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OWNER’S MANUAL 2007 125 EXC SIX DAYS, EXC 200 XC, XC-W, EXC 250 XC, XC-W, EXC SIX DAYS, EXC 300 XC, XC-W, EXC SIX DAYS, EXC ART. NR. 3.211.144EN...
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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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2-STROKE OFFROAD MOTORCYCLES ON PUBLIC ROADS KTM EXC 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.
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SPARE PARTS, ACCESSORIES 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. TRANSPORT When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position.
» SERIAL NUMBER LOCATIONS 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.
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» OPERATION INSTRUMENTS Activating and deactivating display modes In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blink- ing function can be activated by pressing the + button and deactivated by pressing the –...
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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.
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» 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 Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the button to move to the next digit.
» OPERATION INSTRUMENTS Combination switch (EXC/EXC Six Days) 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. The red short circuit button [3] serves to switch off the engine.
» OPERATION INSTRUMENTS Filler cap (EXC/EXC Six Days) To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Filler cap (XC, XC-W) To open the filler cap: Turn the filler cap 45° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 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).
» OPERATION INSTRUMENTS Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap [1]. Turn the screw [2] clockwise to increase damping, turn it counterclockwise to reduce damping during compression.
» OPERATION INSTRUMENTS STANDARD HIGH-SPEED SETTING: – Turn the adjusting screw [1] to the limit in a counterclockwise direction using a box wrench. – Unscrew the respective number of turns for the specific type of shock absorber in a clockwise direction. Typ WP Suspension 14187C27 .
Instructions for your first ride – Make sure the work for the "pre-delivery inspection" was per- – Wear suitable clothing when driving a motorcycle. smart KTM formed by your authorized KTM workshop. The DELIVERY CER- drivers always wear a helmet, boots, gloves, and a jacket, TIFICATE and SERVICE MANUAL will be handed over when you regardless of whether driving all day or just go for a short ride.
Arrange for the braking system to be checked by an author- 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.
» DRIVING INSTRUCTIONS Starting when the engine is cold 1 Open fuel tap 2 Turn on ignition or emergency OFF switch 3 Swing up the side stand 4 Put the gear in neutral 5 Activate cold-starting aid (choke) 6 Leave throttle closed or open it no more than 1/3 and kick down kick- starter vigorously all the way.
– Do not use premixed two-stroke oils, oils for outboard engines engine off, and contact an authorized KTM dealer. or normal engine oil to prepare the mixture. – Do not use gasoline and oil mixtures that are older than one Braking week.
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 maintenance by the driver!
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» PERIODIC MAINTENANCE SCHEDULE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor C/H C/H Replace the throttle slide, jet needle, float needle valve, needle nozzle...
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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 maintenance by the driver!
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PERIODIC MAINTENANCE SCHEDULE 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear...
OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out.
To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 75 bis 85 kg (wearing full protective clothing).
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. 4,4 N/mm According to our experience, the damping rate of the compression stage can 4,2 N/mm remain unchanged.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) XC/EXC Six Days * The fork offset [A] in the XC/EXC Six Days models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the handling to match the race course.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw. Tighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages.
» MAINTENANCE WORK ON CHASSIS AND ENGINE How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp [1] includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another.
– 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 behavior of your motorcycle.
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: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces- sary to top up the brake fluid.
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 author- ized 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 author- ized KTM dealer immediately. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].
» MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in). 1 mm At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.
– 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 behavior 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. TIRES – AIR PRESSURE – Do not mount tires which have not been approved by KTM. Other tires front rear could have adverse effects on the way your motorcycle behaves.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Replacing the battery of the digital speedometer Remove the headlight mask and disassemble the electronic speedometer. Remove the screw connection [A], insert the battery (type Duracell CR 2430) with the writing facing up and reinstall the screw connection. 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.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system The water pump in the engine circulates the cooling liquid. However, the cool- ing liquid can only circulate properly if the cooling circuit contains no air bubbles. Bleeding of the cooling system is therefore required a) after adding more than 0.25 l cooling liquid and b) after refilling the entire cooling system.
[5] and the air filter [6] and filter support [7] from the filter box. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter 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”.
Please note that Motorex 75 clutch fluid must be used for the 125/200 models and Motorex DOT. 5.1 brake fluid for the 250/300 models. Both are available from your KTM dealer. Turn the handlebar until the master cylinder is in a horizontal position, remove the screws [1], the cover [2] and the rubber boot [3].
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» MAINTENANCE WORK ON CHASSIS AND ENGINE Definitions Mixture too rich: Too much fuel in proportion to air. Mixture too lean: Not enough fuel in proportion to air. Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw [2] and the air control screw [3].
» MAINTENANCE WORK ON CHASSIS AND ENGINE Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber leads to engine malfunction. Make sure you do this while the engine is cold.
» MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the engine characteristic via the auxiliary spring (250/300) The engine characteristic can be modified through various thicknesses of the auxiliary spring [1]. An auxiliary spring designed for „good driveability“ (smooth power application) is mounted in the condition at delivery. One of the auxiliary springs can be mounted if you prefer an „even smoother power application“...
» MAINTENANCE WORK ON CHASSIS AND ENGINE Check transmission oil level (125/200) In order to check the transmission oil level the control screw [1] on the clutch cover is to be removed. Oil should just barely escape from the inspection open- ing when the motorcycle is in an upright position.
» CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc.
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» SCHALTPLAN WIRING DIAGRAMM ENGLISH DEUTSCH ITALIANO Capacitor Kondensator Condensatore Driving light lamp Fernlichtkontrolle Spia abbagliante Flasher relay Blinkerrelais Relè indicatori Flasher switch Blinkerschalter Deviatore indicatori di direzione Front brake switch vorderer Bremslichtschalter Interruttore luce ant. di stop Flasher control lamp Blinkerkontrolle spia lampeggiatori Generator...
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» SCHALTPLAN WIRING DIAGRAMM ENGLISH FRANCAIS ESPANOL Capacitor Condensateur Condensador Driving light lamp Temion feu route Lampara aviso luces largas Flasher relay Relais de clignotants Relé de la luz intermitente Flasher switch Bouton de clignotants Interruptor de la luz intermitente Front brake switch Contacteur de frein avant Interruptor de luz del freno delantero...
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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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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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