

29 ENGLISH [4] [A] are offset from the cen- are offset [2] of the handlebar clamps and screws of the handlebar clamps » [3] to 20 Nm (15 ft.lbs). The gap between the handlebar sup- to 20 Nm (15 ft.lbs). MUST BE SECURED WITH LOCTITE 243. [3] [4] includes 2 bores arranged at a distance of 15 mm (0.6 in) from a distance of 15 mm bores arranged at includes 2 [1] to 40 Nm (30 ft.lbs). Mount the handlebar and handlebar clamps, and Mount the handlebar and handlebar to 40 Nm (30 ft.lbs). MISSION (CHAIN, CHAIN WHEELS AND REAR WHEEL BEARINGS) WILL BE SUB- MISSION (CHAIN, CHAIN WHEELS AND REAR WEAR AND IN PREMATURE STRESS, RESULTING JECTED TO UNNECESSARY EVEN CHAIN BREAKAGE. THIS HAPPENS, THE CHAIN COULD CHAIN JUMPING OFF THE CHAIN WHEELS. IF ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE. CYCLE. – TRANS- WITHIN THE SECONDARY PARTS GREAT, IF THE CHAIN TENSION IS TOO – THE IN MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT TOO – TO LOSE CONTROL OF THE MOTOR- IS LIKELY IN EITHER CASE THE OPERATOR ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in can mount the handlebar you mm (0.13 in). Accordingly, ter by 3.5 positions. 4 different screws For this purpose, remove one another. The bores at the handlebar support bores at the handlebar The one another. Jack the motorcycle up on its frame so that the rear wheel no longer touches Jack the motorcycle up on its frame so that the ground. chain sliding component. The dis- Press the chain upward at the end of the arm should be approx. 8 - 10 mm tance between the chain and the swing the upper chain portion (0.31 - 0.39 in). In the course of this procedure, The handlebar position can be readjusted by 22 mm. Thus, you can put the Thus, you can put readjusted by 22 mm. position can be The handlebar triple for you. The upper is the most convenient in the position that handlebar clamp THE SCREWS Check chain tension correct the chain tension. must be taut (see drawing). If necessary, How to change the handlebar position the handlebar How to change of the handlebar support. Position the handlebar support, and tighten screws Position the handlebar support, and of the handlebar support. [4] tighten screws the same size in the front and in port and the handlebar clamps should be the rear. 3 3,5 mm

A 15 mm 15

8-10 mm / 0.3-0.4 in 4 1 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 30 MAINTENANCE WORKONCHASSISANDENGINE 1 23 2 4 B 15 KG 33 lbs max. 272mm 3 3 1 B 4 16 1718 2 Tighten collarnut the frontwheel. close totheadjustingscrewsandthatrearwheelhasbeenalignedwith Before tighteningthecollarnut,verifythatchainadjusters screws Chain maintenance ALWAYS MOUNTTHECHAINTENSIONEREQUALLY ALIGNED. The chainadjusters to usedifferentsecondaryratiosincombinationwiththesamechainlength. The largeadjustingrangeofthechainadjusters(32mm/1.25in)allowsyou NOTE: Loosen collarnut Correct chaintension TIGHTENING TORQUEFORSCREWS: 50NM TIGHTENING TORQUEFORNUTS: 35NM THEM INACROSSWISEORDER. SECURE THESCREWSOFCHAIN WHEELBYAPPLYING LOCTITEANDFASTEN THE INSIDE. WHEN YOUASSEMBLEAREAR SPROCKET WITH14T, THECOLLARMUSTBEON wear fasterifusedonoldsprockets. If youmountanewchain,thesprocketsshouldalsobereplaced. Newchains NOTE: chain. wear offevenly, thereforerepeatthemeasurement atdifferentplacesonthe est whenaspaceof272mm(10.70in)ismeasured.Chains donotalways chain reelsatthelowerstrand.Theshouldbereplaced atthelat- kilograms (33lb)upwards(seefigure).Nowonecanmeasure aspaceof18 Shift thegearintoidlingandpullupperchainstrandwith approx.10-15 To checkthechainwear, observethefollowingindications: Chain wear Also checksprocketsandchainguidesforwear, andreplaceifnecessary. MUST POINTINRUNNINGDIRECTION. WHEN MOUNTINGTHECHAINJOINT, THECLOSEDSIDEOFSAFETYDEVICE OF CONTROL. WOULD BESTRONGLY REDUCEDANDTHEMOTORCYCLECOULDEASILY GETOUT EITHERWISE THEROADADHERENCEANDREARWHEELBRAKINGEFFECTS NO LUBRICATION ISALLOWEDTOREACHTHEREARTIREORBRAKEDISK, chain spray(MotorexChainlube622). brushes orsolvents.Afterlettingthechaindry, youcanuseaspecialX-ring only modestmaintenance.Thebestwayistouselotsofwater, butneveruse For longchainlife,goodmaintenanceisveryimportant.X-ringchainsrequire TIGHTENTHECOLLARNUTWITHREQUIREDTORQUE.ALOOSEWHEEL – IFYOUDON’THAPPENTOHAVE ATORQUEWRENCHAT HAND,MAKESURE – SPINDLE MAY LEADTOANUNSTABLE BEHAVIOR OFYOURMOTORCYCLE. IOR OFYOURMOTORCYCLE. AS POSSIBLE.ALOOSEAXLEMAY LEADTOANUNSTABLE DRIVINGBEHAV- YOU HAVE THETIGHTENINGTORQUECORRECTEDBYAKTMDEALERASSOON [3] equally far. Tighten locknuts. [1] [1] [4] , loosenlocknuts to 80Nm(60ft.lb). can berotatedby180°. » [2] , andturnrightleftadjusting [4] are sitting

31 ENGLISH . Check the [A] » of the brake pads decreases. The brake disk must be at least of the brake pads decreases. The brake mance, long life, for wet slippery terrain. mance, long life, for perfor- – easy to dose, good brake FERODO ID 450 (ORGANIC) mance, short life, for dry terrain, low price. shorter service FERODO 4424 (organic) – better controllability, life, for dry terrain. life than FERODO 4424, TOSHIBA H38 (Sinter) – longer service higher braking performance. [1] IS A SAFETY RISK. HAVE THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE BRAKE DISK IS A SAFETY RISK. HAVE LIMIT. THE SERVICE DEALER. – A BRAKE DISK WORN DOWN TO LESS THAN 2.50 MM (FRONT) / 3.50 MM (REAR) – ON THE BRAKE SYSTEM BE PERFORMED BY A KTM REPAIRS ANY HAVE thickness of the brake disk at several points. 2.50 mm (front) / 3.50 mm (rear) thick at the thinnest point 2.50 mm (front) / 3.50 mm (rear) thick BRAKE FLUID RESERVOIRS: and rear wheel brakes have been The brake fluid reservoirs on the front brake pads are worn it is not neces- designed in such a way that even if the fluid level drops below the mini- sary to top up the brake fluid. If the brake leak or the brake pads are completely mum level either the brake system has a worn. In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, recommend that you one of the best brake fluids is currently available. We continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an If you do not have any DOT 5.1 for refilling, you may use DOT amber color. you should replace it as soon as 4 brake fluid. However, possible with DOT 5.1. Never use brake fluid DOT 5. The color of this silicon oil-based product is purple red. The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid. YOUR IF YOU WASH LEAST ONCE ANNUALLY. THE BRAKE FLUID CHANGED AT HAVE MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE- POCK- THEREFORE, VAPOR BRAKE FLUID TENDS TO ABSORB WATER. QUENTLY. CAUS- LOW TEMPERATURES, FORM IN „OLD“ BRAKE FLUIDS EVEN AT ETS MAY ING THE BRAKE SYSTEM TO FAIL. BRAKE CALIPERS: the This means that use a „floating“ mount. calipers of this series The brake support, which enables to the caliper are not solidly attached brake calipers caliper the screws of the contact.Secure for maximum braking them to ”float” ft.lb). tighten to 25 Nm (19 Loctite 243 and support with BRAKE PADS: at the front with TOSHIBA TT 2701 sintered lining The brake pads are fitted provide an opti- sintered lining at the back. These linings and TOYO B 143 FF The lining type dosing, brake performance and life cycle. mal combination of homologation of the brake pad and also recorded in the is stated on the back papers. available for competition sports. Other brake pads are perfor- (SINTERED) – harder to dose, good brake TOSHIBA H 38 FRONT: REAR: BRAKE DISCS: in the area of the contact the thickness of the brake disc Due to wear, face General information about KTM about General information brakes disc A 1 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 32 MAINTENANCE WORKONCHASSISANDENGINE 1 mm min. 3 1 5 mm min. 3mm 4 2 Refilling thefrontbrakefluidreservoir* CONSULT ANAUTHORIZEDKTMDEALERIMMEDIATELY. SYSTEM HASALEAKORTHEBRAKEPADS ARECOMPLETELY WORN.INTHISCASE, IF THEBRAKEFLUIDLEVELDROPSBELOWMINIMUMEITHER middle oftheglass. voir inahorizontalposition,thebrakefluidlevelshouldnotdropbelow handlebar andthereservoirisprovidedwithaninspectionglass.With thereser- The brakefluidreservoirislinkedwiththehandcylinderat Checking thebrakefluidlevel-front SYSTEM, ANDTHEFRONT-WHEEL BRAKEMAY FAIL DUETOOVERHEATING. FREE TRAVEL ISNOTPROVIDED,PRESSUREWILLBUILDUPINTHEBRAKING RECOGNIZED BYTHEGREATER RESISTANCE OFTHEHANDBRAKELEVER).IFTHIS ONLY THENMAY THEPISTONINHANDBRAKECYLINDERBEMOVED(TO AT THEHANDBRAKELEVER,FREETRAVEL MUSTAT LEASTBE3MM(0.1IN). screw Free travelatthehandbrakelevermaybereadjustedbyusingadjustment Adjusting thefreetravelathandbrakelever DESTROYING THE BRAKEDISC. AGAINST THEBRAKE DISC,THEREBYIMPARING THEBRAKINGEFFECT AND OR ENTIRELY WORN,THESTEELCOMPONENTS OFTHEBRAKEPAD WILLRUB IF THEBRAKEPADS ARE REPLACEDTOOLATE SOTHAT THE LININGISPARTLY SAFETY DON’TPUTOFFHAVING YOURBRAKEPADS CHANGED. THAN 1MM,OTHERWISE THEYCOULDLEADTOBRAKEFAILURE. FORYOUROWN AT THEIRMOSTWORNPOINTBRAKEPAD LININGSSHOULDNOTBETHINNER mm (0.04in)thick. The brakepadscanbeinspectedfrombelow. Theliningsmustbeatleast1 Checking thefrontbrakepads Loosen screws spilled oroverflowingbrakefluidwithwater. 5.1).Replacemembraneandlid,tightenscrews.Rinseoff Brake FluidDOT 5.1(e.g.Motorex voir to5mm(0.2in)belowtherimwithcleanbrakefluidDOT Place handbrakecylinderinahorizontalpositionandfillthefluidreser- 3 mmfreetravel.Turn theadjustingscrew When youpressthehandbrakeleverforwards,shouldhaveatleast brake disc)canbeadjustedforanyhandsize. you feelonthehandbrakeleverwhenpadsarepressedagainst USEONLY CLEANBRAKEFLUIDTAKEN FROMATIGHTLY SEALEDCONTAINER. – DON’TLET BRAKEFLUIDGETINCONTACT WITHPAINT, ITISANEFFECTIVE – BRAKEFLUID CANCAUSESKINIRRITATION. AVOID CONTACT WITHSKINAND – STOREBRAKE FLUIDOUTOFREACHCHILDREN. – NEVERUSE DOT5BRAKEFLUID!ITISBASEDONSILICONEOILANDOFA – PAINT REMOVER. AND CONSULT ADOCTOR EYES. IFYOUGETBRAKEFLUIDINYOUREYES,RINSEWITHPLENTYOFWATER TO IT. PURPLE COLOR.SEALSANDBRAKEHOSESMUSTBEESPECIALLY ADAPTED [1] . Inthisway, thepositionofpointpressure(i.e.resis-tance [2] and removelid [3] » and membrane [1] if necessary. [4] .

