KTM 200 EXC (2012) manual

OWN ER'S MAN UAL 2012 125 EXC EU 125 EXC SIX DAYS EU 200 EXC EU 200 EXC AUS 200 XC ‑ W USA 250 EXC EU 250 EXC AUS 250 EXC SIX DAYS EU 250 XC ‑ W USA 300 EXC EU 300 EXC AUS 300 EXC SIX DAYS EU 300 XC ‑ W USA Art. no. 32117 18en[...]

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DEAR KTM CUSTOME R 1 DEAR KTMCUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Ch[...]

TABLE OF CONTENTS 2 TABLE OFCONTENTS MEANS OF REPRESENTAT ION ............................ ................ 5 IMPORTANT INFORMATION .............................................. .. 6 VIEW OF VEHICLE ............................ ............................ ....... 8 View of vehicle, front left (example)................................... 8 View of[...]

TABLE OF CONTENTS 3 Removing the seat ..................................................... .... 55 Mounting the seat .................................. ....................... 55 Removing the air filter box lid ....................................... .. 56 Installing the air filter box lid.......................................... 56 Removing the [...]

TABLE OF CONTENTS 4 Carburetor configuration (All 200 models) x ................. 115 Carburetor configuration (All 250 models) x ................. 116 Carburetor configuration (All 300 models) x ................. 117 General carburetor configuration x .............................. 118 TECHNICAL DATA - CHASSIS .......................... ..........[...]

MEANS O F REPRES ENTATIO N 5 Symbols used The symbols used are explained below. Indicates an expected reaction (e.g., to a work step or a function). Indicates an unexpected reaction (e.g., to a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, ha[...]

IMPORTA NT INFOR MATION 6 Use definition (All EXC mo dels) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public road traffic[...]

IMPORTA NT INFOR MATION 7 Note Fire hazard   Som e vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first. – Switch off the engine. – Turn handle  of the [...]

VIEW OF VEHICLE 8 3.1 View of vehicl e, front left (ex ample) B00784-10 1 Hand brake lever ( p. 12) 2 Kill switch ( p. 12) 3 Clutch lever ( p. 12) 4 Air filter box lid 5 Fuel tap ( p. 21) 6 Chain guide 7 Side stand ( p. 23) 8 Shift lever ( p. 22) 9 Fork rebound adjustment 10 Fork compression adjustment[...]

VIEW OF VEHICLE 9 3.2 View of vehicl e, rear right (ex ample) B00783-10 1 Filler cap 2 Bleeder screw, fork leg 3 Throttle grip ( p. 12) 4 Chassis number ( p. 10) 5 Kickstarter ( p. 22) 6 Foot brake lever ( p. 23) 7 Shock absorber, compression adjustment 8 Level viewer, rear brake fluid 9 Shock absorber, rebound adjustment[...]

SERIAL N UMBERS 10 4.1 Chassis numb er B00015-10 (XC-W) The chassis number  is stamped on the right side of the steering head. 303438-10 (All EXC models) The chassis number  is stamped on the right side of the steering head. 4.2 Type label 400284-10 (XC-W) The type label  is fixed to the front of the steering head. 303439-10 (All EXC model[...]

SERIAL N UMBERS 11 4.4 Engine numbe r B00016-10 The engine number  is stamped on the left side of the engine under the engine sprocket. 4.5 Fork part numb er B00265-01 The fork part number  is stamped on the inner side of the fork stub. 4.6 Shock absorbe r part number B00786-10 The shock absorber part number  is stamped on the top of the s[...]

CONTROL S 12 5.1 Clutch lever B00001-10 (All 125/200 mode ls) The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B00009-10 (All 250/300 mode ls) The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 5.2 Hand b[...]

CONTROL S 13 5.5 Short circuit bu tton (XC-W) B00002-10 Short circuit button  is fitted on the left side of the handlebar. Possible states • Short circuit button in basic position – In this position, the ignition circuit is closed, and the engine can be started. • Short circuit button pressed – In this position, the ignition circuit is i[...]

