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SERIAL NUMBER LOCATIONS .............................................5
Chassis number................................................................5
Engine number, engine type (125/200)............................5
Engine number, engine type (250/300)............................5
OPERATION INSTRUMENTS ...............................................5
Clutch lever .....................................................................5
Hand brake lever..............................................................5
Electronic speedometer, indicator lamp (EXC)...................6
Electronic speedometer ....................................................6
Tripmaster switch.............................................................7
Short circuit button (SX).................................................11
Combination switch (EXC)..............................................11
Headlamp switch (EXC USA)..........................................11
Flasher switch.................................................................11
Emergency OFF switch (Australia)..................................11
Filler cap.........................................................................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
Compression damping of shock absorber (SX)................14
Compression damping of shock absorber (MXC, EXC) ...15
Rebound damping of shock absorber (SX, MXC, EXC) ...15
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE...................................................................16
Instructions for your first ride .........................................16
Running in .....................................................................16
DRIVING INSTRUCTIONS ..................................................17
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, Parking...........................................................19
Refueling, fuel................................................................19
PERIODIC LUBRICATION - AND MAINTENANCE-SCHEDULE
....20
MAINTENANCE WORK ON CHASSIS AND ENGINE ..........24
Checking and adjusting the steering head bearing..........24
How to change the handlebar position...........................25
Breather plug front fork..................................................25
Cleaning the dust sleeves of the telescopic fork..............25
Basic suspension setup for the weight of the driver ........26
Checking the shock absorber and spring ........................26
Determining the static sag of the shock absorber ...........26
Determining the riding sag of the shock absorber...........26
Checking the basic setup of the telescopic fork ..............27
Changing the spring preload on the telescopic fork (SX models)27
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Changing the spring preload on the telescopic fork (MXC/EXC models).27
Replacing fork springs ....................................................27
Adjusting the spring preload on the fork (SX).................28
Changing the spring preloading of the shock absorber...28
Pivot bearing..................................................................28
Checking the chain tension ............................................29
Correct the chain tension ...............................................29
Chain maintenance ........................................................30
Chain wear.....................................................................30
General information about KTM disc brakes...................31
Adjusting the free travel at the hand brake lever ............32
Checking the brake fluid level - front brake....................32
Refilling the front brake fluid reservoir............................32
Checking the front brake pads .......................................32
Replacing the front brake pads.......................................33
Changing the basic position of the foot brake pedal.......33
Checking the rear brake fluid level .................................33
Refilling the rear brake fluid reservoir .............................33
Checking the rear brake pads.........................................34
Replacing the rear brake pads ........................................34
Dismounting and mounting the front wheel...................34
Dismounting and mounting the rear wheel ....................35
Tires, air pressure ...........................................................36
Checking the spoke tension............................................36
Replacing the battery of the electronic speedometer ......36
Setting the clock of the electronic speedometer..............37
Checking/setting the distance of the magnetic sensor....38
Replacing the headlight lamp .........................................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
Changing the original position of the clutch lever
..............41
Checking the oil level of the hydraulic clutch..................41
Bleeding of the hydraulic clutch......................................41
Exhaust system...............................................................41
Cleaning the spark arrestor (EXC USA)...........................42
Carburetor adjustment ...................................................42
Draining the float chamber of the carburetor .................43
Checking the float level..................................................43
Checking the transmission oil level (125/200) ................44
Changing the transmission oil (125/200)........................44
Checking the transmission oil level (250/300) ................44
Changing the transmission oil (250/300)........................44
CLEANING..........................................................................45
CONSERVATION FOR WINTER OPERATION ....................45
STORAGE...........................................................................45
Using RE Iniation............................................................45
TECHNICAL SPECIFICATIONS - CHASSIS (125/200)..........46
TECHNICAL SPECIFICATIONS - ENGINE (125/200)...........48
TECHNICAL SPECIFICATIONS - CHASSIS (250/300) ............50
TECHNICAL SPECIFICATIONS - ENGINE (250/300)...........52
INDEX.................................................................................54
WIRING DIAGRAM, CARBURETOR SETTING............Appendix
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