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IMPORTANT WARRANTY AND GUARANTEE INFORMATION .3
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .5
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electronic speedometer, indicator lamp (EXC) . . . . . . . . .6
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . .6
Tripmaster switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Activating/deactivating the display modes . . . . . . . . . . . .9
Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
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
Damping action during compression 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 and parking . . . . . . . . . . . . . . . . . . . . . . . . . .19
Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
PERIODIC 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
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Checking the basic setup of the telescopic fork . . . . . . .27
Changing the spring preload on the telescopic fork (SX models) .27
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
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Correct 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
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 spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .36
Replacing the battery of the digital speedometer . . . . . .36
Check/set distance of the magnetic sensor . . . . . . . . . .37
Replacing the headlight lamp/parking light lamp . . . . . .37
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Radiator cover for the cold season . . . . . . . . . . . . . . . . .38
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . .38
Refilling/Bleeding the cooling system . . . . . . . . . . . . . .39
Changing the original position of the clutch lever . . . . .40
Checking the oil level of the hydraulic clutch . . . . . . . .40
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . . .40
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . . . .41
Cleaning the spark arrestor (EXC USA) . . . . . . . . . . . . .41
Draining the float chamber of the carburetor . . . . . . . . .42
Checking the float level . . . . . . . . . . . . . . . . . . . . . . . . .42
Engine characteristic 250/300 SX/MXC/EXC . . . . . . . . .43
Check transmission oil level (125/200) . . . . . . . . . . . . .44
Changing the transmission oil (125/200) . . . . . . . . . . . .44
Check transmission oil level (250/300) . . . . . . . . . . . . .44
Changing the transmission oil (250/300) . . . . . . . . . . . .44
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .45
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . . .45
TECHNICAL SPECIFICATIONS – CHASSIS 125 / 200 . . . . .46
TECHNICAL DATA – ENGINE 125 / 200 . . . . . . . . . . . . . .48
TECHNICAL SPECIFICATIONS – CHASSIS 250/300 . . . . . .50
TECHNICAL DATA – ENGINE 250/300 2004 . . . . . . . . . .52
WIRING DIAGRAM, CARBURETOR SETTING . . . .APPENDIX
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