CONTROL S 14 5.10 Emergency OF F switch (250/3 00 EXC AUS) B00079-10 The emergency OFF switch  is fitted on the right side of the handlebar. Possible states Ignition off – In this position, the ignition circuit is interrupted, a run- ning engine stops, and a non-running engine will not start. Ignition on – In this position, the ignition circ[...]

CONTROL S 15 5.15 Speedometer 400312-01 – Press the button to change the display mode or change to one of the Setup menus. – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 5.16 Speedometer a ctiv[...]

CONTROL S 16 – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. 5.19 Setting the clo ck Condition The motorcycle is stationary. 400330-01 – P[...]

CONTROL S 17 Info If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed. 5.21 Querying lap ti me Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary. 400321-01 – Press the button briefly an[...]

CONTROL S 18 5.24 Display mode SPEED/CLK (clock) 400319-01 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button . No function Press the button for 3 - 5 seconds. The display changes to the Setup menu of the clock. [...]

CONTROL S 19 5.28 Display mode SPEED/TR2 (trip master 2) 400324-01 – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button . This is a very practical function when riding using the[...]

CONTROL S 20 5.31 Display mode SPEED/S1 (s top watch 1) 400327-01 – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor. The calculation of this value starts with the first imp[...]

CONTROL S 21 Table of condition s and menu activ ation Display The motorcycle is stationary. Menu can be acti - vated Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) • Display mode SPEED/A1 (average speed 1) • Display mode SPEED/A2 (average speed 2) • Display mode SPEED/S[...]

CONTROL S 22 303520-10 – Press release button  , turn the filler cap counterclockwise and lift it free. 5.35 Closing the fill er cap 303521-10 – Replace the filler cap and turn clockwise until the release button  locks in place. Info Run the fuel tank breather hose  without kinks. 5.36 Shift lever B00005-10 Shift lever  is mounted o[...]

CONTROL S 23 5.38 Foot brake lev er B00788-10 Foot brake lever  is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 5.39 Side stand B00789-10 The side stand  is on the left side of the vehicle. B00790-10 The side stand is used to park the motorcycle. Info When you are riding, side stand  must[...]

CONTROL S 24 5.42 Unlocking the steering (Al l EXC models) 400731-01 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock.[...]

PREPARIN G FOR US E 25 6.1 Advice on first use Danger Danger of acciden ts   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Mi ssing or poor protective clothing present a[...]

PREPARIN G FOR US E 26 – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes [...]

PREPARIN G FOR US E 27 6.4 Preparations fo r riding on dry sand 600872-10 – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value: Warning Danger of scaldin g   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap[...]

PREPARIN G FOR US E 28 – Change the radiator cap. 600870-01 – Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info Recommendation s on the carburetor setting are available from your autho- rized KTM workshop. 6[...]

PREPARIN G FOR US E 29 – Change the radiator cap. 600868-01 – Adjust the secondary ratio to the terrain. Info The engine oil heats up rapidly if the clutch needs to be operated too fre- quently because the secondary ratio is too long. – Clean the chain. Chain cleaner ( p. 128) – Clean the radiator fins. – Carefully align bent radiator fin[...]

RIDING IN STRUCTIO NS 30 7.1 Checks and m aintenance wo rk when prepar ing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 98) – Check the electrical system. – Check the front brake fluid level. ( p. 70) – [...]

RIDING IN STRUCTIO NS 31 Info Do not open the throttle. (All 125/200 mode ls) – Press the kick starter forcefully through its full range. Info Do not open the throttle. 7.3 Start off Info Before riding, switch on the lights if your vehicle is equipped with a lighting system. This will make it easier for other road users to see you. When you are r[...]

RIDING IN STRUCTIO NS 32 – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. 7.6 Stopping, park ing Warning Risk of misapprop riation   Usage by unauthorized persons. – Never leave the vehicle while the engine is[...]