33 ENGLISH . . [4] [A] when the vehicle is . Remove brake pads . Remove [A] [2] » and pull out bolt and pull out [1] . . Fill DOT5.1 brake fluid (e.g. Motorex Brake Fluid [6] [7] on the inside of the reservoir and remount the screw. in the caliper support and of the leaf spring in the caliper support [B] [3] . The free play at the foot brake pedal must then be adjusted by . The free play at the foot brake pedal [5] PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY TO IT. EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER A DOCTOR. AND CONSULT REMOVER. PAINT MATTERS. OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED. STRONGLY THE BRAKING EFFECT WOULD BE OTHERWISE, MATTERS. THE BRAKE ENSURE THAT TO LEVER, RESPECTIVELY LEVER OR FOOT BRAKE POINT IS ESTAB- THE BRAKE DISK AND THE PRESSURE WILL LIE AGAINST PADS LISHED. – ON SILICONE OIL AND OF A NEVER USE DOT5 BRAKE FLUID! IT IS BASED – STORE BRAKE FLUID OUT OF REACH OF CHILDREN. – WITH SKIN AND CONTACT AVOID BRAKE FLUID CAN CAUSE SKIN IRRITATION. – IT IS AN EFFECTIVE WITH PAINT, DON’T LET BRAKE FLUID GET IN CONTACT – SEALED CONTAINER. FROM A TIGHTLY TAKEN CLEAN BRAKE FLUID USE ONLY – OIL AND FATTY TO KEEP THE BRAKE DISK FREE FROM IMPORTANT IT IS VERY – CORRECTLY. BEEN FITTED CHECK IF CIRCLIPS HAVE AFTER ASSEMBLY, – THE HAND BRAKE ACTUATE BRAKING SYSTEM, ALWAYS AFTER WORKING ON THE 5.1) up to the mark Spilled brake fluid must be rinsed off with water. from the brake caliper. Clean the brake caliper and the brake caliper support caliper and the brake Clean the brake caliper. from the brake for damage, and of the guide bolts Check the sleeves air. with compressed bolts if necessary. grease guide pad Mount the left brake fix it with the bolt. right brake pad and Mount the it stops. Mount the clips. and insert the bolt until fit of the brake pads, be sure to check for correct When mounting the sliding metal-sheet IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE IS NOT PRESENT, IF THIS FREE PLAY THE REAR WHEEL TO BRAKE.THE BRAKE SYSTEM WHEN DRIVING, CAUSING EXTREME IN COMPLETELY EVEN FAIL AND MAY BRAKING SYSTEM OVERHEATS CASES. Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motorcycle on the rear brake cylinder. No air bubble should be visible in inspection glass IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE WORN. IN THIS CASE, ARE COMPLETELY SYSTEM HAS A LEAK OR THE BRAKE PADS AN AUTHORIZED KTM DEALER IMMEDIATELY. CONSULT Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass Press the brake caliper toward the brake disk, to put the brake piston in its put the brake piston the brake disk, to brake caliper toward Press the Remove clips basic position. foot brake pedal * Changing the basic position of the can be altered by turning the stop The basic position of the foot brake pedal screw means of the piston rod must have 3-5 mm (0.12–0.20 Measured on the outside, the foot brake pedal move the piston in the brake cylin- in) of free play before the piston rod can on the foot brake pedal). der (to be recognised from the resistance top up, remove screw To Replacing the front brake pads * the front brake Replacing parked in a vertical position. 1 4 3-5mm A 2 3 B 1 7 6 2 5 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 34 MAINTENANCE WORKONCHASSISANDENGINE 1 mm min. 2 3 2 4 1 6 5 safety device the rightbrakepadandknockbolt Slide theleftbrakepadintocaliperandfixitwithpin.in air andcheckthesleevesofguidepinsfordamage. and removethebrakepads.Carefullycleancaliperwithcompressed Loosen andremovethecollarnut the guidepin piston toreachitsbasicposition.Removethesafetydevice Press thebrakecaliper Replacing therearbrakepads* DESTROYING THEBRAKEDISC. AGAINST THEBRAKEDISC,THEREBYIMPARING THEBRAKINGEFFECTAND OR ENTIRELY WORN,THESTEELCOMPONENTSOFBRAKEPAD WILLRUB IF THEBRAKEPADS AREREPLACEDTOOLATE SOTHAT THELININGISPARTLY SAFETY DON’TPUTOFFHAVING YOURBRAKEPADS CHANGED. THAN 1MM,OTHERWISE THEYCOULDLEADTOBRAKEFAILURE. FORYOUROWN AT THEIRMOSTWORNPOINTBRAKEPAD LININGSSHOULDNOTBETHINNER may notbelessthan1mm(0.04in). The brakepadscanbeinspectedfromtherear. Thethicknessofthelinings Checking therearbrakepads Loosen the2clampingscrews front wheelnolongertouchestheground. To removethe frontwheel,jackthemotorcycleuponitsframesothat Dismounting andmountingthefrontwheel Hold thefrontwheel,pulloutwheelspindle right sideoftheforkfist. Carefully removethefrontwheelfromfork. AFTERWORKINGONTHEBRAKINGSYSTEM,ONEMUSTALWAYS ACTUATE THE – AFTERASSEMBLY, CHECKIFCIRCLIPSHAVE BEENFITTEDCORRECTLY. – ITISVERY IMPORTANT TOKEEPTHEBRAKEDISKFREEFROMOILANDFATTY – MAKESURETHEBRAKEDISCISALWAYS ONTOPWHENYOULAY DOWNTHE – DONOTOPERATE THEHANDBRAKE WHENTHEFRONTWHEELHASBEEN – SURE POINTISESTABLISHED. THAT THEBRAKEPADS WILLLIEAGAINSTTHEBRAKEDISKANDPRES- HAND BRAKELEVERORFOOTLEVER,RESPECTIVELY SOASTOENSURE MATTERS. OTHERWISE, THEBRAKINGEFFECTWOULDBESTRONGLY REDUCED. WHEEL, OTHERWISE THEBRAKEDISCCANBEDAMAGED. DISMOUNTED. [2] [3] . from thebrakecaliperwithadrifttowardschainwheel [1] in thedirectionofchainwheelforbrake [4] [5] » on theleftsideofforkfists. , loosentheclampingscreews [3] in asfaritwillgo.Mountthe [7] . [2] , knockout [6] on the

35 ENGLISH [A] on the right [6] and pull out the [2] » , tighten the clamping screws , tighten the of the distance bushings and mount the distance bushings and mount of the distance [5] , remove the chain tensioner [B] [1] until you can push the rear wheel forwards. until you can push the rear wheel forwards. [3] YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON YOU HAVE DRIVING BEHAV- LEAD TO AN UNSTABLE AS POSSIBLE. A LOOSE AXLE MAY IOR OF YOUR MOTORCYCLE. THE PRESSURE POINT RETURNS. REDUCED. THE BRAKING EFFECTS WOULD BE STRONGLY OTHERWISE MATTERS, OF YOUR MOTORCYCLE. BEHAVIOR LEAD TO AN UNSTABLE SPINDLE MAY DISMOUNTED. THE BRAKE DISC CAN BE DAMAGED. WHEEL, OTHERWISE OF GREASE TO PRE- A NEW COAT AND APPLY AND COLLAR NUT THOROUGHLY VENT THE THREAD FROM JAMMING. YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON TORQUE CORRECTED BY A KTM THE TIGHTENING YOU HAVE DRIVING BEHAV- LEAD TO AN UNSTABLE AXLE MAY AS POSSIBLE. A LOOSE IOR OF YOUR MOTORCYCLE. UNTIL THE PRESSURE POINT RETURNS. REDUCED. EFFECT WOULD BE STRONGLY THE BRAKING OTHERWISE MATTERS, – HAND, MAKE SURE A TORQUE WRENCH AT IF YOU DON’T HAPPEN TO HAVE – UNTIL THE REAR BRAKE AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING –BRAKE DISK FREE FROM OIL AND FATTY TO KEEP THE IMPORTANT IT IS VERY – TORQUE. A LOOSE WHEEL TIGHTEN THE COLLAR NUT WITH THE REQUIRED – THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN NOT OPERATE DO – DOWN THE WHEN YOU LAY ON TOP SURE THE BRAKE DISC IS ALWAYS MAKE – AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE IF THE – HAND, MAKE SURE A TORQUE WRENCH AT TO HAVE IF YOU DON’T HAPPEN – THE HAND BRAKE MOUNTING THE FRONT WHEEL, KEEP OPERATING AFTER – TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY IMPORTANT VERY IT IS wheel spindle the chain off the rear sprocket, pull out the wheel spindle and carefully Take remove the rear wheel from the swing arm. fork leg axle passage to prevent the axle shaft from turning and tighten the to prevent the axle shaft from turning fork leg axle passage (30ft.lb). collar nut to 40 Nm down from the motorcycle on the right fork leg. Take Loosen the clamp screws fork a few times wheel brakes and push down on the its stand. Press the front fork legs come into alignment. vigorously so that the on both fork accomplished, tighten the clamp screws Only after this has been lbs). legs with 15 Nm(7 ft. bushing and mount the axle the fork, position front wheel, lift it into install the To the collar nut shaft. Mount the rear wheel no longer touches Jack the motorcycle up on its frame so that the ground. Remove the collar nut Before tightening the col- The rear wheel is remounted in the reverse order. lar nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain tensioners lie on the tension screws. and the bearing surface and the bearing wheel Dismounting and mounting the rear Before remounting the front wheel, clean and grease the shaft seal rings shaft seal grease the clean and wheel, the front remounting Before A 3 B 2 1 7 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 36 MAINTENANCE WORKONCHASSISANDENGINE Road Off-road TIRES –AIRPRESSURE 1,5 bar 1,0 bar front 2,0 bar 1,0 bar rear 1 Checking spoketension anywhere onyourmotorcycle. cle ridesandmustthereforebecheckedwheneveryouaregettingreadytogo Tire type,tirecondition,andairpressurelevelaffectthewayyourmotorcy- Tires, airpressure Remove thescrewconnection Remove theheadlightmaskanddisassembleelectronic speedometer. Replacing thebatteryofdigitalspeedometer dealer. have thespokesretightenedandwheelcenteredbyaKTM must betheresult.Dulltonesareindicatorsofloosespokes.Ifnecessary, tap oneachspokewiththebladeofascrewdriver(seephoto).Acleartone tension, especiallyonanewmotorcycle,atregularintervals.Forchecking, unbalanced andbeforelongotherspokeswillhavecomeloose.Checkspoke thus forridingsafety. Aloosespokecausesthewheeltobecome The correctspoketensionisveryimportantforthestabilityofwheelsand with thewritingfacingupandreinstallscrewconnection. Tire pressureshouldbecheckedregularly ona“cold”tire.Properpres- – Refertothespecificregulationsinyourcountryforminimumtiretread – Tire conditionhastobecheckedeverytime youwanttorideyourmotor- – Tire sizecanbefoundinthetechnicalspecifications andinthehomolo- – IFAIRPRESSUREISTOOLOW, ABNORMALWEARANDOVERHEATING OFTHE – WORNTIRESCANHAVE ANEGATIVE EFFECTONHOWYOURMOTORCYCLEPER- – FORYOUROWNSAFETYREPLACEDAMAGEDTIRESIMMEDIATELY. – FRONTANDREARWHEELSMAY ONLY BEFITTEDWITHTIRESHAVING THE – DONOTMOUNTTIRESWHICHHAVE NOTBEENAPPROVEDBYKTM.OTHER – EXCESSIVELY TENSIONEDSPOKESMAY RUPTUREDUETOLOCALOVERLOAD- – SPOKES CAN TEARIFYOUCONTINUETORIDEWITHTHEMLOOSE.THISMAY – sure ensuresoptimumdrivingcomfortandextendsthelifeofyourtires. tread isdownto2mm(0.08in). requirements. We recommendyoureplacethetiresatlatestwhen objects thatmighthavebecomeembeddedinthem. cycle. Beforeleaving,checktiresforpuncturesandnailsorothersharp gation certificate TIRE CANRESULT FORMS, ESPECIALLY ONWETSURFACES SAME TREADLAYOUT. USEHOMOLOGATED TIRES BEHAVES. TIRES COULDHAVE ADVERSEEFFECTSONTHEWAY YOURMOTORCYCLE ING.THE SPOKESMUSTBETENSIONEDTO5NM. LEAD TOANUNSTABLE HANDLINGOFYOURMOTORCYCLE. [1] , insertthebattery(typeDuracellCR2430) »

37 ENGLISH in or off. must be 2-4 mm, must be 2-4 . Disengage retain- [1] [5] [1] carefully out of the reflector. Pull carefully out of the reflector. and the sensor and the sensor [2] [3] » off the headlamp and remove rubber cap off the headlamp and remove rubber cap [4] otherwise malfunctions on the speedometer might occur. speedometer might malfunctions on the otherwise by screwing the sensor can be corrected This distance connector When changing the parking- ing clip and take the bulb out of the reflector. light lamp, simply pull it out of the holder. Loosen both rubber bands and tilt the headlight mask to the front. Pull the Loosen both rubber bands and tilt the headlight parking light lamp with holder Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket. above. mount the lamp reverse the worksteps indicated To The distance between the magnet between the magnet The distance light lamp Replacing the headlight lamp/parking Check/set distance of the magnetic sensor distance of the Check/set 1 3 4 2 1 4 5 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 38 MAINTENANCE WORKONCHASSISANDENGINE 2 4 when engineistcold 10 mm 1 3 OE Theradiatorshuttercanbe obtained NOTE: Remount theradiatorprotection. ator asillustrated. not bereplacedbywateralone. mixture offersfrostprotectionaswellgoodcorrosionandshould uid. Theantifreezeshouldbedesignedfortemperaturesofatleast-25°C.This Use amixtureof50%antifreezeanddistilledwaterforthecoolingliq- the coolingeffect. effect decreaseswiththetravelingspeed.Dirtyradiatorsadditionallyreduce The coolingliquidiscooledbytheairstream.Thismeansthat radiators. stat opensandthecoolingliquidisalsopumpedthroughtwoaluminum cooling liquidhasreachedatemperatureofapproximately55°C,thethermo- coolant circulatesinthecylinderandhead.Assoonas its operatingtemperaturemorequickly. Whentheengineiscold,liquid Some modelsareequippedwithathermostat (see Bleedingthecoolingsystem). b) afterrefillingtheentirecoolingsystem. a) afteraddingmorethan0.25lcoolingliquidand Bleeding ofthecoolingsystemisthereforerequired bubbles. ing liquidcanonlycirculateproperlyifthecoolingcircuitcontainsnoair The waterpumpintheenginecirculatescoolingliquid.However, thecool- Cooling system RATRADN OETA .5L(.6U GALLONS) COOLINGLIQUID. OR AFTERADDING MORETHAN0.25L(0.06US THE COOLINGSYSTEM MUSTBEBLEDAFTER DRAINING THECOOLINGLIQUID USE ARAGTOCOVERTHECAP AND OPENSLOWLY TORELEASEPRESSURE. IS COLD.IFYOUHAVE TOOPENTHERADIATOR CAPWHENTHEENGINEISHOT, IF POSSIBLE,ALWAYS CHECKTHELEVELOFCOOLING LIQUIDWHENTHEENGINE and bleedthesystem. is cold(seediagram).Intheeventofcoolantbeingdrained, alwaysfill The coolantshouldbe10mm(0.4in)abovetheradiatorfins whentheengine Checking thecoolantlevel tion For thispurpose,detachtheleftradiatorprotec- peratures, theradiatorcover To ensurethat theenginereachesitsoperativetemperaturealsoatlowtem- Radiator coverforthecoldseason valve intheradiatorcap Pressure inducedbyheatingofthecoolantinsystemiscontrolleda CORROSION ANDCOOLANTFOAMING. MOTOREX ANTI-FREEZE).USINGLOWER-GRADEANTIFREEZEAGENTSCANCAUSE FOR THECOOLINGSYSTEM,USEONLY WITHHIGH-GRADEANTIFREEZE(E.G. is admissiblewithout,havingtoexpectanytrouble. IFCOOLANT GETS INTOYOUREYES,RINSETHEMOUTWITHWATER IMMEDI- – INCASECOOLANT ISINGESTED,CONSULT ADOCTORIMMEDIATELY. – COOLANTIS TOXIC. KEEPTHECOOLANTOUTOFREACHCHILDREN. – INCASEYOUGETBURNT, HOLDTHEAFFECTEDPART OFYOURBODYUNDER – DONOTDETACH ANYRADIATOR HOSESWHILETHEENGINEISHOT. THE – IFPOSSIBLE,ALWAYS CHECK LEVELOFCOOLINGLIQUIDWHENENGINEIS – ATELY ANDGOSEEADOCTOR. RUNNING COLDWATER RIGHTAWAY. ESCAPING HOTCOOLANTANDTHESTEAMMAY CAUSESERIOUSBURNS. SURE. CAUTION-SCALDINGHAZARD. HOT, USEARAGTOCOVERTHECAPANDOPENSLOWLY TORELEASEPRES- COLD. IFYOUHAVE TOOPENTHERADIATOR CAP [4] and mountthecoverinfrontofleftradi- from yourKTMdealer [2] ; awatertemperatureofupto120°C(248°F) [3] must bemounted. » [1] so thattheenginereaches [2] WHEN THEENGINEIS 4 3

