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KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
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KTM workshop. If maintenance work should become necessary during a competition, it must be performed by a trained mechanic. For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products.
2-STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS KTM EXC and XC-W models were designed for offroad use only and are only suitable for longer rides on public roads to a certain extent. The engine is subjected to completely different performance demands on public roads and must be adapted to these operating conditions.
SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.
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 motor- cycles, making the service hour counter a very practical function.
SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press button Changes to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures...
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OPERATION INSTRUMENTS » LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds.
OPERATION INSTRUMENTS » SPEED / A2 display mode (average speed 2) A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.
OPERATION INSTRUMENTS » Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. [A] = Light off (this function is not available in all models) [B] = Low beam on [C] = High beam on You may use button [2] to actuate the horn.
OPERATION INSTRUMENTS 2,3,4,5, (6) » Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [1] without kinks. Filler cap (XC, XC-W) To open the filler cap: Turn the filler cap 45°...
» OPERATION INSTRUMENTS Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic posi- tion can be adjusted to your seat position (see maintenance work).
Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates.The high-speed setting is effective at fast compression...
OPERATION INSTRUMENTS » Compression damping of shock absorber (XC-W, EXC) The compression damping (during compression) can be adjusted for the XC- W and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [1] with a screwdriver.
MILES) OR 5 HOURS! – WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. SMART KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES, AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A SHORT RIDE. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE.
Arrange for the braking system to be checked by an ized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings.
The highly inflammable components in modern fuels volatilize if left stand- ing for longer periods of time. If the motorcycle has not been used for over 1 week, the fuel should be drained from the float chamber. The engine will...
TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER. Stopping and parking Close the throttle and apply the hand and foot brake simultane- ously.
Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings THE KILOMETER READING FOR INSPECTION INTERVALS SHOULD NOT EXCEED 5 HOURS. MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP IS NOT A SUBSTITUTE FOR CARE AND MAINTEN- ANCE BY THE DRIVER! »...
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PERIODIC MAINTENANCE SCHEDULE 125/200 SX/XC/EXC/XC-W 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER Clean and adjust carburetor Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs Check the cylinder and piston for wear Check function of exhaust control Check piston pin bearing...
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Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings THE KILOMETER READING FOR INSPECTION INTERVALS SHOULD NOT EXCEED 5 HOURS. MAINTENANCE WORK PERFORMED BY YOUR AUTHORIZED KTM WORKSHOP IS NOT A SUBSTITUTE FOR CARE AND MAINTE- NANCE BY THE DRIVER! »...
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PERIODIC MAINTENANCE SCHEDULE 250/300 SX/XC/EXC/XC-W 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER Clean and adjust carburetor Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs Check the cylinder and piston for wear Check function of exhaust control Check piston pin bearing...
CARBURETOR OR FUEL TANK – ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.
The type number of the telescopic fork is embossed on the inside of the fork leg axle passage. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged.
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) (SX / XC) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course.
Retighten the five pinch bolts to 15 Nm (SX) / 20 Nm (EXC, XC-W). – IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.
THE SCREWS [4] MUST BE SECURED WITH LOCTITE 243. 3,5 mm Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The dis- tance between the chain and the swing arm should be approx.
Tighten collar nut [1] to 80 Nm (60 ft.lb). – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.
– A BRAKE DISK WORN DOWN TO LESS THAN 2.50 MM (FRONT) / 3.50 MM (REAR) IS A SAFETY RISK. HAVE THE BRAKE DISK REPLACED AS SOON AS IT REACHES THE SERVICE LIMIT. – HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER. BRAKE FLUID RESERVOIRS:...
IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4].
IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].
SURE POINT IS ESTABLISHED. Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen the 2 clamping screws [4] on the left side of the fork fists.
15 Nm(7 ft. lbs). – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Check/set distance of the magnetic sensor The distance between the magnet [2] and the sensor [1] must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing the sensor [1] in or off. Replacing the headlight lamp/parking light lamp Loosen both rubber bands and tilt the headlight mask to the front.