RIDING IN STRUCTIO NS 33 A A 400382-10 – Fill the fuel tank with fuel up to measurement  . Guideline Measurement of  35 mm (1.38 in) Total fuel tank capacity, approx. (EXC EU, EXC SIX DAYS) 9.5 l (2.51 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 127) Total fuel tank capacity, approx. (EXC AUS, XC ‑ W) 10 l [...]

SERVICE SCHEDULE 34 8.1 Service sched ule S20A S40A Check that the electrical equipment is functioning properly. • • Check and charge the battery. x (All 250/300 models) • • Change the gear oil. x ( p. 98) • • Check the front brake linings. ( p. 71) • • Check the rear brake linings. ( p. 75) • • Check the brake discs. ( p. 70) ?[...]

SERVICE SCHEDULE 35 8.2 Maintenance w ork (as an add itional order) S10N S40A S80A J1A Change the front brake fluid. x • Change the rear brake fluid. x • Change the foot brake cylinder seals. x • Change the hydraulic clutch fluid. x ( p. 67) • Grease the steering head bearing. x ( p. 53) • Check/set the carburetor components. x • • Pe[...]

TUNING T HE CHASS IS 36 9.1 Checking the b asic chassis setting with the rider's w eight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. 401030-01 – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspe[...]

TUNING T HE CHASS IS 37 (All 250/300 mode ls) Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Full payload 1.25 turns Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 9.4 Adjusting the l ow-speed com pression damp ing of the sho ck absorber Caution Danger of acciden ts   Disas[...]

TUNING T HE CHASS IS 38 B00792-10 – Turn adjusting screw  clockwise with a screwdriver to the last click. Info Do not loosen nut  ! – Turn back counterclockwi se by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 mode ls) Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks Sport 22 cl[...]

TUNING T HE CHASS IS 39 9.8 Checking the r iding sag of th e shock absor ber 0 0 A A 0 0 C C 400990-10 – Measure distance  of the unloaded rear wheel. ( p. 38) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down [...]

TUNING T HE CHASS IS 40 – Tighten screw  . Guideline Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) – Install the shock absorber. x ( p. 54) 9.10 Adjusting the r iding sag x – Remove the shock absorber. x ( p. 54) – After removing the shock absorber, clean it thoroughly. B00292-10 – Choose and mount a suitable spring. Guidel[...]

TUNING T HE CHASS IS 41 9.12 Adjusting the c ompression d amping of the fork Info The hydraulic compressio n damping determines the fork suspension behavior. 100020-10 – Remove protection covers  . – Turn adjusting screws  clockwise all the way. Info Adjusting screws  are located at the bottom end of the fork legs. Make the same adjust[...]

TUNING T HE CHASS IS 42 Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 9.14 Adjusting the s pring preload of the fork B00795-01 – Turn the adjusting screws counterclockwise all the way. Info Make the same adjustment on both fork legs. – Turn back clockwise by the number of turns corresponding to the fork typ[...]

TUNING T HE CHASS IS 43 0 0 2 2 0 0 1 1 0 0 2 2 0 0 1 1 400223-10 – Remove screws  . Remove the handlebar clamp. Remove the handlebar and lay it to one side. Info Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. – Remove screws  . Remove the handlebar support. – Place the hand[...]

SERVICE WORK ON T HE CHASS IS 44 10.1 Raising the mo torcycle with t he lift stand B00796-01 (All 125/200 mode ls) Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels must no [...]

SERVICE WORK ON T HE CHASS IS 45 303391-10 (All EXC models) – Remove bleeder screws  briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. 303637-10 (XC-W) – Remove bleeder screws  briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. ?[...]

SERVICE WORK ON T HE CHASS IS 46 10.6 Positioning the fork protec tion B00800-11 – Position the fork protection on the left fork leg. Mount and tighten screws  . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the brake line. Position the clamp and mount and tighten screws  . – Position the fork protection on the ri[...]

SERVICE WORK ON T HE CHASS IS 47 303391-10 (XC-W) – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder screws  toward the front. B00799-11 (EXC EU/AUS, XC ‑ W) – Tighten screws  . Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) – Tig[...]