39 ENGLISH from the filter [7] , tilt aside and remove [4] and filter support [6] is fastened. » [1] on the right radiator. on the right radiator. and the air filter [3] at the cylinder head. Reinstall it as soon as the cooling liq- at the cylinder head. [5] [2] AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY AGE THE FOAM. KTM RECOMMENDS THE REMOVER AND LIQUID MAINTENANCE (BIO DIRT MOTOREX FOR AIR FILTER BIO POWER). AND CAUSE DAMAGE AND INCREASED WEAR. PENETRATE MAY DUST AND DIRT TER IS NOT MOUNTED CORRECTLY. – DAM- WITH FUEL OR PETROLEUM SINCE THESE NOT CLEAN FOAM FILTER DO – OTHERWISE, YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. START NEVER – AND DAMAGE THE ENGINE IF THE AIR FIL- CAN ACCUMULATE DUST AND DIRT the throttle cap uid emerges free of air bubbles (only for 125/200 engines). uid emerges free of Remove the screw free of bubbles at the right radiator. Now add cooling liquid until it emerges that no more air can enter the right Then immediately mount the screw so radiator. up the left radiator until the coolant can be seen approx. 10 mm Top (0.4 in) above the radiator fins. ride. Check the coolant level again after a short Pour approx. 0.5 litres (0.13 USPour approx. into the system. gallons) coolant Remove screw The air filter must be cleaned prior to each race or whenever dust has accu- The air filter must be cleaned prior to each clean, lift the filter box cover mulated. To front. (see illustration) and pull off towards the bracket Detach the bottom of the filter retaining Thoroughly wash the air filter in special cleaning fluid (Motorex Bio Dirt do not wring it out Remover) and allow it to dry well. Only press out the filter, under any circumstances. Oil the dry air filter with a high-grade filter oil (Motorex liquid Bio Power). Also clean the air filter box. Check the carburetor collar for damage and that it is filled correctly. Mount the air filter on the filter support. Insert the air filter and filter support in the throttle cap and mount them in the filter box, aligning in a central position, and fix with the filter retaining bracket. The cooling system must be bled as described below after draining the below after draining bled as described system must be The cooling US than 0.25 l (0.06 or after adding more cooling liquid cooling liq- gallons) uid. that the drain screw Make sure Cleaning the air filter * Refilling/Bleeding the cooling system the cooling Refilling/Bleeding box. The SX models do not have a throttle cap. box. The SX models do not have a throttle 4 3 5 1 6 4 2 7 1 6 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 40 MAINTENANCE WORKONCHASSISANDENGINE 3 2 6 SX 4 1 2 EXC 3 8 1 7 fluid tothe250/300models,availablefromyourauthorized KTMworkshop. 75) tothe125/200modelsandDOT5.1(MotorexBrake Fluid 5.1)brake If necessary, addbiodegradableSAE10hydraulicoil(MotorexKupplungsfluid 4 mmbelowtheupperedge. boot increases thedistancebetweenclutchleverandhandlebar. clutch leverandthehandlebar. Turning theadjustingscrewcounterclockwise Turning the adjusting screwclockwisereducesthedistancebetween for everyhandsize. position oftheclutchlever, thusallowingadjustmenttoanoptimalposition Changing theoriginalpositionofclutchlever COOLED DOWN,TOAVOID BURNS. NING. DONOTSTART WORKONTHEEXHAUSTSYSTEMUNTILITHASPROPERLY THE EXHAUSTSYSTEMBECOMESVERY HOTWHILETHEMOTORCYCLEISRUN- outer pipe To replacetheglass-fiberyarnset your authorizedKTMworkshop. acteristic. Theinsulatingmaterialsuitableforyourexhaustisavailablefrom In additiontocausingahighernoise-level,itwillalsoaffectthepowerchar- the holesinperforatedpipewithtime,causingsilencerto“burnout”. Lubrication andServiceChart).Theinsulatingmaterialfibersescapethrough Have thefillingcheckedregularlybyanauthorizedKTMworkshop(see If theendcap Exhaust system* For thispurpose,removescrews To checkthe oillevelinthemastercylinderofclutchremovecover. Checking theoillevelofhydraulicclutch EXCESSIVE FORCE. TAIN LIMITS.ONLY TURNTHEADJUSTINGSCREWMANUALLY ANDNEVERAPPLY ADJUSTMENT OFTHECLUTCHLEVERPOSITIONISONLY POSSIBLEWITHINCER- The adjustingscrew tightening thefixingscrews. Make surethecapsarescrewedontightly. Mountthemufflerstress-freebefore the outerpipe.Mountendcap. BREMBOCLUTCHFITTINGSAREINSTALLED INTHE250/300MODELS AND – KTMUSESBIODEGRADABLE,HYDRAULICMINERALOILTOACTUATE THE – IS AVAILABLE FROM YOURAUTHORIZEDKTMWORKSHOP). SMOOTHLY, NEVERADDHYDRAULICOILTO THESESYSTEMS(ASUITABLE FLUID FILLED WITHDOT5.1BRAKEFLUID.TOMAKESURETHECLUTCH OPERATES CLUTCH OPERATES SMOOTHLY. NEVERREFILLWITHBRAKEFLUID. LABLE FROMYOURAUTHORIZEDKTMWORKSHOP)TOMAKE SUREYOUR OTHER HYDRAULICOIL.ALWAYS USEORIGINALKTMHYDRAULICOIL(AVAI- HYDRAULIC CLUTCHIN125/200MODELS.DONOTMIXTHISOIL WITHANY [4] . Theoillevelinthehorizontal-standingmastercylindershouldbe [3] . Tape anewglass-fiberyarnsettotheinnertubeandslideon [1] can beremoved,thesilencerisfilledwithglass-fiberyarn. [1] can beusedforindividualadjustmentoftheoriginal [2] » [2] and cover remove theendcapandpulloff [3] together withtherubber

41 ENGLISH in the mas- [11] . Fill the bleeder syringe . Fill the bleeder [8] and mount the bleeder syringe. and mount the bleeder [10] » and the rubber boot and the rubber [7] , the cover , the cover [6] with a suitable fluid (see Technical Specifications - Engine). Remove the Specifications - Engine). fluid (see Technical with a suitable [9] the slave cylinder bleeder screw from Press oil into the system until the fluid runs out of the hole Press oil into the system ter cylinder without bubbles. Occasionally extract the fluid from the master bubbles. Occasionally extract the fluid ter cylinder without keep it from overflowing. cylinder reservoir to bleeder screw, remove the bleeder syringe, mount the After you finish bleeding, reservoir and mount the cover (see above). correct the level in the The clutch control needs to be bled as soon as the resistance in the clutch resistance in the bled as soon as the control needs to be The clutch (special tool) will need a bleeder syringe You to feel unresponsive. lever starts from your KTM dealer. Both are available hydraulic oil. and biodegradable position, remove cylinder is in a horizontal until the master the handlebar Turn the screws Bleeding the hydraulic clutch * the hydraulic clutch Bleeding 10 11 9 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 42 retor malfunction(e.g.overlyrichmixture).Therefore,thesepartsshouldbereplacedafter10000kilometers(6000miles). As aresultofenginevibrations,throttlevalve,jetneedle,andneedlearesubjectedtoincreasedwear. Thiswearmaycau Basic informationoncarburetorwear Iftheenginedoesnotrunproperlydespiteachangedadjustment,lookformechanicalfaultsandcheckignitionsystem NOTE: >chooseleanercarburetoradjustment highaltitudeortemperatures RULE OFTHUMB: jet needleissufficientandthatchangesofotherpartsthecarburetorwillnotgreatlyaffectengineperformance. ter system,air-tight exhaustsystemandanintactcarburetor. Experiencehasshownthatadjustingthemainjet,idlingjet the carburetorneedstobeadjustedaccordingdatasheet-seeappendix).Essentialrequirementsareaclean Always startwiththeoriginalcarburetorsetting(theprovidedfactoryismeantforbreak-inoperation;afterbrea Basic informationonchangingthecarburetorsetting 1:40 –1:60 Mixing ratio(2-strokemotoroil:superfuel) temperature ofapprox.20°C(68°F),mainlyforoff-roaduseandcentralEuropeanpremium-gradefuel(95ROZ). The originalcarburetorsettingwasadaptedforanaltitudeofapprox.500meters(1600ft.)abovesealevel,andtheambient Basic informationontheoriginalcarburetorsetting Carburetor adjustment* MAINTENANCE WORKONCHASSISANDENGINE INTHECASEOFALEANERADJUSTMENTCARBURETOR,PROCEEDCAUTIOUSLY. ALWAYS REDUCETHEJETSIZEINSTEPS OFONE – NOTENOUGHOILORLOW-GRADE OILCANCAUSEEROSIONOFTHEPISTON.IFYOUUSETOOMUCHENGINESTART SMOK- – MOTOREXCROSSPOWER2T). ONLY USEHIGH-GRADE2-STROKEENGINEOILOFKNOWNBRANDS(E.G. – ONLY USEPREMIUM-GRADEGASOLINEROZ95(USA=PREMIUMRON91)MIXEDWITHHIGH-GRADE TWO-STROKEENGINEOIL.OTHER – NUMBER TOAVOID OVERHEATING ANDPISTONSEIZURE. ING ANDFOULTHESPARK PLUGANDTHEEXHAUSTCONTROLSYSTEM. TYPES OFGASOLINECANCAUSEENGINEFAILURE, ANDWILLVOIDYOURWARRANTY.

D (depends onoilquality)

B A o liueo o eprtrs >chooserichercarburetoradjustment low altitudeortemperatures throttle valve idle jet jet needle jet needle main jet idle adjustingscrew air controlscrew 3 2 by meansoftheaircontrolscrew. control screw=openby1.5turns).Thenadjusttothenormalidlingspeed and stableenginespeedusingtheaircontrolscrew(basicpositionof ing thescrewcounterclockwiseproducesaloweridlingspeed.Createround air controlscrew. Turning itclockwise producesahigheridlingspeedandturn- To thisend,slightly increasetheidlingspeedofenginebymeans ments whentheengineishot. Not enoughfuelinproportiontoair. Mixture toolean: Too muchfuel inproportiontoair. Mixture toorich: Definitions float needleisleaking. the mixturetocarburetorwillbetoorich,fuellevel toohighorthe and developsitsfullpowernotsmoothlybutsuddenlyathigh enginespeeds, throttle setting,theenginesputtersandsmokeswhen isfullyopened throttle valveinfluencesthisrange.If,despitegoodidling-speedandpart- Engine behaviorwhenthethrottleopens.Theidlejetandshapeof Opening upB of theaircontrolscrew Operation withclosedthrottlevalve.Thisrangeisinfluencedbytheposition Idling rangeA [2] and theaircontrolscrew » [3] . Onlymakeadjust- k-in period, se carbu- andthe ir fil- .

