Ktm 250 EXC 2004 User Manual

OWNER`S MANUALMANUALE D`USOMANUEL D`UTILISATIONMANUAL DE INSTRUCCIONESART.NR: 3.210.76125 SX, EXC200 SX, EXC250 SX, EXC300 MXC, EXCBEDIENUNGSANLEITUNG

ENGLISH9SPEED/TRP2 (trip 2) display modeThe TRP2 trip meter is always active and counts to 999.9. Contrary toTRP1, the displayed figure can be changed

ENGLISH10XXXXXXXXXXXXXXXXXXXXXno functionno functionstarts / stops LAPfigure LAP remainsnext figureno functionno functionno functionno functionno func

ENGLISH11Short circuit button (SX)The short circuit button 1 turns off the engine. When pressing this button,the ignition circuit is short-circuited.C

ENGLISH12Filler capTo open it: turn filler cap counter-clockwise.To close it: put filler cap back on and tighten it by turning it clockwise.Install ta

ENGLISH13KickstarterThe kickstarter is mounted on the left side of the engine. Its upper part canbe swivelled.Foot brake pedalThe foot brake pedal is

ENGLISH14Compression damping of forkHydraulic compression damping determines the reaction when the fork iscompressed. The degree of compression can be

ENGLISH15Compression damping of shock absorber (MXC, EXC)The compression damping (during compression) can be adjusted for theMXC and EXC shock absorbe

ENGLISH16WARNING–WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. SMARTKTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES, AND AJACKET, REGARDLES

ENGLISH17What you should check before each startWhen you start off, the motorcycle must be in a perfect technical condition.For safety reasons, you sh

ENGLISH18Starting when the engine is cold1 Open fuel tap2 Turn on ignition or emergency OFF switch3 Put the gear in neutral4 Activate cold-starting

ENGLISH1IMPORTANTPLEASE READ THIS MANUAL CAREFULLY AND COMPLETELYBEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREATDEAL OF INFORMATION AND ADVICE WH

ENGLISH19Refueling, fuel125-300: Unleaded premium gasoline RON 95 mixed withhigh grade two stroke oil. Mixture ratio 1:40 - 1:60Fuel and engine oil sh

ENGLISH20PERIODIC MAINTENANCE SCHEDULEafter20 hoursor2000 kilometers1st serviceafter 10 hoursor1000 kilometersafter4000 kilometeroronce a yearIF MOTOR

ENGLISH21IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDERCheck gear box oil level ●Check brake fluid level ●Check brake pads for wear ●

ENGLISH22RECOMMENDED INSPECTION OF THE125/200/250/300 SX AND EXC ENGINEUSED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP(ADDITIONAL ORDER FOR THE KTM

ENGLISH23

ENGLISH24WARNINGMAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAY

ENGLISH25How to change the handlebar positionThe handlebar position can be readjusted by 22 mm. Thus, you can put thehandlebar in the position that is

ENGLISH26Basic suspension setup for the weight of the driverTo achieve maximum handling performance and to prevent the fork, shockabsorber, swing arm

ENGLISH27According to our experience, the damping rate of the compression stagecan remain unchanged. The damping rate of the rebound stage can bereduc

ENGLISH28Adjusting the spring preload on the fork (SX)The spring preload on the SX models can be adjusted (changed) by 10 mmby turning adjusting screw

ENGLISH2IntroductionWe would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcy

ENGLISH29Check chain tensionJack the motorcycle up on its frame so that the rear wheel no longer tou-ches the ground.Press the chain upward at the end

ENGLISH30Chain maintenanceFor long chain life, good maintenance is very important. X-ring chainsrequire only modest maintenance. The best way is to us

ENGLISH31General information about KTM disc brakesBRAKE CALIPERS:The brake calipers of this series use a ”floating” mount. This means that thebrake ca

ENGLISH32Adjusting the free travel at the hand brake leverFree travel at the hand brake lever may be readjusted by using adjustmentscrew 1. In this wa

ENGLISH33Replacing the front brake pads *Press the brake caliper toward the brake disk, to put the brake piston in itsbasic position. Remove clips 1 a

ENGLISH34Checking the rear brake padsThe brake pads can be inspected from the rear. The thickness of the liningsmay not be less than 1 mm (0.04 in).W

ENGLISH35Before remounting the front wheel, clean and grease the shaft seal rings Aand the bearing surface B of the distance bushings and mount the di

ENGLISH36Tires, air pressureTire type, tire condition, and air pressure level affect the way your motorcy-cle rides and must therefore be checked when

ENGLISH37Check/set distance of the magnetic sensorThe distance between the magnet 2 and the sensor 1 must be 2-4 mm,otherwise malfunctions on the spee

ENGLISH38Cooling systemThe water pump in the engine circulates the cooling liquid. However, thecooling liquid can only circulate properly if the cooli

ENGLISH3IMPORTANT WARRANTY ANDGUARANTEE INFORMATIONKTM sports motorcycles are designed and constructed to resist the usualwear and tear of normal use

ENGLISH39Refilling/Bleeding the cooling systemThe cooling system must be bled as described below after draining the cooling liquid or after adding mor

ENGLISH40Changing the original position of the clutch leverThe adjusting screw 1 can be used for individual adjustment of the originalposition of the

ENGLISH41Cleaning the spark arrestor (EXC USA) *With these models, the spark arrestor is part of the exhaust silencer. Clean itevery 4000 km (2500 mil

ENGLISH42Opening up BEngine behavior when the throttle opens. The idle jet and the shape of thethrottle valve influences this range. If, despite good

ENGLISH43Engine characteristic 250/300 SX/MXC/EXC*The engine characteristic can be modified through various thicknesses ofthe auxiliary spring 1. An a

ENGLISH44Check transmission oil level (125/200)In order to check the transmission oil level the control screw 1 on the clutchcover is to be removed. O

ENGLISH45Should you wish to make a pause over a longer space of time, please observe the following instructions:– Clean motorcycle thoroughly (see cha

ENGLISH46125 SX 125 EXC 200 SX 200 EXCFrame Central chrome-moly-steel frameFork White Power – Upside down 48 MAWheel travel front/rear 300/335 mm (11.