SERVICE WORK ON T HE CHASS IS 48 10.10 Installing the f ork protector x B00801-10 – Position the fork protection on the left fork leg. Mount and tighten screws  . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, chassis M6[...]

SERVICE WORK ON T HE CHASS IS 49 10.13 Installing the l ower triple clam p x (EXC EU/AUS, XC ‑ W) 0 0 2 2 0 0 1 1 500151-10 – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 128) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether the[...]

SERVICE WORK ON T HE CHASS IS 50 B00810-11 – Tighten screw  . Guideline Screw, top steering stem M8 20 Nm (14.8 lbf ft) B00799-13 – Tighten screws  . Guideline Screw, top triple clamp M8 20 Nm (14.8 lbf ft) B00798-12 – Position the brake caliper. Mount and tighten screws  . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) [...]

SERVICE WORK ON T HE CHASS IS 51 B00807-11 – Position the upper triple clamp with the steering. – Mount screw  but do not tighten yet. – Position the clutch line and wiring harness. B00811-10 – Position the fork legs. Info The upper milled groove in the fork leg must be flush with the top edge of the upper triple clamp. Position bleeder [...]

SERVICE WORK ON T HE CHASS IS 52 B00798-13 – Position the brake caliper. Mount and tighten screws  . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite ® 243™ – Mount cable binder  . – Position the brake line, wiring harness and clamp. Mount and tighten screws  . – Install the front fender. ( p. 54) – Mo[...]

SERVICE WORK ON T HE CHASS IS 53 B00813-10 (EXC SIX DAYS) – Loosen screws  . Remove screw  . – Loosen and retighten screw  . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Tighten screws  . Guideline Screw, top triple clamp M8 17 N[...]

SERVICE WORK ON T HE CHASS IS 54 10.20 Removing the front fender B00814-10 – Remove screws  . Remove the front fender. – Make sure the spacers remain in place. 10.21 Installing the f ront fender B00814-10 – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws  . Guideline Remaining s[...]

SERVICE WORK ON T HE CHASS IS 55 Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. B00816-11 (All 250/300 mode ls) – Push splash protector  to the side and position t[...]

SERVICE WORK ON T HE CHASS IS 56 10.26 Removing the air filter box lid B00819-10 – Pull off the air filter box lid in area  sideways and remove it toward the front. 10.27 Installing the a ir filter box lid B00819-11 – Insert the air filter box lid into the rear area  and clip it into the front area  . 10.28 Removing the air filter x No[...]

SERVICE WORK ON T HE CHASS IS 57 B00820-10 – Put in both parts together, position them, and fix them with air filter holder  . Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. – Install the air filter box lid. ( p. 56) 10.30 Cleaning the a ir filter and air filter box x Warnin[...]

SERVICE WORK ON T HE CHASS IS 58 10.32 Installing the m ain silencer B00821-11 – Mount the main silencer with rubber sleeve  . – Mount and tighten screws  . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 10.33 Changing the g lass fiber yarn filling of th e main silenc er x Warning Danger of burns   The exhaust system gets ver[...]

SERVICE WORK ON T HE CHASS IS 59 B00090-10 – Turn handle  of the fuel tap to the OFF position. (Figure 601157-10 p. 21) – Pull off the fuel hose. Info Remaining fuel may run out of the fuel hose. – Remove screws  with the collar sleeve. (All EXC models) – Hang the horn and horn bracket to one side. B00822-10 – Remove screw  with [...]

SERVICE WORK ON T HE CHASS IS 60 B00822-11 – Mount the fuel tank vent hose. – Mount and tighten screw  with the rubber bushing. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) (All EXC models) – Position the horn with the horn bracket. B00090-11 – Mount and tighten screws  with the collar sleeve. Guideline Remaining screws, [...]

SERVICE WORK ON T HE CHASS IS 61 10.38 Checking the c hain tension Warning Danger of acciden ts   Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. Apart from prema[...]

SERVICE WORK ON T HE CHASS IS 62 1 2 3 1 6 1 7 1 8 0 0 0 B B 0 0 A A 400987-10 – Pull on the upper part of the chain with the specified weight  . Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance  of 18 chain links in the lower chain section. Info Chain wear is not always even; repeat this measurem[...]