43 ENGLISH » and clean it with compressed air. Then, mount the plug Then, mount and clean it with compressed air. [1] Following every wet-cleaning procedure, the float chamber of the carburetor Following every wet-cleaning procedure, water that may have penetrated into should be drained in order to remove any in the float chamber leads to engine malfunction. it. Water cold. Close the fuel tap, and place Make sure you do this while the engine is of absorbing the leaking fuel. which is capable a cloth under the carburetor, Unscrew the plug AND TOXIC. WHEN HANDLING FUEL, BE SURE TO FLAMMABLE FUEL IS EASILY ANY WORK ON THE FUEL SYS- EXERCISE THE UTMOST CAUTION. NEVER PERFORM ALLOW THE ENGINE ALWAYS TEM NEAR OPEN FLAMES OR BURNING CIGARETTES. BEEN HAVE CLEAN UP ANY FUEL WHICH MAY IMMEDIATELY TO COOL OFF FIRST. FLAMMABLE. IN FUEL ARE ALSO EASILY WITH SATURATED SPILLED. MATERIALS A CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES, CONSULT 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 In this position, the edge of the float needle valve is not pressed together. should be parallel with the float chamber sealing surface (see illustration). Operation with partly open throttle valve. This range is only influenced by the is only influenced valve. This range with partly open throttle Operation setting is controlled The optimum part-throttle (shape and position). jet needle range. jet in the upper range and by the main setting in the lower by the idling it is reduced power when cycle or with runs on a four-stroke If the engine by must be lowered open, the jet needle with the throttle partly accelerated full accelerating under pings, especially when If then the engine one notch. revs, the jet needle should be raised. power at maximum engine range at a occur at the lower end of the part throttle If these faults should pings, adjust make the idling range leaner; if the engine running, four-stroke the idling range richer. D Full throttle range is influenced by fully open (flat out). This range Operation with the throttle plug is found jet needle. If the porcelain of the new spark the main jet and the after a short dis- or white coating or if the engine rings, to have a very bright is required. If the porcelain is dark tance of riding flat out, a larger main jet be replaced by a smaller one. brown or black with soot the main jet must Draining the float chamber of the carburetor Part-throttle range C Part-throttle together with the gasket, open the fuel tap, and check the float together with the gasket, open the chamber for leaks. air control screw idle adjusting screw main jet jet needle jet needle idle jet throttle valve 1 RANGE OF ACTION 60°

RICHER LEANER RICHER

C D TYPE NOZH NOZG NOZF NOZE NOZD JET NEEDLE MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 44 MAINTENANCE WORKONCHASSISANDENGINE 2 3 6 3 5 2 1 2 4 lift offtheclosingcover To mount,tiltthemotorcycleapprox.45°toleft,removebothscrews ply). Sparepartnumber548.37.072.000,REDcolormark Auxiliary springforaggressiveenginecharacteristic(includedinscopeofsup- supply) Sparepartnumber548.37.072.100,GREENcolormark Auxiliary springforanevensmootherpowerapplication(includedinscopeof Spare partnumber546.37.072.300,YELLOWcolormark Auxiliary springforgooddriveability(mountedinconditionatdelivery) power application“oran„aggressiveenginecharacteristic“. One oftheauxiliaryspringscanbemountedifyoupreferan„evensmoother power application)ismountedintheconditionatdelivery. auxiliary spring The enginecharacteristiccanbemodifiedthroughvariousthicknessesofthe Engine characteristic250/300SX/XC/EXC* the clutchcoveruntilrecessinspringinsert red orthegreenauxiliaryspringandcontrol [4] information. ignition rotorandadifferentexhaust.AskyourKTMdealerformore If youpreferasmootherenginepowerapplication,canmountdifferent characteristic. Make sureyoudonotturnthedollyscrewsincethiswillimpairengine that thedollyscrew arm. ChecktheO-ringinclosingcovermountcover, ensuring from theclutchcover. Pullbothspringsoffthespringinsert,mount [1] . Anauxiliaryspringdesignedfor„gooddriveability“(smooth [6] [3] engages intheauxiliaryspring. and removethespringsincludingspringinsert » [4] [5] engages intherocker and slidebothinto [2] ,

45 ENGLISH E. G. E. G. E. G. E. G. on the clutch on the clutch [5] [1] and drain used oil [7] and drain the used oil into and drain the used oil [4] and and check the engine for leaks. [3] [2] ). ). ). ). » and check engine for leaks. [6] and top up with oil (e. g. Motorex Top Speed 4T 15W50). Speed and top up with oil (e. g. Motorex Top and top up with oil (e. g. Motorex Top Speed 4T 15W50). Top with oil (e. g. Motorex and top up [6] [2] MOTOREX TOP SPEED 4T 15W50 MOTOREX TOP SPEED 4T 15W50 MOTOREX TOP SPEED 4T 15W50 MOTOREX TOP SPEED MOTOREX TOP SPEED 4T 15W50 cover is to be removed. Oil should just barely escape from the inspection open- remove the ing when the motorcycle is in an upright position. If necessary, plug warm and set up the motorcy- change the transmission oil run the engine To cle on a horizontal surface. Remove the oil drain screw TRANSMISSION AND CLUTCH WILL BE SUBJECT TO EXCESSIVE WEAR AND TEAR, OIL ( HIGH-GRADE IF YOU USE TOO LITTLE OR LOW GRADE OIL. USE ONLY Check transmission oil level (250/300) In order to check the transmission oil level the control screw TRANSMISSION AND CLUTCH WILL BE SUBJECTED TO EXCESSIVE WEAR AND TEAR OIL ( HIGH-GRADE IF YOU USE TOO LITTLE OR LOW GRADE OIL. USE ONLY Changing the transmission oil (250/300) * In order to check the transmission oil level the control screw oil level the control check the transmission In order to open- from the inspection just barely escape be removed. Oil should cover is to remove the If necessary, an upright position. the motorcycle is in ing when plug WEAR AND TEAR WILL BE SUBJECTED TO EXCESSIVE TRANSMISSION AND CLUTCH HIGH-GRADE OIL ( OR LOW GRADE OIL. USE ONLY IF YOU USE TOO LITTLE oil (125/200) * Changing the transmission on a hor- up the engine and park the motorcycle change the gear oil warm To oil drain plugs izontal surface. Remove TO EXCESSIVE WEAR AND TEAR TRANSMISSION AND CLUTCH WILL BE SUBJECTED HIGH-GRADE OIL ( USE ONLY IF YOU USE TOO LITTLE OR LOW GRADE OIL. Check transmission oil level (125/200) oil level Check transmission into a container. Clean the magnet of the oil drain screw and reinstall oil drain into a container. Speed 4T screw with seal. Pour in 0.7 litres engine oil (e. g. Motorex Top 15W50), replace plug an appropriate container. Clean the magnets of the oil drain plugs and mount the magnets of the oil drain plugs and Clean an appropriate container. Fill in 0.7 l oil (e. g. Motorex Top them together with the appropriate gaskets. Speed 4T 15W50), mount the plug 4 2 1 7 3 5 6 MAINTENANCE WORK ON CHASSIS AND ENGINE ENGINE AND CHASSIS ON WORK MAINTENANCE

ENGLISH 46 This way, youcan avoidthelongwaitingtimesatyourshopbeginning ofthenextbikingseason. jobs, repairs,oranyrefittingbe necessary, youshouldhavethemcarriedout during theoff-season(lowerworkloadatmechani NOTE: Beforeyouputyourmotorcycleawayforthewinter, youshouldcheckall partsfortheirfunctionandwear. Shouldanyse USE AFTERAPERIODOFSTORAGE TO RUST. UP ENOUGHANDTHETHUSDEVELOPEDSTEAMWOULDCONDENSE DURINGTHECOMBUSTIONPROCESSANDCAUSEVALVES ANDEXHAUST IT WOULDBEVERY BADTOLETTHEENGINERUNFORASHORT TIMEDURINGTHESTORAGEPERIOD.ENGINEWOULDNOTGETWARMED Should youwishtomakeapauseoverlongerspaceoftime,pleaseobservethefollowinginstructions: AFTER RIDESONSALTED ROADS,CLEANMOTORCYCLETHOROUGHLY WITHCOLDWATER ANDLETITDRY WELL. THE BRAKINGPOWER. KEEP THEANTI-CORROSIONAGENTFROMGETTINGINTOCONTACT WITHTHEBRAKEDISCS,OTHERWISE THISWILLSIGNIFICANTLY REDUCE cautions againsttheaggressiveroadsalt. In theeventthatmotorcycleisalsousedinwinterandonroadswhereonehastoexpectsaltspraying,youwillhaveta TO PREMATURE WEAR. ETC. THEHIGHPRESSUREWILLCAUSEWATER TOPENETRATE INTOTHECOMPONENTSANDCANCAUSETHEMTOMALFUNCTIONORLEAD IF USINGAPOWERWASHER, DONOTPOINTTHEWATER JETAT THEELECTRICCOMPONENTS, PLUGS,CABLES,BEARINGS,CARBURETOR, The harddirtcanberemovedbeforewashingwiththehelpofasoftwaterjet. The bestmannerwouldbetousewarmwaterthathasbeenmixedwithanormalbrand-namewashingdetergentandsponge. Clean yourmotorcycleregularlyinordertomaintainthebeautyofitsplasticsurfaces. STORAGE CONSERVATION FORWINTEROPERATION CLEANING Take ashort,carefultestridefirst. – Checkthemotorcycleasbeforeeachstart(seedrivinginstructions) – Fillupthetankwithfreshfuel. – Coverthemotorcyclewithanairpermeatedtarporblanket.Donotusenonairtightmaterials asapossiblehumiditymightnot – Thestorageplaceshouldbedry andnotbesubjectedtotoobigtemperaturefluctuations. – Lubricatebearingpointsofthe controllevers,footrests,etc.aswellthechain. – Correcttirepressure. – Letfuelflowoutoftankintoan appropriatecontainer. – Removesparkplugandfill inapprox.5ccmofengineoilintothecylinderthroughopening.Actuatekick-starter10times – Lettheenginewarmupagain, closefuelcockandwaituntiltheenginediesoffbyitself.Inthiswaycarburetorjetsar – Checkantifreezeandamountof coolingliquid. – Changeengineoil(old oil containsaggressivecontaminants). – Cleanmotorcyclethoroughly(see chapter:CLEANING) – treattheengine,carburetor, swingarm,andallother bareorgalvanizedparts(exceptforbrakediscs)withawax-basedanti – cleanthemotorcyclethoroughlyandletitdryaftereachride – To preventfailuresintheelectricsystem, youshouldtreattheignitionlock,emergencyOFFswitch,shortcircuitbu – Afterthemotorcyclehascooleddown,oilandgreaseallglidingbearingparts.Treat thechainwithaspray. – Slidebacktheprotectivecoversonhandlebar-mounted instrumentssothatanywatermayhaveseepedintothispartof – Afterthemotorcyclehasbeenrinsedwithasoftwaterjet,itshouldbedriedbyairpressureandcloth.Thentakeshort – You shouldusenormalbrand-namedetergentstocleanthemotorcycle.Especiallydirtypartsalsobecleanedwithhe – Beforecleaningwithwater, plugtheexhaustpipetopreventwateringress. – able toescapeandtherebycausecorrosion. order todistributetheoilontocylinderwallsandmountsparkplug. vented frombecomingresin-cloggedbytheoldfuel. sion agent. the lightswitchandsocketconnectorswithcontactspray. the motorcycleisallowedtoevaporate. can evaporatefrominaccessablepartsoftheengineandbrakes. until theenginehasreachedworkingtemperatureandalsousebrakes.Bywarmingthesecomponents,residualwater of apaintbrush. » » » cs' shops). ke pre- -corro- e pre- drive rvice tton, be in lp

47 ENGLISH » 125/200 EXC WP PDS 5018 MCC 12187B02 15 – 22 72 N/mm linear 4 mm 99,8 kg 90/90 - 21“ MT 83 M59 80/100 - 21“ 51M, 1,0 bar (14 psi) 1,5 bar (21 psi) 120/90 - 18“ MT 83 M402 100/100 - 18“ 59M, 1,0 bar (14 psi) 2,0 bar (28 psi) 8.5 / 10 liters (2.2 / 2.8 US gallons) 14:42 t (14:48 t) 14:48 t 200 EXC 125 SX WP PDS 5018 DCC 12187B01 15 LS (low speed) 2,5 HS (high speed) 22 72 N/mm linear 5 mm STANDARD ADJUSTMENT – SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload 98,6 kg 90/90 - 21“ MT 83 – 1,0 bar (14 psi) 1,5 bar (21 psi) 120/90 - 18“ MT 83 – 1,0 bar (14 psi) 2,0 bar (28 psi) 8.5 liters (2.2 US gallons) 14:42 t (13:50 t) – 125 EXC 5 mm 110 mm SAE 5 125/200 EXC WP 4860 MA 14187B02 20 21 3,8 N/mm 925 mm (36,5 in) 390 mm (15,3 in) 92,4 kg 13:50 t – 5/8 x 1/4 " 52t 38t, 40t, 42t, 45t, 48t, 49t, 50t, 51t, headlightparking lightbrake-rear lightflasher light63° 1471 ± 10 mm (57.9 in ± 0.4 in) 12V 35/35W Bilux (base Ba20d) 12V 5W (base W2, 1x9,5d) 12V 21/5W (base BaY15d) Ba15s) 12V 10W (base Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated brake disc Ø 220 mm (8.7 in), Disc brake with carbon-steel (0.1 in) front / 3.50 mm (0.14 in) rear limit 2.50 mm Wear M59 80/100 - 21“51M, – 1,0 bar (14 psi) – M70 100/90 - 19“ 57M, – 1,0 bar (14 psi) – 7.5 liters (2 US gallons) 125 SX frame Central chrome-moly-steel 48 MA – Upside down WP Suspension (11.8/13.2 in) 300/335 mm WP PDS 5018 swingarm aluminium absorber, (Progressive Damping System) shock brake caliper floated brake disc Ø 260 mm (10.2 in), Disc brake with carbon-steel 18 20 4,2 N/mm 5 mm 100 mm SAE 5 125 SX WP 4860 MA-PA 14187B01 STANDARD ADJUSTMENT – FORK Air chamber length Fork oil Spring Spring preload Compression adjuster Rebound adjuster Weight (without fuel) Weight Wheel base Seat height, unloaded Ground clearance, unloaded Steering head angle Bulbs Final drive ratio XC-W Chain final sprockets Available Air pressure road driver only Fuel tank capacity Final drive ratio Rear tires XC-W Air pressure offroad Air pressure offroad only Air pressure road driver Rear tires Brake discs Front tires Front tires XC-W Front brake Rear brake Fork front/rear Wheel travel Rear suspension CHASSIS Frame TECHNICAL SPECIFICATIONS – CHASSIS 125 SX, 125 – CHASSIS SPECIFICATIONS TECHNICAL EXC 200 EXC,