Remount the radiator protection. NOTE: The radiator shutter can be obtained from your KTM dealer Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see diagram). In the event of the coolant being drained, always fill and bleed the system.
The SX models do not have a throttle cap. – DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID BIO POWER).
Exhaust system * If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to “burn out”.
The clutch control needs to be bled as soon as the resistance in the clutch lever starts to feel unresponsive. You will need a bleeder syringe (special tool) and biodegradable hydraulic oil. Both are available from your KTM dealer. Turn the handlebar until the master cylinder is in a horizontal position, remove the screws [6], the cover [7] and the rubber boot [8].
MAINTENANCE WORK ON CHASSIS AND ENGINE Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ). Mixing ratio (2-stroke motor oil : super fuel) 1:40 –...
MAINTENANCE WORK ON CHASSIS AND ENGINE JET NEEDLE RANGE OF ACTION TYPE RICHER NOZD NOZE NOZF NOZG NOZH 60° Part-throttle range C main jet Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled jet needle by the idling setting in the lower range and by the main jet in the upper range.
Make sure you do not turn the dolly screw since this will impair the engine characteristic. If you prefer a smoother engine power application, you can mount a different ignition rotor and a different exhaust. Ask your KTM dealer for more information.
MOTOREX TOP SPEED 4T 15W50 Changing the transmission oil (125/200) * To change the gear oil warm up the engine and park the motorcycle on a hor- izontal surface. Remove oil drain plugs [3] and [4] and drain the used oil into an appropriate container.
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.
Air-filter 250 SX 250 EXC Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM Torque Chamber 249 ccm 249 ccm 66.4 / 72 mm (2.62 / 2.84 in) 66.4 / 72 mm (2.62 / 2.84 in) 72 / 72 mm (2.84 / 2.84 in) unleaded fuel with at least RON 95 (USA = Premium RON 91), mixed with high grade two stroke oil (Motorex Cross Power 2T) 1:40 –...
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TECHNICAL SPECIFICATIONS – ENGINE 250 SX, EXC, 300 XC, EXC TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head Nuts-cylinder base Flywheel collar nut Flange bolt pump part (kickstarter) Nut for primary sprocket (LH thread) Nut for inner clutch hub Crankcase and cover bolts Spark plug Other screws BASIC CARBURETOR SETTING...
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» SCHALTPLAN WIRING DIAGRAMM ENGLISH Capacitor Driving light lamp Flasher relay Flasher switch Front brake switch Flasher control lamp Generator Handle bar switch for -multi-func.-digital-speedometer Headlight High / low beam switch Horn Horn switch Ignition coil Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
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» SCHALTPLAN WIRING DIAGRAMM ENGLISH Capacitor Driving light lamp Flasher relay Flasher switch Front brake switch Flasher control lamp Generator Handle bar switch for multi-func.-digital-speedometer Contacteur au guidon pour ordinateur de bord Headlight High / low beam switch Horn Horn switch Ignition coil Left front flasher Left rear flasher...
EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles.
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EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles.
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EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles.
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EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles.
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EXC Modelle: Die oben angeführten Vergaserregulierungen gelten nur für entdrosselte Motorräder. Um die volle Motorleistung zu erhalten, sind neben der Vergaserregulierung auch noch andere Maßnahmen erforderlich, Ihr KTM Händler hilft Ihnen gerne. WENN SIE ÄNDERUNGEN AM MOTORRAD VORNEHMEN, GEHT DIE STRASSENZULASSUNG VERLOREN, DER BETRIEB AUF ÖFFENTLICHEN STRAS- SEN IST DANN VERBOTEN UND STRAFBAR! AUSSERDEM ERLISCHT DER VERSICHERUNGSSCHUTZ! EXC models: The carburetor adjustments described above only apply to dethrottled motorcycles.
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