SERVICE WORK ON T HE CHASS IS 63 400985-01 – Check the chain guide for wear. Info Wear can be seen on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. x 100865-10 – Check the chain guide for tightness. » If the chain guide is loose: – Tighten the chain guide. Guideline Remaining screw[...]

SERVICE WORK ON T HE CHASS IS 64 B00825-10 – Loosen nut  . – Loosen nuts  . – Adjust the chain tension by turning adjusting screws  to the left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws  on the left and right so that the markings on the left and right chain adjusters are in the same pos[...]

SERVICE WORK ON T HE CHASS IS 65 10.42 Checking the f rame x 401347-01 – Check the frame for cracking and deformation. » If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. x Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by K[...]

SERVICE WORK ON T HE CHASS IS 66 B00827-01 (All 250/300 mode ls) – Check the throttle cable routing. The throttle cable must be routed to the carburetor on the left side of the upper frame tube behind the handlebars. » If the throttle cable is not routed as specified: – Correct the throttle cable routing. 10.45 Checking the r ubber grip 401197[...]

SERVICE WORK ON T HE CHASS IS 67 B00009-11 (All 250/300 mode ls) – Adjust the basic setting of the clutch lever to your hand size by turning adjust- ing screw  . Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to increase the distance between[...]

SERVICE WORK ON T HE CHASS IS 68 400245-10 (All 125/200 mode ls) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Remove screws  . – Remove cover  with membrane  . B00041-10 – Fill bleeding syringe  with the appropriate hydraulic fluid. Bleed syringe (503290500 00) Hydraulic fluid (15) ( p[...]

BRAKES 69 11.1 Checking free travel of ha nd brake lever Warning Danger of acciden ts   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating. Adjust free travel on hand brake lever according to specifications. 400196-11 (XC-W) – P[...]

BRAKES 70 11.4 Checking the b rake discs Warning Danger of acciden ts   Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) A A 400257-10 – Check the thickness of the front and rear brake discs at several places on the disc to see if it confo[...]

BRAKES 71 Warning Danger of acciden ts   Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental ha zard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel,[...]

BRAKES 72 11.8 Changing the f ront brake linin gs x Warning Danger of acciden t   Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation   Bra ke fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and k[...]

BRAKES 73 0 0 7 7 0 0 6 6 100397-01 – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. 100398-10 – Fit the brake linings, insert the bolt, and mount the locking split pins. – Operate the hand brake lever several times until the brake linings are lying correctly against on[...]

BRAKES 74 B00828-10 – Disconnect spring  . – Loosen nut  and, with push rod  , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever individually, loosen nut  and turn screw  accordingly. Info The range of adjustment is limited. – Turn push rod  accordingly until you have f[...]

BRAKES 75 Warning Danger of acciden ts   Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental ha zard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel,[...]

BRAKES 76 11.15 Installing the r ear brake linin gs x Warning Danger of acciden ts   Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Warning Danger of acciden ts   Reduced braking efficiency due to use of non-approve d b[...]

BRAKES 77 400233-10 – Remove the rear brake linings. x ( p. 75) – Stand the vehicle upright. – Remove screw cap  with membrane  and the O-ring. – Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir. – Install the rear brake linings. x ( p. 76) – Add brake flu[...]

WHEELS, TIRES 78 12.1 Removing the front wheel x – Raise the motorcycle with the lift stand. ( p. 44) B00055-10 – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. 500084-10 – Remove screw ?[...]

WHEELS, TIRES 79 500084-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw  . Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against on the brake disc. – Remove the motorcyc[...]

WHEELS, TIRES 80 400260-10 – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the wheel bearing. x – Clean and grease shaft seal rings  and bearing surface  of the spacers. Long-life grease ( p. 128) – Insert the spacers. B00831-10 – Lift the rear wheel into the swing arm, position it[...]

WHEELS, TIRES 81 – Change the tire. – Check the tire age. Info The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires are changed [...]