ENGLISH 48 EHIA PCFCTOS–CASS15S,EXC,200EXC TECHNICAL SPECIFICATIONS–CHASSIS125SX, Other collarnutsonchassis Other screwsonchassis Spoke nipple Screw adjustingringspringpreloadshockabs. Engine brace Engine mountingbolt Ball jointforpushrod Sprocket screws Shock absorber, bottom Shock absorber, top Allan headscrew, handlebarsupport Hexagon collarscrew, handlebarclamp Hexagon nut,swingarmbolt Collar nut,rearwheelspindle Clamping screws,forkstubs Clamping screws,lowerforkbridge(SX) Clamping screws,upperforkbridge(SX) Clamping screws,lowerforkbridge(EXC) Clamping screws,upperforkbridge(EXC) Brake disks Brake caliper, front Collar screw, frontwheelspindle TIGHTENING TORQUES–CHASSIS M8 M8 M6 M8 M24x1,5 M10 M8 M6 M10 M8 M6 M4,5 /M5 M6 M8 M10 M6 M8 M12 M12 M10 M8 M16x1,5 M20x1,5 M8 M8 M8 10 Nm 5 Nm 8 Nm 33 Nm 60 Nm 10 Nm 35 Nm 70 Nm 70 Nm Loctite 243+40Nm 20 Nm 100 Nm 80 Nm 15 Nm 12 Nm 17 Nm 15 Nm 20 Nm 14 Nm Loctite 243+25Nm 40 Nm 50 Nm 30 Nm 15 Nm 45 Nm 25 Nm »

49 ENGLISH » 12 : 33 „1G33“ „2S15“ 15 : 31 „2G31“ „3S17H“ 17 : 28 „3S28H“ „4S19H“ 19 : 26 „4S26“ „5G17H“ 17 : 19 „5G19H“ „6G22H“ 22 : 20 „6E20H“ KOKUSAN 2K-3 12V / 110 W KOKUSAN 2K-2 12V 40 W 193 ccm (2.52 / 2.362 in) 64 / 60 mm rings two plain compression (17°) BTDC 1.6 mm (0.063 in) NGK BR 8 EG 47 mm (1.85 in) 6 speed, claw actuated 200 EXC 12 : 33 „1G33“ „2S15“ 15 : 31 „2G31“ „3S17H“ 17 : 28 „3S28H“ „4S19H“ 19 : 26 „4S26“ „5S21“ 21 : 25 „5S25“ „6G20“ 20 : 20 „6G20“ KOKUSAN 2K-3 12V / 110 W – – 124.8 ccm (2.126 / 2.145 in) 54 / 54.5 mm rings two plain compression BTDC 1.4 mm (0.055 in) (16.5°) NGK BR9 EVX 43,5 mm (1.68 in) 6 speed, claw actuated 125 EXC 13 : 32 „1S32“ 0,7 liter Motorex Top Speed 4T 15W50 0,7 liter Motorex Top 13t / 14t for chain 5/8 x 1/4" at least -25 °C (-13 °F) water, 1.2 litres, 50% anti freeze, 50% distilled KOKUSAN 2K-1 no generator – – carburetor setting see table flat-slide carburetor, wet foam type air filter insert straight cut spur gears, primary ratio 23:73 operated (Motorex Kupplungs-Fluid 75) multiple disc clutch in oil bath, hydraulically 6 speed, claw actuated „2S15“ 15 : 30 „2S30“ „3S17H“ 17 : 28 „3S28H“ „4S20H“ 20 : 28 „4S28“ „5S19“ 19 : 23 „5S23“H „6S22“ 22 : 24 „6S24“H 1 deep-groove ball bearing / 1 cylinder roller bearing 1 deep-groove ball bearing needle bearing needle bearing cast piston ring one plain compression 0,0 mm BTDC 1.4 mm (0.055 in) (16.5°) NGK BR9 EVX 0,60 mm 43,5 mm (1.68 in) 125 SX and exhaust control engine with intake two-stroke single-cylinder, Liquid-cooled, 124.8 ccm (2.126 / 2.145 in) 54 / 54.5 mm oil high grade two stroke RON 91), mixed with 95 (USA = Premium with at least RON unleaded fuel Cross Power 2T). high grade, two- stroke oil (Motorex 1:40-1:60 when using contact your importer When in doubt, please (upper edge piston- upper edge cylinder) (height of the control flap) Carburetor Air-filter Generator output Ignition system XC-W Generator output Coolant Ignition system 6th gear Gear lubrication chain sprockets Available 3rd gear 4th gear 5th gear 1st gear 2nd gear Clutch Transmission Gear ratio Electrode gap Dimension „Z“ Primary drive Ignition timing Spark plug Piston Piston ring Dimension „X“ Crankshaft bearing Connecting rod bearing Piston pin bearing Oil / gasoline ratio Piston displacement Bore / stroke Fuel ENGINE Design TECHNICAL SPECIFICATIONS – ENGINE 125 SX, 125 – ENGINE SPECIFICATIONS TECHNICAL EXC 200 EXC,

ENGLISH 50 EHIA PCFCTOS–EGN 2 X EXC,200EXC TECHNICAL SPECIFICATIONS–ENGINE125SX, Performance restrictor Air adjustmentscrewopen Throttle valve Needle positionfromtop Jet needle Starting jet Idling jet Main jet Carburetor settingmark Carburetor BASIC CARBURETORSETTING Other screws Spark plug Crankcase andclutchcoverbolts Nut forinnerclutchhub Nut forprimarysprocket(LHthread) Flywheel collarnut Nuts-cylinder base Flange bolts-cylinder-head TIGHTENING TORQUES-ENGINE – 1,5 5.5 II R1469D (R1468D) 85 45 (48) 188 (185/190) 98SA1 Keihin PWK39 125 SX M18x1,5 M16x1,5 M12x1 M8 M7 – 1,5 7 V R1472N (NOZE/NOZF) 85 35 (45/48) 145 (168/170/172) 8KTPC Keihin PWK36SAG (4,2 KW) 125 EXCEU M 10 M 8 M 6 M 14X1,25 M6 85 45 170 (168/172) FK0070 Keihin PWK36SAG 125 EXCSIX-DAYS – 1 7 IV NOZE (NOZF) 85 45 172 (170/175) FJ0040 Keihin PWK38AG 200 XC-W 200 XC 45 Nm 25 Nm 10 Nm 25 Nm 10 Nm 130 Nm 130 Nm 60 Nm 30 Nm 18 Nm – 1,5 6.5 III NOZE (NOZF) 85 35 (45) 180 (170/172/175) 8KTUC Keihin PWK38AG (7 KW) 200 EXCEU 200 EXCAUS slide stop36 1,5 6.5 III R1475J (NOZE/NOZF) »

51 ENGLISH » 250/300 XC, EXC WP PDS 5018 MCC 12187B04 15 – 22 76 N/mm linear 5 mm 102,6 kg 250/300 EXC 90/90 - 21“ MT 83 M59 80/100 - 21“ 51M, 1,0 bar (14 psi) 1,5 bar (21 psi) 140/80 - 18“ MT 83 110/100 - 18“ 64M, M402 1,0 bar (14 psi) 2,0 bar (21 psi) 8.5 / 10 liters (2.2 / 2.6 US gallons) 13:40 t 13:50 t 250 SX WP PDS 5018 DCC 12187B03 15 LS (low speed) 2,5 HS (high speed) 22 76 N/mm linear 5 mm STANDARD ADJUSTMENT – SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload 100,6 kg 300 XC – M59 80/100 - 21“51M, 1,0 bar (14 psi) 1,5 bar (21 psi) – 110/100 - 64M, M402 1,0 bar (14 psi) 2,0 bar (21 psi) 11,2 liters (2.9 US gallons) – 13:50 t 5 mm 110 mm SAE 5 250/300 XC, EXC WP 4860 MA 14187B04 20 21 4.0 N/mm 925 mm (36,5 in) 385 mm (15.2 in) 97,7 kg 13:48 t 13:48 t 5/8 x 1/4 " 52t 38t, 40t, 42t, 45t, 48t, 49t, 50t, 51t, headlightparking lightbrake-rear lightflasher light63,5° 1475 ± 10 mm (58.1 in ± 0.4 in) 12V 35/35W Bilux (base Ba20d) 12V 5W (base W2, 1x9,5d) 12V 21/5W (base BaY15d) Ba15s) 12V 10W (base Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated brake disc Ø 220 mm (8.7 in), Disc brake with carbon-steel (0.1 in) front / 3.50 mm (0.14 in) rear limit 2.50 mm Wear M59 80/100 - 21“51M, – 1,0 bar (14 psi) – M70 110/90 - 19“ 62M, – 1,0 bar (14 psi) – 7.5 liters (2 US gallons) 250 SX frame Central chrome-moly-steel 48 MA – Upside down WP Suspension (11.8/13.2 in) 300/335 mm WP PDS 5018 aluminium swingarm absorber, (Progressive Damping System) shock brake caliper floated brake disc Ø 260 mm (10.2 in), Disc brake with carbon-steel 18 20 4.4 N/mm 5 mm 100 mm SAE 5 250 SX WP 4860 MA-PA 14187B03 STANDARD ADJUSTMENT – FORK Air chamber length Fork oil Spring Spring preload Compression adjuster Rebound adjuster Weight (without fuel) Weight Wheel base Seat height, unloaded Ground clearance, unloaded Steering head angle Bulbs Final drive ratio XC-W Chain final sprockets Available Air pressure road driver only Fuel tank capacity Final drive ratio Rear tires XC-W Air pressure offroad Air pressure offroad only Air pressure road driver Rear tires Brake discs Front tires Front tires XC-W Front brake Rear brake Fork front/rear Wheel travel Rear suspension CHASSIS Frame TECHNICAL SPECIFICATIONS – CHASSIS 250 SX, EXC, 300 XC, EXC XC, 300 EXC, 250 SX, CHASSIS – SPECIFICATIONS TECHNICAL

ENGLISH 52 TECHNICAL SPECIFICATIONS–CHASSIS250SX,EXC,300XC,EXC Other collarnutsonchassis Other screwsonchassis Spoke nipple Screw adjustingringspringpreloadshockabs. Engine brace Engine mountingbolt Ball jointforpushrod Sprocket screws Shock absorber, bottom Shock absorber, top Allan headscrew, handlebarsupport Hexagon collarscrew, handlebarclamp Hexagon nut,swingarmbolt Collar nut,rearwheelspindle Clamping screws,forkstubs Clamping screws,lowerforkbridge(SX) Clamping screws,upperforkbridge(SX) Clamping screws,lowerforkbridge(EXC) Clamping screws,upperforkbridge(EXC) Brake disks Brake caliper, front Collar screw, frontwheelspindle TIGHTENING TORQUES–CHASSIS M8 M8 M6 M8 M24x1,5 M10 M8 M6 M10 M8 M6 M4,5 /M5 M6 M8 M10 M6 M8 M12 M12 M10 M8 M16x1,5 M20x1,5 M8 M8 M8 10 Nm 5 Nm 8 Nm 33 Nm 60 Nm 10 Nm 35 Nm 70 Nm 70 Nm Loctite 243+40Nm 20 Nm 100 Nm 80 Nm 15 Nm 10 Nm 15 Nm 15 Nm 20 Nm 14 Nm Loctite 243+25Nm 40 Nm 50 Nm 30 Nm 15 Nm 45 Nm 25 Nm »

53 ENGLISH » 72 / 72 mm (2.84 / 2.84 in) 72 / 72 mm 250/300 XC 14 : 28 15 : 24 18 : 24 21 : 24 22 : 21 KOKUSAN 2K-3 12V / 110 W KOKUSAN 2K-2 (XC, XC-W) 12V 40 W 300 XC/EXC 293.15 ccm rings two plain compression NGK BR 7 ES 66.4 / 72 mm (2.62 / 2.84 in) 66.4 / 72 250/300 EXC, XC-W 14 : 30 17 : 26 19 : 23 20 : 20 29 : 23 KOKUSAN 2K-3 12V / 110 W KOKUSAN 2K-2 (XC, XC-W) 12V 40 W 250 EXC 249 ccm rings two plain compression NGK BR7 ES 21 : 24 22 : 21 Speed 4T 15W50 0,7 liter Motorex Top 13t / 14t for chain 5/8 x 1/4" at least -25 °C (-13 °F) 1.2 litres, 50% anti freeze, 50% distilled water, KOKUSAN 2K-1 no generator – – carburetor setting see table flat-slide carburetor, wet foam type air filter insert 47,5 mm (1.87 in) 5200/min spring), 7900/min (green spring) 7000/min (red spring), 7500/min (yellow straight cut spur gears, primary ratio 26:72 operated (DOT 5.1) multiple disc clutch in oil bath, hydraulically 5 speed, claw actuated 250 SX 14 : 28 15 : 24 18 : 24 1:40 – 1:60 when using high grade, two- stroke oil. 1:40 – 1:60 when using ratio to be on the safe side contact your importer or use 1:40 mix When in doubt, please / 1 cylinder roller bearing 1 deep-groove ball bearing needle bearing needle bearing cast piston rings two plain compression in) 0 + 0,1 mm (0 + 0.004 1,9 mm (0.074 in) BTDC NGK BR8 ECM 0,60 mm 250 SX engine single-cylinder two-stroke Liquid-cooled system and KTM Control exhaust Valve Twin with KTM Chamber Torque 249 ccm mm (2.62 / 2.84 in) 66.4 / 72 grade two stroke oil (Motorex Cross Power 2T) RON 95 (USA = Premium RON 91), mixed with high unleaded fuel with at least (upper edge piston- upper edge cylinder) (height of the control flap) Air-filter Ignition system XC-W Generator output Vergaser Coolant Ignition system Generator output Gear lubrication chain sprockets Available 3rd gear 4th gear 5th gear Gear ratio 1st gear 2nd gear Clutch Transmission TVC start open TVC fully open Primary drive Spark plug Electrode gap Dimension „Z“ Dimension „X“ Ignition timing Piston pin bearing Piston Piston ring Crankshaft bearing Connecting rod bearing Fuel Oil / gasoline ratio Piston displacement Bore / stroke ENGINE Design TECHNICAL SPECIFICATIONS – ENGINE 250 SX, EXC, 300 XC, EXC EXC XC, 300 EXC, SX, 250 – ENGINE SPECIFICATIONS TECHNICAL