ENGLISH47Collar screw, front wheel spindle M 24x1,5 40 NmBrake caliper, front M 8 Loctite 243 + 25 NmBrake disk, front M 6 10.9 Loctite 243 + 15 NmBra

ENGLISH48Engine 125 SX 125 EXC 200 SX 200 EXCDesign Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust controlPiston displaceme

ENGLISH4PageIMPORTANT WARRANTY AND GUARANTEE INFORMATION .3SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .5Chassis number .

ENGLISH49TIGHTENING TORQUES - ENGINEFlange bolts - cylinder-head M 7 18 NmNuts-cylinder base M 8 30 NmFlywheel collar nut M 12x1 60 NmNut for primary

ENGLISH50250 SX 300 MXC 250/300 EXCFrame Central chrome-moly-steel frameFork White Power – Up Side Down 48 MAWheel travel front/rear 300/335 mm (11.8/

ENGLISH51Collar screw, front wheel spindle M 24x1,5 40 NmBrake caliper, front M 8 Loctite 243 + 25 NmBrake disk, front M 6 10.9 Loctite 243 + 15 NmBra

ENGLISH52Engine 250 SX 250 EXC 300 MXC/EXCDesgin Liquid-cooled single-cylinder two-stroke engine with KTM Twin Valve Control exhaust system and KTM To

ENGLISH53TIGHTENING TORQUESFlange bolts - cylinder-head M 8 35 NmNuts-cylinder base M 10 35 NmFlywheel collar nut M 12x1 60 NmNut for primary sprocket

ENGLISH54Page Activating/deactivating the display modes . . . . . . . . . . . .9Adjusting the free travel at the hand brake lever . . . . . .32Adju

ANHANG – APPENDICEAPPENDIX – APÉNDICE1

ANHANG – APPENDICEAPPENDIX – APÉNDICE2flasher relayGstop buttonbrwhhorn switchhigh/low beam switchvbureblblblcapacitorblhornfrontbrake switchwiring di

ANHANG – APPENDICEAPPENDIX – APÉNDICE3ye-blyebrwhvbureblblblblwiring diagrammEXC-USA 125-300 2004Imain harnessDC523.11.075.000pick up22.05.2003TPSigni

ANHANG – APPENDICEAPPENDIX – APÉNDICE4SX 125-250G3red-blackgreengeneratorignition coil19.05.2003pick upstop buttonyellow-blackblackbrownredblue-whiteI

ENGLISH5Chassis numberThe chassis number is stamped on the right side of the steering head tube.Enter this number in the field on page no 1.Engine num

ANHANG – APPENDICEAPPENDIX – APÉNDICE5ENGLISCH DEUTSCH ITALIENISCHCapacitor Kondensator CondensatoreCDI CDI CDIDriving light lamp Fernlichtkontrolle S

ANHANG – APPENDICEAPPENDIX – APÉNDICE6ENGLISCH FRANZÖSISCH SPANISCHCapacitor Condensateur CondensadorCDI CDI CDIDriving light lamp Temion feu route La

ANHANG – APPENDICEAPPENDIX – APÉNDICE7VERGASERREGULIERUNGKTM 125 SX EUROPA / USA 2004 KEIHIN PWK 39CARBURETOR SETTING-20°C bis -7°C -6°C bis 5°C

ANHANG – APPENDICEAPPENDIX – APÉNDICE8VERGASERREGULIERUNGKTM 125 EXC EUR 2004 KEIHIN PWK 38 AGCARBURETOR SETTING-20°C bis -7°C -6°C bis 5°C 6°C

ANHANG – APPENDICEAPPENDIX – APÉNDICE9VERGASERREGULIERUNGKTM 200 SX EUROPA / USA 2004 KEIHIN PWK 39CARBURETOR SETTING-20°C bis -7°C -6°C bis 5°C

ANHANG – APPENDICEAPPENDIX – APÉNDICE10VERGASERREGULIERUNGKTM 200 MXC/EXC EUR/USA 2004 KEIHIN PWK 38 AGCARBURETOR SETTING-20°C bis -7°C -6°C bis

ANHANG – APPENDICEAPPENDIX – APÉNDICE11VERGASERREGULIERUNGKTM 250, 300 MXC/EXC EUR/USA 2004 KEIHIN PWK S36 AGCARBURETOR SETTING-20°C bis -7°C -6°C

ANHANG – APPENDICEAPPENDIX – APÉNDICE12VERGASERREGULIERUNGKTM 250 SX EUR/USA 2004 KEIHIN PWK S38 AGCARBURETOR SETTING-20°C bis -7°C -6°C bis 5°C

KTM-Sportmotorcycle AG A–5230 Mattighofenwww.ktm.atKTM Group Partner

ENGLISH6Electronic speedometer, indicator lamp (EXC)The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator i

ENGLISH7Tripmaster switchThe switch has three buttons: MODE, + (plus) and – (minus).WARNINGDO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE

ENGLISH8SPEED/CLK (clock) display modeCLK will display time in hours, minutes and seconds.+ BUTTON no function– BUTTON no functionpress the MODE BUTTO