WHEELS, TIRES 82 Guideline Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 lbf ft) Torque wrench with various accessories in set (584290940 00)[...]

ELECTRIC AL SYST EM 83 13.1 Removing the battery x (All 250/300 m odels) Warning Risk of injury   Ba ttery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep the battery away from sp[...]

ELECTRIC AL SYST EM 84 Warning Environmental ha zard   The battery contains elements that are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning E[...]

ELECTRIC AL SYST EM 85 101395-10 – Remove screw  . 101396-10 – Lift rear fairing  slightly and pull starter relay  out of the bracket. B00832-10 – Remove the protection caps. – Remove the faulty main fuse  . Info A defective fuse is indicated by a burned-out fuse wire  . A reserve fuse  is located in the starter relay. –[...]

ELECTRIC AL SYST EM 86 13.6 Refitting the he adlight mask with the hea dlight (All EXC models) 303402-11 – Connect the electric plug connector  . B00833-11 – Position the headlight mask and fix it with the rubber band  . Info Ensure that the holding lugs engage in the fender. – Position the brake line and wiring harness. Put on the clam[...]

ELECTRIC AL SYST EM 87 13.8 Checking the h eadlight settin g (All EXC mod els) 0 0 A A 0 0 B B 400726-10 – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark a distance  under the first mark. Guideline Distance  5 cm (2 in[...]

ELECTRIC AL SYST EM 88 100864-10 – Position locking cap  and turn it clockwise all the way using a coin. – Press any button on the speedometer. The speedometer is activated. – Position the speedometer in the holder. – Mount and tighten the screws with the washers. (All EXC models) – Refit the headlight mask with the headlight. ( p. 86)[...]

COOLING SYSTEM 89 14.1 Cooling system B00834-10 (All 125/200 mode ls) Water pump  in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap  . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.[...]

COOLING SYSTEM 90 14.3 Checking the c oolant level Warning Danger of scaldin g   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse im[...]

COOLING SYSTEM 91 B00835-11 (All 250/300 mode ls) – Remove screw  . Remove radiator cap  . – Completely drain the coolant. – Mount screw  with a new seal ring and tighten it. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 14.5 Refilling with c oolant x Warning Danger of poisoni ng   Coolant is poisonous and a heal[...]

COOLING SYSTEM 92 B00836-10 – Fill the radiator completely with coolant. – Mount radiator cap  . – Run the engine until it is warm. – Check the coolant level. ( p. 90)[...]

TUNING T HE ENGIN E 93 15.1 Checking the p lay in the thro ttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3… 5 mm (0.12… 0.2 in) » If the throttle cab[...]

TUNING T HE ENGIN E 94 0 0 0 D D 0 0 C C 0 0 B B 0 0 A A 500282-01 Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw  and the idle air adjusting screw  . Transition range B Behavior of the engine when the throttle slide is being opened. This range is influenced by the idling jet and by the [...]

TUNING T HE ENGIN E 95 – Turn idle air adjusting screw  slowly in a clockwise direction until the idle speed begins to fall. – Note the position and turn the idle air adjusting screw slowly counterclock wise until the idle speed falls again. – Adjust to the point between these two positions with the highest idle speed. Info If there is a l[...]

TUNING T HE ENGIN E 96 15.6 Checking the b asic position of the shift lever 0 0 0 A A 400692-10 – Sit on the vehicle in the riding position and determine the distance  between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot 10… 20 mm (0.39… 0.79 in) » If the distance does not meet speci[...]

TUNING T HE ENGIN E 97 B00057-10 – Remove screws  . 0 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 B00056-11 – Take locking cap  , adjusting spring  , auxiliary spring  and spring insert  out of the clutch cover. – Pull both springs off of the spring insert. B00058-10 – Mount the desired auxiliary spring  and adjusting spring  and s[...]

SERVICE WORK ON T HE ENGIN E 98 16.1 Checking the g ear oil level Info The gear oil level must be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. B00049-10 (All 125/200 mode ls) – Remove gear oil level check screw  . – Check the gear oil level. A small amount of gear oil should flow out of the hole.[...]

