125/200/250/300 SX, MXC, EXC BEDIENUNGSANLEITUNG OWNERS HANDBOOK MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2003 Art.Nr. 3.210.49 04/2002 IMPORTANT PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: IGNORING THESE INSTRUCTIONS, CAN BE DANGEROUS TO LIFE AND LIMB. ! CAUTION ! IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE'S TRAFFIC SAFETY. Please insert the serial numbers of your motorcycle in the boxes below Chassis number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS, MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS. PRIOR NOTICE IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT . IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION. ENGLISH 1 WARNING Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it. We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed by a 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. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Have services carried out by a KTM dealer so that your warranty claim remains intact. Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others. We wish you a lot of fun when driving ! ENGLISH 2 KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA Attachments: Spare parts manual chassis & engine ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL. © by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved IMPORTANT WARRANTY AND GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations. The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule. No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle. The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the brakes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached. THE SX/SXS AND MXC MODELS ARE PROHIBITED ON PUBLIC ROADS. The EXC models are only allowed on public roads in the original homologated (throttled) version. Without this performance restriction (i.e. dethrottled), these models are only allowed to be driven off-road but not on public roads. The EXC models are designed for off-road sports endurance competitions(enduro) and not suitable for predominant motocross use. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. ENGLISH 3 Observance of the service, maintenance and tuning instructions for the engine and chassis specified in the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on checking the basic chassis setting). TABLE OF CONTENTS Page 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 Page 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.................................................... ...