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SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .6
Indicator lamps (EXC) . . . . . . . . . . . . . . . . . . . . . . .10
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . .11
Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . .11
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Emergency OFF switch (Australia) . . . . . . . . . . . . . . .11
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Filler cap (XC, XC-W) . . . . . . . . . . . . . . . . . . . . . . . .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
Spring preload of the fork(XC/EXC Six Days) . . . . . . . .14
Compression damping of shock absorber (XC-W, EXC) .15
Shock absorber compression damping (XC-W/EXC) . . .15
Shock absorber rebound damping XC-W, 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
Changing the spring preloading of the shock absorber
. .24
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Basic suspension setup for the weight of the driver . . .25
Checking the shock absorber and spring . . . . . . . . . .25
Determining the static sag of the shock absorber . . . .25
Determining the riding sag of the shock absorber . . . .25
Changing the spring preload on the telescopic fork . . .26
Checking the basic setup of the telescopic fork . . . . .26
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .27
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .27
Cleaning the dust sleeves of the telescopic fork . . . . .27
Changing the fork offset (caster) (XC) . . . . . . . . . . . .28
Checking and adjusting the steering head bearing . . .29
Page
How to change the handlebar position . . . . . . . . . . . .30
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .30
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .31
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
General information about KTM disc brakes . . . . . . . .32
Adjusting the free travel at the hand brake lever . . . . .33
Checking the brake fluid level - front brake . . . . . . . .33
Refilling the front brake fluid reservoir . . . . . . . . . . .33
Checking the front brake pads . . . . . . . . . . . . . . . . .33
Replacing the front brake pads . . . . . . . . . . . . . . . . .34
Changing the basic position of the foot brake pedal . .34
Checking the rear brake fluid level . . . . . . . . . . . . . .34
Refilling the rear brake fluid reservoir . . . . . . . . . . . .34
Checking the rear brake pads . . . . . . . . . . . . . . . . . .35
Replacing the rear brake pads . . . . . . . . . . . . . . . . .35
Dismounting and mounting the front wheel . . . . . . . .35
Dismounting and mounting the rear wheel . . . . . . . . .36
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .37
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37
Replacing the battery of the digital speedometer . . . .37
Check/set distance of the magnetic sensor . . . . . . . . .38
Replacing the headlight lamp/parking light lamp . . . .38
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Checking the coolant level . . . . . . . . . . . . . . . . . . . .39
Refilling/Bleeding the cooling system . . . . . . . . . . . .40
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .40
Checking the oil level of the hydraulic clutch . . . . . . .41
Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Changing the original position of the clutch lever . . . .41
Bleeding the hydraulic clutch . . . . . . . . . . . . . . . . .42
Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .42
Draining the float chamber of the carburetor . . . . . . .44
Checking the float level . . . . . . . . . . . . . . . . . . . . . .44
Adjusting the engine characteristic via the ignition curve
. .44
Adjusting the engine characteristic via the auxiliary spring
.45
Check transmission oil level (125/200) . . . . . . . . . . .46
Changing the transmission oil (125/200) . . . . . . . . . .46
Check transmission oil level (250/300) . . . . . . . . . . .46
Changing the transmission oil (250/300) . . . . . . . . . .46
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .47
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
TECHNICAL SPECIFICATIONS – CHASSIS 125 / 200 . . .48
TECHNICAL SPECIFICATIONS – ENGINE 125 / 200 . . .50
TECHNICAL SPECIFICATIONS – CHASSIS 250 / 300 . . .52
TECHNICAL SPECIFICATIONS – ENGINE 250 / 300 . . .54
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
WIRING DIAGRAM, CARBURETOR TABLE . . . . .APPENDIX