SERVICE WORK ON T HE ENGIN E 99 16.3 Draining the ge ar oil x Warning Danger of scaldin g   Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediatel y with lukewarm water. Warning Environmental ha zard   Hazardous substances cause environme[...]

SERVICE WORK ON T HE ENGIN E 100 Danger Danger of poisoni ng   Exhaust gases are poisonous and inhaling them may result in unconsciousnes s and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. – Start[...]

CLEANING , CARE 101 17.1 Cleaning the m otorcycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, et[...]

CLEANING , CARE 102 17.2 Checks and m aintenance ste ps for winter o peration Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against the aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects [...]

STORAGE 103 18.1 Storage Warning Danger of poisoni ng   Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediate ly with soap and water. If fuel is swallowed, con[...]

TROUBLE SHOOTING 104 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) (All 250/300 models) Operating error – Go through the steps of starting the engine. ( p. 30) Battery discharged – Recharge the battery. x ( p. 83) – Check the charging voltage. x – Check the closed current. x – Check the alternator. x Main [...]

TROUBLE SHOOTING 105 Faults Possible cause Action Engine stalls or is popping into the carburetor Lack of fuel – Turn handle  of the fuel tap to the ON posi- tion. – Refuel. ( p. 32) Engine takes in bad air – Check the intake flange and carburetor for tightness. Socket connector or ignition coil is loose or oxidized – Clean the plug-in c[...]

TECHNICA L DATA - ENGINE 106 20.1 125 EXC EU, 12 5 EXC SIX DAY S EU Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Nee[...]

TECHNICA L DATA - ENGINE 107 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 20.3 All 250 models Design 1-cylinder 2-stroke engine, water-cool[...]

TECHNICA L DATA - ENGINE 108 Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 rectangular rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48.5 mm (1.909 in) Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydrau lical[...]

TECHNICA L DATA - ENGINE TIG HTENING TORQUES 109 21.1 All 125/200 mo dels Screw, membrane M4 2 Nm (1.5 lbf ft) Loctite ® 243™ Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, alternator cover M5 5 Nm (3.7 lbf ft) – Screw, centrifugal timer M5 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, exhaust control cover M5 5 Nm (3.7 l[...]

TECHNICA L DATA - ENGINE TIG HTENING TORQUES 110 21.2 All 250/300 mo dels Screw, angle lever, exhaust control M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, exhaust control cover M5 6 Nm (4.4 lbf ft) – Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, retaining[...]

TECHNICA L DATA - CARBURET OR 111 22.1 125 EXC EU, 12 5 EXC SIX DAY S EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (NOZF / NOZG / NOZH) Main jet 100 (168/170/172) Idling jet 38X38 (45) Starting jet 50 (85) Idle air adjusting screw Open 2.75 turns Throttle slide 7 w[...]

TECHNICA L DATA - CARBURET OR 112 22.5 250 EXC EU, 25 0 EXC SIX DAY S EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N8RW / N8RJ / N8RK) Main jet 110 (162/165) Idling jet 38X38 (35) Starting jet 50 (85) Idle air adjusting screw Open 1.5 turns Throttle slide 7 with c[...]

TECHNICA L DATA - CARBURET OR 113 22.9 300 EXC AUS Carburetor type KEIHIN PWK 36S AG Carburetor identification number 3600C Needle position 1st position from top Jet needle N3CJ (N8RW / N8RJ / N8RK / N2ZK / N2ZJ / N2ZL) Main jet 160 (162/165) Idling jet 35 Starting jet 85 Idle air adjusting screw Open 3.5 turns Throttle slide 7 with cut-out Slide s[...]

TECHNICA L DATA - CARBURET OR 114 401348-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw is open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces![...]

TECHNICA L DATA - CARBURET OR 115 22.12 Carburetor con figuration (All 2 00 models) x Danger Loss of approval for road use and ins urance coverage   Th e motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from pu[...]