ENGLISH 54 TECHNICAL SPECIFICATIONS–ENGINE250SX,EXC,300XC,EXC Performance restrictor Air adjustmentscrewopen Throttle valve Needle positionfromtop Jet needle Starting jet Idling jet Main jet Carburetor settingmark Carburetor BASIC CARBURETORSETTING Other screws Spark plug Crankcase andcoverbolts Nut forinnerclutchhub Nut forprimarysprocket(LHthread) Flange boltpumppart(kickstarter) Flywheel collarnut Nuts-cylinder base Flange bolts-cylinder-head TIGHTENING TORQUES-ENGINE – 1 6.5 III N1EF (N1EG/N1EE) 85 42 (40) 158 (155,160) FK0100 Keihin PWK36SAG 250 SX M18x1,5 M6 M12x1 M10 M8 M 10 M 8 M 6 M14X1,25 M6 M18x1,5 35 160 (162) FK0080 Keihin PWK36SAG 250 EXCSIX-DAYS,300SIX-DAYS 300 XC/XC-W, 250 XC-W, – 1 7 IV N3EH (N3EW) 85 45 Nm 25 Nm 10 Nm 25 Nm 10 Nm Loctite 243+100Nm Loctite 243+150Nm Loctite 243+10Nm 60 Nm 35 Nm 27 Nm 35 160 (162) 3600B Keihin PWK36SAG (250: 6,6KW300:9,2KW) 250/300 EXC-AUS 250/300 EXC-EU slide stop38 3,5 7 I N3CJ (N8RF/N8RG) 85 »

55 ENGLISH Page . .16 . .15 Hand brake lever ...... 5 . . . Headlamp switch (XC-W) ...... 11 ...... positionHow to change the handlebar ...... 30 Indicator lamps (EXC) . . .10 ...... Instructions for your first ride ...... 16 Kickstarter ...... 13 Maintenance work on chassis and engine ...... 24 Operation instruments...... 5 ...... Periodic maintenance schedule ...... 20 Pivot bearing.24 ...... Radiator cover for the cold season ...... 39 Rebound damping of fork ...... 14 ...... Refilling the front brake fluid reservoir ...... 33 Refilling the rear brake fluid reservoir ...... 34 Refilling/Bleeding the cooling system...... 40 Replacing fork springs ...... 27 Replacing the battery of the digital speedometer . . . .37 Replacing the front brake pads ...... 34 lampReplacing the headlight lamp/parking light . . . .38 Replacing the rear brake pads ...... 35 . . Running in ...... 16 Serial number locations ...... 5 . . . . Setting the clock ...... 10 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 and parking ...... 19 Storage ...... 47 ...... Specifications – Chassis 125 / 200Technical ...... 48 Specifications – Chassis 250 / 300Technical ...... 52 Specifications – Engine 125 / 200Technical ...... 50 Specifications – Engine 250 / 300Technical ...... 54 air pressureTires, ...... 37 What to do when the engine is „flooded“ ...... 18 What you should check before each start ...... 17 Rebound damping of shock absorber (SX, XC-W, EXC) XC-W, Rebound damping of shock absorber (SX, General tips and warnings for starting the motorcycle General tips and warnings Exhaust system Exhaust system Filler cap . . . .12 ...... (XC, XC-W)Filler cap ...... 12 ...... Flasher switch. . . .11 ...... Foot brake pedal...... 13 ...... Fuel tap . .12 ...... about KTM disc brakesGeneral information ...... 32 41 Page . .15 . .24 » Conservation for winter operation ...... 47 Cooling system ...... 39 Correct chain tension . . . .31 ...... Damping action during compression of shock absorber (SX).14 ...... Determining the riding sag of the shock absorber . . . .25 Determining the static sag of the shock absorber . . . .25 Dismounting and mounting the front wheel ...... 35 Dismounting and mounting the rear wheel ...... 36 Draining the float chamber of the carburetor ...... 44 Driving instructions ...... 17 Electronic speedometer ...... 6 Emergency OFF switch (Australia) ...... 11 Engine characteristic 250/300 SX/XC/EXC ...... 45 engine typeEngine number, ...... 5 Changing the transmission oil (125/200) ...... 46 Changing the transmission oil (250/300) ...... 46 Chassis number ...... 5 Check chain tension ...... 30 Check transmission oil level (125/200) ...... 46 Check transmission oil level (250/300) ...... 46 Check/set distance of the magnetic sensor ...... 38 bearingChecking and adjusting the steering head . . .29 Checking spoke tension ...... 37 . forkChecking the basic setup of the telescopic . . . . .26 Checking the brake fluid level - front brake ...... 33 Checking the coolant level . .39 ...... Checking the float level ...... 44 Checking the front brake pads...... 33 ...... Checking the oil level of the hydraulic clutch . .41 . . . . . Checking the rear brake fluid level ...... 34 . Checking the rear brake pads ...... 35 Checking the shock absorber and spring ...... 25 Choke knob...... 12 ...... Cleaning ...... 47 Cleaning the air filter ...... 40 Cleaning the dust sleeves of the telescopic fork . . . . .27 Clutch lever ...... 5 Combination switch (EXC) ...... 11 Compression damping of fork ...... 14 Activating and deactivating display modes and deactivating display Activating ...... 7 . . hand brake leverthe free travel at the Adjusting . . . . .33 weight of the driver setup for the Basic suspension . . .25 hydraulic clutch Bleeding the ...... 42 . . . . . Braking. .19 ...... Breather plug front fork. . . .27 ...... Carburetor adjustment ...... 43 ...... Chain maintenance ...... 31 ...... Chain wear.31 ...... position of the foot brake pedalChanging the basic . .34 (caster) (SX / XC) Changing the fork offset ...... 28 position of the clutch leverChanging the original . . . .41 preload on the telescopic fork Changing the spring (SX models) .26 ...... fork Changing the spring preload on the telescopic (XC/EXC models) ...... 26 Compression damping of shock absorber (XC-W, EXC) Compression damping of shock absorber (XC-W, Changing the spring preloading of the shock absorber Changing the spring preloading of the shock INDEX INDEX

ENGLISH 56

SCHALTPLAN

6 0 0 2 0 0 3 - 5 2 1 C X E

m m a r g a i d g n i r i w

0 5 3 . 5 7 0 . 1 1 . 8 4 5 s s e n r a h n i a m 5 0 0 2 . 2 0 . 0 2

p u k i p c r o t n e g a r e e s l t n o r f t f r h a f e l

l i o c i t i n g n o i

G u p

r b D C I » WIRING DIAGRAMM bl-wh re re-bl br re-wh bu-wh gn ye-bl br

headlight w h

r e h s a l f r a e r t f e l

r b

g n

re gn

u p re-bl re-wh ye wh

u b

r b

l b - y l - y e b e

l n t h r e h s a f t o r f g i r

r b rear light/brakelight

b l

b r

brake switch brake

h w

front h n g - h w - n g w

e y

driving lightlamp

b r

u b r e h s a l f r a r t h g i r e

flasher control lamp control flasher

b r

l b

br ye ye-re wh-gn l b

u p

br ye-re

l b

bl-wh or

b l

r s n e s d e e p s o multi-func.-digital-speedometer

ye-re

c t i w s e k a r b

h br

r a e r l b

l b

h w e r - e y

r o t i c a p a c

e y r b

b - r b e - e y l r

r - e y e r b

r b

r i f i c r r o t e r e t e - a l u g

h w

e r

u b

r o h

n br bu re bl pu or or gn ye ye-re ye-bl wh

e r

f y a l e r r e h s a l

) l o i p ( a n t o

c a l h t i w s r b e d n a h

t s r e h a l h c i w s f

u t s t s n o t t b p o h c i w n r o h

c t i s m e b / g i h h w a w o l h

1 ANHANG – APPENDICE APPENDIX – APÉNDICE light switch stop switch handle bar switch (optional)

re wh wh ye bu

regulator-rectifier ye-bl

bl wh bl U br

multi-func.-digital-speedometer speed sensor

bl v bl

br rear light/brakelight

ye-bl ye-bl ye gn re-wh wh re re-bl

headlight wh br ye-bl gn bu-wh re-wh re-bl re br bl-wh WIRING DIAGRAMM WIRING » I C D

3 G ignition coil

pick up generator

X C -W 2 0 0 -2 5 0 2006 wiring diagramm main harness 548.11.075.000 20.02.2005 SCHALTPLAN SCHALTPLAN

ANHANG – APPENDICE APPENDIX – APÉNDICE 2

SCHALTPLAN

m m a r g a i d g n i r i w

5 0 0 2 . 2 0 . 0 2 0 0 1 . 5 7 0 . 1 1 . 8 4 5 s s e n r a h n i a m 2006 0 0 3 -W C X

p u k c i p a e r o t r n e g

l t g i i o c n o i i n

G 3 D C I » WIRING DIAGRAMM bl-wh

br re re-bl re-wh bu-wh gn ye-bl

h w

headlight

r b

h w

re re-bl re-wh gn ye wh

l b - y l - y e b e

rear light/brakelight

b r

h w

l b

b l

r s n e s d e e p s o multi-func.-digital-speedometer

l b

ye-bl

h w

e y

r b

r e i f t e t a u e r i c r - r o l g

h w

u b

ye wh wh

e r

n ) l a o i t p o (

h c s r a b e l d a t i w n h

t h c i w s p o t s

t t i l h c i w s h g

3 ANHANG – APPENDICE APPENDIX – APÉNDICE generator pick up

stop button G 3

black yellow-black green red red-black red-white

brown

blue-white I C D WIRING DIAGRAMM WIRING »

ignition coil

S X 1 2 5 -2 5 0 2 0 0 6 548.39.032.000 26.03.2005 SCHALTPLAN SCHALTPLAN

ANHANG – APPENDICE APPENDIX – APÉNDICE 4 r ryg:ga gr:grigio pu:violetto pi:rosa or:arancione re:rosso br:marrone wh:bianco gr:verde bu:blu ye:giallo bl:nero pu:violett gr:grau pi:rosa or:orange br:braun re:rot wh:weiß CAVO COLORATO gr:grün bu:blau ye:gelb bl:blau Pickup lucediposizione pu: purple gr: grey KABELFARBEN Avvisatore acustico pi: pink or: orange Bobinad‘accensione br: brown wh: white Interruttoreluce post.distop Interruttoreavvisatoreacustico re: red gr: green Indicatorepost.sx Impulsgeber Faroanteriore bu: blue Indicatoreant.sx Standlicht Generatore ye: yellow hintererBremslichtschalter bl: black CDI CABLE COLOURS Tachimetro digitalemultifunzione linkerhintererBlinker Hupe Zündspule linkervordererBlinker Commutatoreabbagliante/anabbagliante Hornschalter Relèindicatori Deviatoreindicatorididirezione spialampeggiatori Scheinwerfer Multifunktionsdigitaltacho Condensatore ITALIANO Rear light/brakelight Generator Rear brakeswitch Spiaabbagliante Interruttoreluceant.distop Auf-Abblendschalter Position light Pick up Multi-func.-digital-speedometer CDI Blinkerschalter Blinkerkontrolle Left rearflasher vordererBremslichtschalter Blinkerrelais Left frontflasher Ignition coil Kondensator Horn switch Fernlichtkontrolle DEUTSCH Horn High /lowbeamswitch Headlight Handle barswitchfor-multi-func.-digital-speedometer Generator Flasher controllamp Front brakeswitch Flasher switch Flasher relay Driving lightlamp CDI Capacitor ENGLISH SCHALTPLAN tpsic tpshle Interruttored‘emergenza Sensorevelocità Indicatorepost.dx Regolatore-raddrizzatore Stopschalter Indicatoreant.dx Geschwindigkeitssensor RechterhintererBlinker rechtervordererBlinker Regelgleichrichter Stop switch Speed sensor Right rearflasher Right frontflasher Regulator-rectifier » WIRING DIAGRAMM hinteres Begrenzungslicht/Bremslicht Lenkerschalter fürKombiinstrument Luce post.diposizione/stop I nterruttore sulmanubriopertachimetromultifunzione

