OWNER'S MANUAL 2010 125 EXC EU 125 EXC SIX DAYS EU 150 XC USA 200 EXC EU 200 EXC AUS 200 XCW USA 250 EXC EU 250 EXC SIX DAYS EU 250 EXC AUS 250 XC EU/USA 250 XCW USA 300 EXC EU 300 EXC SIX DAYS EU 300 EXC AUS 300 XC EU/USA 300 XCW USA Art. no. 3211466en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below. Chassis number ( Engine number ( p. 10) p. 10) p. 10) Dealer's stamp Key number (EXC, EXC SIX DAYS) ( The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design can, however, not be completely excluded. All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria TABLE OF CONTENTS TABLE OF CONTENTS 2 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... Advice on first use ......................................................... Running in the engine.................................................... Preparing the vehicle for difficult operating conditions ...... Preparations for riding on dry sand .................................. Preparations for riding on wet sand ................................. Preparations for riding on wet and muddy surfaces ........... Preparations for riding at high temperatures and riding slowly........................................................................... Preparations for riding at low temperatures and in snow .... RIDING INSTRUCTIONS .................................................... Checks before putting into operation ............................... Starting ........................................................................ Starting up ................................................................... Shifting, riding .............................................................. Braking ........................................................................ Stopping, parking .......................................................... Refueling...................................................................... SERVICE SCHEDULE......................................................... Important maintenance work to be carried out by an authorized KTM workshop .............................................. Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. Important checks and maintenance work to be carried out by the rider ............................................................. MAINTENANCE WORK ON CHASSIS AND ENGINE.............. Jacking up the motorcycle .............................................. Removing the motorcycle from the work stand.................. Checking the basic chassis setting with the rider's weight .......................................................................... Compression damping of shock absorber.......................... Adjusting the high-speed compression damping of the shock absorber .............................................................. Adjusting the low-speed compression damping of the shock absorber .............................................................. Adjusting the rebound damping of the shock absorber....... Measuring the sag of the unloaded rear wheel .................. Checking the static sag of the shock absorber .................. Checking the riding sag of the shock absorber .................. Adjusting the spring preload of the shock absorber ...... Adjusting the riding sag Removing the shock absorber Installing the shock absorber Checking the basic setting of the fork.............................. Adjusting the compression damping of the fork ................ Adjusting the rebound damping of the fork....................... Adjusting the spring preload of the fork (EXC, EXC SIX DAYS, XC-W) .................................................... Bleeding the fork legs .................................................... Cleaning the dust boots of the fork legs ........................... Loosening the fork protection.......................................... Positioning the fork protection ........................................ Checking the play of the steering head bearing................. Adjusting the play of the steering head bearing Removing the fork legs Installing the fork legs Removing the fork protector Installing the fork protector ....................................... Removing the front fender .............................................. Installing the front fender............................................... MEANS OF REPRESENTATION ............................................ 5 IMPORTANT INFORMATION ................................................ 6 VIEW OF VEHICLE............................................................... 8 View of the vehicle from the left front (example) ................. 8 View of the vehicle from the right rear (example) ................ 9 LOCATION OF SERIAL NUMBERS ...................................... 10 Chassis number............................................................. 10 Type label..................................................................... 10 Key number (EXC, EXC SIX DAYS) .................................. 10 Engine number.............................................................. 10 Fork part number........................................................... 10 Shock absorber part number........................................... 11 CONTROLS ....................................................................... 12 Clutch lever .................................................................. 12 Hand brake lever ........................................................... 12 Throttle grip.................................................................. 12 Short circuit button (EXC, EXC SIX DAYS)........................ 12 Short circuit button (XCW/XC)........................................ 13 Emergency OFF switch (200 EXC AUS) ........................... 