TECHNICA L DATA - CARBURET OR 116 22.13 Carburetor con figuration (All 2 50 models) x Danger Loss of approval for road use and ins urance coverage   Th e motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from pu[...]

TECHNICA L DATA - CARBURET OR 117 22.14 Carburetor con figuration (All 3 00 models) x Danger Loss of approval for road use and ins urance coverage   Th e motorcycle is authorized for public road traffic in the homologous (reduced) version only. – In the derestricted version, the motorcycle must be used only on closed off property remote from pu[...]

TECHNICA L DATA - CARBURET OR 118 22.15 General carbur etor configurat ion x 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075-10 1... 5 Needle position from above The five needle positions are shown here. The carburetor configurati on depends on the defined ambient and operating conditions.[...]

TECHNICA L DATA - CHASSIS 119 Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA PA Suspension travel Front 300 mm (11.81 in) Rear 335 mm (13.19 in) Fork offset 22 mm (0.87 in) Shock absorber WP Suspension PDS 5018 DCC Brake system Disc brakes, brake calipers on floating bearings Brake discs - [...]

TECHNICA L DATA - CHASSIS 120 23.1 Lighting equip ment Headlight (All EXC models) S2 / socket BA20d 12 V 35/35 W Parking light (All EXC models) W5W / socket W2.1x9.5d 12 V 5 W Indicator lamps (All EXC models) W2.3W / socket W2x4.6d 12 V 2.3 W Turn signal (All EXC models) R10W / socket BA15s 12 V 10 W Brake/tail light (All EXC models) LED License pl[...]

TECHNICA L DATA - FORK 121 24.1 All 125/200 mo dels Fork part number 14.18.7L.61 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 24 clicks Standard 22 clicks Sport 20 clicks Full payload 20 clicks Rebound damping Comfort 22 clicks Standard 20 clicks Sport 18 clicks Full payload 18 clicks Spring preload - Preload Adjuster Co[...]

TECHNICA L DATA - FORK 122 Weight of rider: 85… 95 kg (187… 209 lb.) 513 mm (20.2 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.4 N/mm (25.1 lb/in) Fork length 940 mm (37.01 in) Air chamber leng[...]

TECHNICA L DATA - SHOCK ABS ORBER 123 25.1 All 125/200 mo dels Shock absorber part number 12.18.7L.61 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Full payload 15 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport 1.25 turns Full payload 1.[...]

TECHNICA L DATA - SHOCK ABS ORBER 124 Spring preload Comfort 7 mm (0.28 in) Standard 7 mm (0.28 in) Sport 7 mm (0.28 in) Full payload 8 mm (0.31 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 72 N/mm (41[...]

TECHNICA L DATA - TIGHTENIN G TORQUE S FOR CH ASSIS 125 Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, battery terminal (All 250/300 models) M5 2.5 Nm (1.84 lbf ft) – Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) – Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 lbf ft) – Remaining nuts, chassis M6 10 Nm[...]

SUBSTAN CES 126 2-stroke engin e oil According to – JASO FC ( p. 130) Guideline – Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex ® products. Fully synthetic Supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to – DOT Guideline – Use only brake fluid that complies with the s[...]

SUBSTAN CES 127 Hydraulic fluid (15) According to – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Motorex ® products. Supplier Motorex ® – Hydraulic Fluid 75 Shock absorbe r oil (SAE 2.5) (501803[...]

AUXILIAR Y SUBSTA NCES 128 Air filter cleane r Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Re mover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and p reserving mat erials for meta l, rubber and p lastic Guideline – KTM recommends Motor[...]

AUXILIAR Y SUBSTA NCES 129 Rubber grip ad hesive (00062 030051) Supplier KTM-Sportmotorcy cle AG – GRIP GLUE Universal oil s pray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthet ic[...]

STANDAR DS 130 JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustio n is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions requir[...]

INDEX 131 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 A[...]

INDEX 132 Frame checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Front fender installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Front wheel installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

INDEX 133 Start number plate installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Steering locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

*321 171 8en* 3211718en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 05/2011 Photo: Mitterbauer[...]