5 ANHANG – APPENDICE APPENDIX – APÉNDICE Interruptor de manillar para instrumento combinado Interruptor de manillar para Contacteur au guidon pour ordinateur de bord Contacteur au guidon pour WIRING DIAGRAMM WIRING » CABLE COLOURSbl: black ye: yellowbu: bluegr: greenre: redwh: whitebr: brownor: orange COULEUR DE CABLEpi: pink gr: greypu: purple bl: noir ye: jaune bu: bleu COLOR DE CABLE gr: vert wh: blanc re: rouge br: brun or: orange pi: rose gr: gris pu: violet bl: negro ye: amarillo bu: azul gr: verde wh: blanco re: rojo br: marron or: naranja pi: rosado pu: violeta gr: gris Rear brake switchRear light / brakelightRegulator-rectifierRight front flasherRight rear flasherSpeed sensorStop switch Feu rouge/stop Contacteur de frein arrière Régulateur/redresseur Clignotant avant droit droit Clignotant arrière del freno trasero Interruptor de luz Capteur de vitesse Contacteur stop Regulador rectificador Luces de parqueo traseras /luces de freno Luz intermitente derecha delantera Luz intermitente derecha trasera Sensor de velocidad Interruptor parada Left front flasherLeft rear flasherMulti-func.-digital-speedometerPick upPosition light Ordinateur de bord gauche Clignotant avant Clignotant arrière gauche digital multifuncional Velocímetro Feu de position Capteur d’allumage Luz intermitente izquierda delantera Luz intermitente izquierda trasera Generador de impulsos Luz de posicion Handle bar switch for multi-func.-digital-speedometer HeadlightHigh / low beam switchHornHorn switchIgnition coil Contacteur code/phare Phare Bouton d’avertisseur sonore Bobine d’allumage Interruptor de encender/apagar la luz larga sonore Avertisseur Interruptor del cláxon Bobina de encendido Cláxon Faro Flasher switchFront brake switchFlasher control lampGenerator Contacteur de frein avant de clignoteur Temion Bouton de clignotants Genrateur Interruptor de luz del freno delantero Interruptor de la luz intermitente Lampara aviso intermitentes Generador ENGLISHCapacitorCDI lampDriving light Flasher relay FRANCAISroute feu Temion Condensateur Relais de clignotants CDI Lampara aviso luces largas Relé de la luz intermitente ESPANOL Condensador CDI SCHALTPLAN SCHALTPLAN

ANHANG – APPENDICE APPENDIX – APÉNDICE 6 EXC models: SEN ISTDANNVERBOTENUNDSTRAFBAR!AUSSERDEMERLISCHT DERVERSICHERUNGSSCHUTZ! WENN SIEÄNDERUNGENAMMOTORRADVORNEHMEN,GEHTDIE STRASSENZULASSUNGVERLOREN,DERBETRIEBAUFÖFFENTLICHENSTRAS- Händ Um dievolleMotorleistungzuerhalten,sindnebenderVergaserregulierung auchnochandereMaßnahmenerforderlich,IhrKTM Modelle: EXC Kraftstoff: SuperBleifreiROZ95 NICHT FÜRSTRASSENBETRIEB Hauptdüse = HD NadelClipPositionvonoben = Leerlaufdüse POS = LD Luftregulierschraubeoffen = LSO Modelli EXC: PUBLIC ROADS!YOURINSURANCECOVERAGEWILLALSOBECANCELLED! CHANGES TOYOURMOTORCYCLEWILLCAUSEYOULOSE ROADAPPROVAL. ITWILLBEILLEGALTOOPERATE THEMOTORCYCLEON buretor adjustmentforfullengineperformance.Your KTM dealerwillbepleasedtoassistyou. QUEDA ENTONCES PROHIBIDA YESPUNIBLE. ¡ADEMÁS CADUCALAPROTECCIÓN DEL SEGURO! SI EFECTÚACAMBIOS ENLAMOTOCICLETA, SEPIERDEELPERMISO DECIRCULACIÓNENCARRETERAS; LACIRCULACIÓNENVÍAS PÚBLICAS motor, ademásdelaregulacióndelcarburador sonnecesariastambiénotras medidas.SudistribuidorKTM leayudarácontodogus Modèles EXC: CHE DICONSEGUENZAÈVIETATO EPASSIBILE DIPENA!INOLTRE DECADELACOPERTURA ASSICURATIVA! MODIFICHE APPORTATE ALLAMOTOCICLETTA DETERMINANOLAPERDITA DELL'OMOLOGAZIONE STRADALE,L'IMPIEGOSUSTRADEPUBBLI- oltre allataraturadelcarburatore, anchealtremisure.IlvostroconcessionarioKTMsaràsempredisposto adaiutarvi. Modelos EXC: QUE ESTINTERDITEETTOMBE SOUSLECOUPDELALOI.PLUSCOUVERTURE D'ASSURANCEDISPARAÎT. QUAND ONEFFECTUEDESTRANSFORMATIONS SURUNEMOTO,L'HOMOLOGATION N'ESTPLUSVALABLE, L'UTILISATION SURLAVOIEPUBLI- mesures sontnécessairesenplus decesréglages.LesagentsKTMconnaissentmesures. VERGASERTABELLE KEIHIN PWK36SAG CARBURETOR SETTING VERGASERREGULIERUNG Meeresniveau MEERESHÖHE 10000 ft ALTIDUDE Sea level 1500 m 1501 m 2300 m 2301 m 3000 m 2501 ft 5000 ft 5001 ft 7500 ft 7501 ft 1000 ft 1001 ft 2500 ft 751 m 300 m 301 m 750 m The carburetoradjustmentsdescribedaboveonlyapplytodethrottled motorcycles.Othermeasureswillberequiredinadditiont Le taraturesuindicatedelcarburatorevalgonosolopermotociclette potenziate.Perottenerelapienapotenzadelmotoresono Die obenangeführtenVergaserregulierungen geltennurfürentdrosselteMotorräder. Los reglajesdelcarburador arribaindicadossonválidos solamenteparamotocicletas sinreducción.Paraalcanzarla potencia p Les réglagesdecarburateurdécrits ci-dessusvalentseulementpourdesmachinesdébridées.Pourobtenir lapleinepuissance,d HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO TEMPERATURE TEMPERATUR MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE - 20°Cbis-7°C -2°F to20°F » NOZD NOZD NOZC NOZE NOZE 0,75 0,75 0,75 178 182 170 175 172 52 50 48 48 45 5 5 4 5 4 1 1 CARBURETOR TABLE 19°F to41°F - 6°Cbis5°C NOZD NOZD NOZE NOZE NOZE 0,75 0,75 175 172 170 170 168 1,5 50 48 48 45 45 5 4 4 4 1 1 3 5 1 3 125 EXC2006 42°F to60°F 6°C bis15°C 2 4 NOZD NOZE NOZE NOZE NOZF 0,75 170 170 168 172 165 1,5 1,5 45 48 48 45 42 4 4 1 1 3 4 3 16°C bis24°C 61 °F to78°F NOZE NOZE NOZE NOZF NOZF 170 170 162 168 165 1,5 1,5 40 48 45 45 42 Fuel: unleadedfuelwithatleastRON95 J=Mainjet = MJ Needleclippositionfromtop Idlingjet = = POS IJ Airscrewopenfromfully-seated = ASO N 4 4 2 2 1 1 3 3 O T F F USA =PremiumRON91 O R H H 25°C bis36°C 79°F to98°F I G H NOZG NOZE NOZE NOZF NOZF 170 162 170 168 165 W 1,5 1,5 40 38 45 42 45 4 2 2 2 2 1 3 3 A Y U U S ler hilftIhnengerne. E to. 99°F to120°F 37°C bis49°C NOZG NOZE NOZF NOZF 162 160 168 165 1,5 1,5 40 38 45 42 2 2 2 2 3 3 o thecar- richieste, lena del 'autres

7 ANHANG – APPENDICE APPENDIX – APÉNDICE 'autres lena del richieste, o the car- 1 2 2 2 2 1 42 42 40 40 1,5 1,5 162 168 170 165 NOZF NOZG NOZG NOZH 37°C bis 49°C 99°F to 120°F to. E ler hilft Ihnen gerne. S U U Y A 1 2 2 3 2 2 1 42 45 42 40 40 1,5 1,5 1,5 W 162 170 168 172 165 NOZF NOZE NOZG NOZG NOZH H G I 79°F to 98°F 25°C bis 36°C H H R O USA = Premium RON 91 F F T O 2 2 3 3 2 1 N ASO = Air screw open from fully-seated IJPOS = = Idling jet Needle clip position from top MJ = Main jet Fuel: unleaded fuel with at least RON 95 45 45 42 42 40 1,5 1,5 1,5 1,5 168 170 172 175 165 NOZF NOZE NOZE NOZG NOZG °F to 78°F 61 16°C bis 24°C 2 2 3 4 3 45 48 42 42 45 1,5 1,5 1,5 1,5 1,5 168 170 175 178 172 NOZF NOZE NOZE NOZE NOZG 4 2 6°C bis 15°C 42°F to 60°F 200 EXC 2006 200 EXC 3 1 5 2 4 3 3 1 4 48 42 45 45 48 1,5 1,5 1,5 1,5 170 178 172 175 180 NOZF NOZE NOZE NOZE NOZD - 6°C bis 5°C 19°F to 41°F CARBURETOR TABLE CARBURETOR 4 3 3 1 4 1 5 48 45 45 48 50 1,5 1,5 1,5 178 172 175 180 182 NOZE NOZE NOZE NOZD NOZD » -2°F to 20°F - 20°C bis -7°C NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE POS MJ ASO IJ POS MJ POS MJ ASO IJ ASO IJ POS MJ ASO IJ POS MJ ASO IJ TEMPERATUR TEMPERATURE HD LD HD POS LSO NADEL POS NADEL POS HD LSO LD NADEL NADEL POS LSO LD NADEL POS HD LSO LD HD LD LSO Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia p Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. gelten nur für entdrosselte Motorräder. Die oben angeführten Vergaserregulierungen Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition t The carburetor adjustments described above only apply to dethrottled motorcycles. Other 300 m 301 m 750 m 751 m 1001 ft 1000 ft 2500 ft 2501 ft 5001 ft 5000 ft 7501 ft 7500 ft 1501 m 1500 m 2301 m 2300 m 3000 m Sea level ALTIDUDE 10000 ft MEERESHÖHE Meeresniveau KEIHIN PWK 38 AG KEIHIN PWK VERGASERREGULIERUNG SETTING CARBURETOR VERGASERTABELLE VERGASERTABELLE mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures. SUR LA VOIE PUBLI- L'UTILISATION N'EST PLUS VALABLE, SUR UNE MOTO, L'HOMOLOGATION QUAND ON EFFECTUE DES TRANSFORMATIONS DISPARAÎT. D'ASSURANCE QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE Modelos EXC: oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi. oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre STRADALE, L'IMPIEGO SU STRADE PUBBLI- DELL'OMOLOGAZIONE DETERMINANO LA PERDITA ALLA MOTOCICLETTA MODIFICHE APPORTATE ASSICURATIVA! DECADE LA COPERTURA DI PENA! INOLTRE E PASSIBILE CHE DI CONSEGUENZA È VIETATO Modèles EXC : motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gus motor, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SEGURO! QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. buretor adjustment for full engine performance. Your THE MOTORCYCLE ON IT WILL BE ILLEGAL TO OPERATE CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED! Modelli EXC: Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTMUm die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung Händ VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: EXC Modelle: NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 95 LSO = Luftregulierschraube offen LD =POS Leerlaufdüse = Nadel Clip Position von oben HD = Hauptdüse ANHANG – APPENDICE APPENDIX – APÉNDICE 8 EXC models: SEN ISTDANNVERBOTENUNDSTRAFBAR!AUSSERDEMERLISCHT DERVERSICHERUNGSSCHUTZ! WENN SIEÄNDERUNGENAMMOTORRADVORNEHMEN,GEHTDIE STRASSENZULASSUNGVERLOREN,DERBETRIEBAUFÖFFENTLICHENSTRAS- Händ Um dievolleMotorleistungzuerhalten,sindnebenderVergaserregulierung auchnochandereMaßnahmenerforderlich,IhrKTM Modelle: EXC Kraftstoff: SuperBleifreiROZ95 NICHT FÜRSTRASSENBETRIEB Hauptdüse = HD NadelClipPositionvonoben = Leerlaufdüse POS = LD Luftregulierschraubeoffen = LSO Modelli EXC: PUBLIC ROADS!YOURINSURANCECOVERAGEWILLALSOBECANCELLED! CHANGES TOYOURMOTORCYCLEWILLCAUSEYOULOSE ROADAPPROVAL. ITWILLBEILLEGALTOOPERATE THEMOTORCYCLEON buretor adjustmentforfullengineperformance.Your KTM dealerwillbepleasedtoassistyou. QUEDA ENTONCES PROHIBIDA YESPUNIBLE. ¡ADEMÁS CADUCALAPROTECCIÓN DEL SEGURO! SI EFECTÚACAMBIOS ENLAMOTOCICLETA, SEPIERDEELPERMISO DECIRCULACIÓNENCARRETERAS; LACIRCULACIÓNENVÍAS PÚBLICAS motor, ademásdelaregulacióndelcarburador sonnecesariastambiénotras medidas.SudistribuidorKTM leayudarácontodogus Modèles EXC: CHE DICONSEGUENZAÈVIETATO EPASSIBILE DIPENA!INOLTRE DECADELACOPERTURA ASSICURATIVA! MODIFICHE APPORTATE ALLAMOTOCICLETTA DETERMINANOLAPERDITA DELL'OMOLOGAZIONE STRADALE,L'IMPIEGOSUSTRADEPUBBLI- oltre allataraturadelcarburatore, anchealtremisure.IlvostroconcessionarioKTMsaràsempredisposto adaiutarvi. Modelos EXC: QUE ESTINTERDITEETTOMBE SOUSLECOUPDELALOI.PLUSCOUVERTURE D'ASSURANCEDISPARAÎT. QUAND ONEFFECTUEDESTRANSFORMATIONS SURUNEMOTO,L'HOMOLOGATION N'ESTPLUSVALABLE, L'UTILISATION SURLAVOIEPUBLI- mesures sontnécessairesenplus decesréglages.LesagentsKTMconnaissentmesures. VERGASERTABELLE KEIHIN PWK36SAG CARBURETOR SETTING VERGASERREGULIERUNG Meeresniveau MEERESHÖHE 10000 ft ALTIDUDE Sea level 1500 m 1501 m 2300 m 2301 m 3000 m 2501 ft 5000 ft 5001 ft 7500 ft 7501 ft 1000 ft 1001 ft 2500 ft 751 m 300 m 301 m 750 m The carburetoradjustmentsdescribedaboveonlyapplytodethrottled motorcycles.Othermeasureswillberequiredinadditiont Le taraturesuindicatedelcarburatorevalgonosolopermotociclette potenziate.Perottenerelapienapotenzadelmotoresono Die obenangeführtenVergaserregulierungen geltennurfürentdrosselteMotorräder. Los reglajesdelcarburador arribaindicadossonválidos solamenteparamotocicletas sinreducción.Paraalcanzarla potencia p Les réglagesdecarburateurdécrits ci-dessusvalentseulementpourdesmachinesdébridées.Pourobtenir lapleinepuissance,d HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO TEMPERATURE TEMPERATUR MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE - 20°Cbis-7°C -2°F to20°F » N1ED N1ED N1EE N1EE N1EF 168 165 162 160 158 48 45 45 42 42 5 4 1 1 4 1 3 1 1 3 CARBURETOR TABLE 19°F to41°F - 6°Cbis5°C N1ED N1EE N1EE N1EF N1EF 165 160 162 158 158 42 42 40 45 45 4 3 1 1 1 1 4 1 3 3 5 1 3 250 SX2006 42°F to60°F 6°C bis15°C 2 4 N1EG N1EE N1EE N1EF N1EF 155 162 160 158 158 42 40 40 45 42 2 1 1 1 4 1 3 1 3 3 16°C bis24°C 61 °F to78°F N1EG N1EG N1EE N1EF N1EF 155 160 158 158 152 1,5 40 40 42 42 38 Fuel: unleadedfuelwithatleastRON95 J=Mainjet = MJ Needleclippositionfromtop Idlingjet = = POS IJ Airscrewopenfromfully-seated = ASO N 2 1 1 3 1 1 3 3 2 O T F F USA =PremiumRON91 O R H H 25°C bis36°C 79°F to98°F I G H N1EH N1EG N1EG N1EF N1EF 155 152 150 158 158 W 1,5 40 38 42 40 38 2 1 2 2 1 1 1 3 3 A Y U U S ler hilftIhnengerne. E to. 99°F to120°F 37°C bis49°C N1EH N1EG N1EG N1EF 155 152 158 150 1,5 40 40 38 38 2 1 1 2 2 3 1 o thecar- richieste, lena del 'autres