13 Emergency OFF switch (250/300 EXC AUS) .................... 13 Electric starter button (300 EXC EU, 300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC) ........... 13 Electric starter button (250/300 EXC AUS)...................... 13 Light switch (EXC, EXC SIX DAYS) .................................. 14 Light switch (XC-W) ....................................................... 14 Horn button (EXC, EXC SIX DAYS) .................................. 14 Turn signal switch (EXC, EXC SIX DAYS).......................... 14 Overview of indicator lamps (EXC, EXC SIX DAYS) ............ 14 CONTROLS (ALL EXC/XC-W MODELS)................................. 15 Speedometer................................................................. 15 Speedometer activation and test ..................................... 15 Tripmaster switch .......................................................... 15 Setting kilometers or miles ............................................. 15 Setting the clock ........................................................... 16 Adjusting speedometer functions .................................... 16 Querying the lap time .................................................... 17 Display mode SPEED (speed) ......................................... 17 Display mode SPEED/H (service hours)............................ 17 Display mode SPEED/CLK (clock) ................................... 18 Display mode SPEED/LAP (lap time) ............................... 18 Display mode SPEED/ODO (odometer) ............................. 18 Display mode SPEED/TR1 (trip master 1) ........................ 18 Display mode SPEED/TR2 (trip master 2) ........................ 19 Display mode SPEED/A1 (average speed 1)...................... 19 Display mode SPEED/A2 (average speed 2)...................... 19 Display mode SPEED/S1 (stop watch 1) .......................... 20 Display mode SPEED/S2 (stop watch 2) .......................... 20 CONTROLS ....................................................................... 22 Fuel tap........................................................................ 22 Opening the filler cap .................................................... 22 Closing the filler cap...................................................... 22 Choke (EXC AUS, XCW/XC) ............................................ 22 Choke (EXC EU, EXC SIX DAYS) ..................................... 23 Shift lever..................................................................... 23 Kickstarter .................................................................... 23 Foot brake lever............................................................. 24 Side stand .................................................................... 24 Steering lock (EXC, EXC SIX DAYS) ................................. 24 Locking the steering (EXC, EXC SIX DAYS)....................... 24 Unlocking the steering (EXC, EXC SIX DAYS) ................... 25 26 26 27 27 27 28 29 30 30 31 31 31 32 32 32 33 33 35 35 36 37 38 38 38 38 38 38 39 40 41 41 42 42 43 43 44 44 44 45 46 47 47 47 47 48 48 49 50 51 51 51 51 x x............................................. x..................................... x..................................... x............ x.............................................. x............................................... x....................................... x TABLE OF CONTENTS Removing the headlight mask with the headlight (EXC, EXC SIX DAYS) ............................................................. Refitting the headlight mask with the headlight (EXC, EXC SIX DAYS) ............................................................. Removing the start number plate (XCW/XC)..................... Installing the start number plate (XCW/XC)...................... Handlebar position ........................................................ Adjusting the handlebar position Checking the play in the throttle cable............................. Adjusting the play in the throttle cable ....................... Checking the chain for dirt ............................................. Cleaning the chain......................................................... Checking the chain tension ............................................ Checking the rear sprocket/engine sprocket for wear ......... Checking chain wear ...................................................... Adjusting the chain tension ............................................ Adjusting the chain guide Checking the brake discs................................................ Checking the free travel of the hand brake lever ............... Adjusting the basic position of the hand brake lever (XCW/XC)..................................................................... Adjusting free travel of hand brake lever (EXC, EXC SIX DAYS) ............................................................. Checking the front brake fluid level ................................. Adding front brake fluid ............................................ Checking the front brake linings...................................... Changing the front brake linings Checking the free travel of the foot brake lever ................. Adjusting the basic position of the foot brake lever ...... Checking the rear brake fluid level .................................. Adding rear brake fluid Checking the rear brake linings ....................................... Removing the rear brake linings Installing the rear brake linings Changing the rear brake linings Removing the front wheel Installing the front wheel Removing the rear wheel ........................................... Installing the rear wheel Checking the tire condition.............. ...