9 ANHANG – APPENDICE APPENDIX – APÉNDICE 'autres lena del richieste, o the car- 3 2 2 1 1 3 1 35 35 35 35 1,5 160 155 155 158 N8RG N8RH N8RH N8RH 37°C bis 49°C 99°F to 120°F to. E ler hilft Ihnen gerne. S U U Y A 3 2 1 1 2 1 1 3 4 35 35 35 35 35 1,5 W 160 155 155 158 160 N8RF N8RG N8RH N8RH N8RH H G I 79°F to 98°F 25°C bis 36°C H H R O USA = Premium RON 91 F F T O 3 2 1 1 1 3 1 4 4 N ASO = Air screw open from fully-seated IJPOS = = Idling jet Needle clip position from top MJ = Main jet Fuel: unleaded fuel with at least RON 95 35 35 35 35 35 1,5 160 155 158 160 162 N8RF N8RF N8RG N8RH N8RH °F to 78°F 61 16°C bis 24°C 3 1 1 1 3 1 1 4 4 4 35 35 35 35 35 160 158 162 165 160 N8RF N8RF N8RF N8RG N8RH 4 2 6°C bis 15°C 42°F to 60°F 250 EXC 2006 250 EXC 3 1 5 3 1 1 1 1 1 4 5 4 4 35 38 35 35 35 160 165 168 160 162 N8RF N8RF N8RF N8RF N8RG - 6°C bis 5°C 19°F to 41°F CARBURETOR TABLE CARBURETOR 1 1 1 1 1 4 5 5 4 4 35 38 40 35 35 165 168 170 160 162 N8RF N8RF N8RF N8RF N8RE » -2°F to 20°F - 20°C bis -7°C NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE POS MJ ASO IJ POS MJ POS MJ ASO IJ ASO IJ POS MJ ASO IJ POS MJ ASO IJ TEMPERATUR TEMPERATURE HD LD HD POS LSO NADEL POS NADEL POS HD LSO LD NADEL NADEL POS LSO LD NADEL POS HD LSO LD HD LD LSO Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Pour obtenir la pleine puissance, d Les réglages de carburateur décrits ci-dessus valent seulement pour des machines débridées. Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin reducción. Para alcanzar la potencia p Los reglajes del carburador arriba indicados son válidos solamente para motocicletas sin Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. gelten nur für entdrosselte Motorräder. Die oben angeführten Vergaserregulierungen Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere la piena potenza del motore sono Le tarature suindicate del carburatore valgono solo per motociclette potenziate. Per ottenere The carburetor adjustments described above only apply to dethrottled motorcycles. Other measures will be required in addition t The carburetor adjustments described above only apply to dethrottled motorcycles. Other 300 m 301 m 750 m 751 m 1001 ft 1000 ft 2500 ft 2501 ft 5001 ft 5000 ft 7501 ft 7500 ft 1501 m 1500 m 2301 m 2300 m 3000 m Sea level ALTIDUDE 10000 ft MEERESHÖHE Meeresniveau KEIHIN PWK 36S AG KEIHIN PWK VERGASERREGULIERUNG SETTING CARBURETOR VERGASERTABELLE VERGASERTABELLE mesures sont nécessaires en plus de ces réglages. Les agents KTM connaissent ces mesures. SUR LA VOIE PUBLI- L'UTILISATION N'EST PLUS VALABLE, SUR UNE MOTO, L'HOMOLOGATION QUAND ON EFFECTUE DES TRANSFORMATIONS DISPARAÎT. D'ASSURANCE QUE EST INTERDITE ET TOMBE SOUS LE COUP DE LA LOI. DE PLUS LA COUVERTURE Modelos EXC: oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre disposto ad aiutarvi. oltre alla taratura del carburatore, anche altre misure. Il vostro concessionario KTM sarà sempre STRADALE, L'IMPIEGO SU STRADE PUBBLI- DELL'OMOLOGAZIONE DETERMINANO LA PERDITA ALLA MOTOCICLETTA MODIFICHE APPORTATE ASSICURATIVA! DECADE LA COPERTURA DI PENA! INOLTRE E PASSIBILE CHE DI CONSEGUENZA È VIETATO Modèles EXC : motor, además de la regulación del carburador son necesarias también otras medidas. Su distribuidor KTM le ayudará con todo gus motor, SE PIERDE EL PERMISO DE CIRCULACIÓN EN CARRETERAS; LA CIRCULACIÓN EN VÍAS PÚBLICAS SI EFECTÚA CAMBIOS EN LA MOTOCICLETA, SEGURO! QUEDA ENTONCES PROHIBIDA Y ES PUNIBLE. ¡ADEMÁS CADUCA LA PROTECCIÓN DEL buretor adjustment for full engine performance. Your KTM dealer will be pleased to assist you. buretor adjustment for full engine performance. Your THE MOTORCYCLE ON IT WILL BE ILLEGAL TO OPERATE CHANGES TO YOUR MOTORCYCLE WILL CAUSE YOU TO LOSE YOUR ROAD APPROVAL. PUBLIC ROADS! YOUR INSURANCE COVERAGE WILL ALSO BE CANCELLED! Modelli EXC: Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTMUm die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung Händ VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: EXC Modelle: NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 95 LSO = Luftregulierschraube offen LD =POS Leerlaufdüse = Nadel Clip Position von oben HD = Hauptdüse ANHANG – APPENDICE APPENDIX – APÉNDICE 10 EXC models: SEN ISTDANNVERBOTENUNDSTRAFBAR!AUSSERDEMERLISCHT DERVERSICHERUNGSSCHUTZ! WENN SIEÄNDERUNGENAMMOTORRADVORNEHMEN,GEHTDIE STRASSENZULASSUNGVERLOREN,DERBETRIEBAUFÖFFENTLICHENSTRAS- Händ Um dievolleMotorleistungzuerhalten,sindnebenderVergaserregulierung auchnochandereMaßnahmenerforderlich,IhrKTM Modelle: EXC Kraftstoff: SuperBleifreiROZ95 NICHT FÜRSTRASSENBETRIEB Hauptdüse = HD NadelClipPositionvonoben = Leerlaufdüse POS = LD Luftregulierschraubeoffen = LSO Modelli EXC: PUBLIC ROADS!YOURINSURANCECOVERAGEWILLALSOBECANCELLED! CHANGES TOYOURMOTORCYCLEWILLCAUSEYOULOSE ROADAPPROVAL. ITWILLBEILLEGALTOOPERATE THEMOTORCYCLEON buretor adjustmentforfullengineperformance.Your KTM dealerwillbepleasedtoassistyou. QUEDA ENTONCES PROHIBIDA YESPUNIBLE. ¡ADEMÁS CADUCALAPROTECCIÓN DEL SEGURO! SI EFECTÚACAMBIOS ENLAMOTOCICLETA, SEPIERDEELPERMISO DECIRCULACIÓNENCARRETERAS; LACIRCULACIÓNENVÍAS PÚBLICAS motor, ademásdelaregulacióndelcarburador sonnecesariastambiénotras medidas.SudistribuidorKTM leayudarácontodogus Modèles EXC: CHE DICONSEGUENZAÈVIETATO EPASSIBILE DIPENA!INOLTRE DECADELACOPERTURA ASSICURATIVA! MODIFICHE APPORTATE ALLAMOTOCICLETTA DETERMINANOLAPERDITA DELL'OMOLOGAZIONE STRADALE,L'IMPIEGOSUSTRADEPUBBLI- oltre allataraturadelcarburatore, anchealtremisure.IlvostroconcessionarioKTMsaràsempredisposto adaiutarvi. Modelos EXC: QUE ESTINTERDITEETTOMBE SOUSLECOUPDELALOI.PLUSCOUVERTURE D'ASSURANCEDISPARAÎT. QUAND ONEFFECTUEDESTRANSFORMATIONS SURUNEMOTO,L'HOMOLOGATION N'ESTPLUSVALABLE, L'UTILISATION SURLAVOIEPUBLI- mesures sontnécessairesenplus decesréglages.LesagentsKTMconnaissentmesures. VERGASERTABELLE KEIHIN PWK36SAG CARBURETOR SETTING VERGASERREGULIERUNG Meeresniveau MEERESHÖHE 10000 ft ALTIDUDE Sea level 1500 m 1501 m 2300 m 2301 m 3000 m 2501 ft 5000 ft 5001 ft 7500 ft 7501 ft 1000 ft 1001 ft 2500 ft 751 m 300 m 301 m 750 m The carburetoradjustmentsdescribedaboveonlyapplytodethrottled motorcycles.Othermeasureswillberequiredinadditiont Le taraturesuindicatedelcarburatorevalgonosolopermotociclette potenziate.Perottenerelapienapotenzadelmotoresono Die obenangeführtenVergaserregulierungen geltennurfürentdrosselteMotorräder. Los reglajesdelcarburador arribaindicadossonválidos solamenteparamotocicletas sinreducción.Paraalcanzarla potencia p Les réglagesdecarburateurdécrits ci-dessusvalentseulementpourdesmachinesdébridées.Pourobtenir lapleinepuissance,d HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO HD POS NADEL LD LSO TEMPERATURE TEMPERATUR MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO MJ POS IJ ASO NEEDLE NEEDLE NEEDLE NEEDLE NEEDLE - 20°Cbis-7°C -2°F to20°F » N8RE N8RF N8RF N8RF N8RF 170 168 165 162 160 40 38 35 35 35 5 4 4 3 4 1 1 1 1 1 CARBURETOR TABLE 19°F to41°F - 6°Cbis5°C N8RG N8RF N8RF N8RF N8RF 162 160 168 165 160 35 35 35 38 35 3 3 4 4 1 1 1 1 1 3 5 1 3 300 EXC2006 42°F to60°F 6°C bis15°C 2 4 N8RH N8RG N8RF N8RF N8RF 160 165 162 158 160 35 35 35 35 35 3 4 3 1 1 2 1 1 1 3 16°C bis24°C 61 °F to78°F N8RH N8RH N8RG N8RF N8RF 162 160 158 155 160 1,5 35 35 35 35 35 Fuel: unleadedfuelwithatleastRON95 J=Mainjet = MJ Needleclippositionfromtop Idlingjet = = POS IJ Airscrewopenfromfully-seated = ASO N 3 3 1 2 1 1 1 2 3 O T F F USA =PremiumRON91 O R H H 25°C bis36°C 79°F to98°F I G H N8RH N8RH N8RH N8RG N8RF 160 158 155 155 160 W 1,5 35 35 35 35 35 3 2 1 1 2 1 1 2 3 A Y U U S ler hilftIhnengerne. E to. 99°F to120°F 37°C bis49°C N8RH N8RH N8RH N8RG 158 155 155 160 1,5 35 35 35 35 1 2 1 1 2 2 3 o thecar- richieste, lena del 'autres

11 ANHANG – APPENDICE APPENDIX – APÉNDICE ANHANG – APPENDICE APPENDIX – APÉNDICE 12 OWNER’S MANUAL 2006

125 SX, EXC 200 EXC, XC, XC-W 250 SX, EXC, XC, XC-W 300 EXC, XC, XC-W ART. NR. 3.211.72EN ENGLISH

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