KTM 125 EXC EU 2011 Manual

SETUP INSTRUCTIONS 2011
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
250 EXC EU
250 EXC AUS
250 EXC SIX DAYS EU
250 XC‑W USA
300 EXC EU
300 EXC AUS
300 EXC SIX DAYS EU
300 XC‑W USA
Art. no. 3211693en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-
tions, 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 spe-
cial equipment that does not belong to the regular scope of delivery.
© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, 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

MEANS OF REPRESENTATION 2
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies a page reference (more information is provided on the specified page).
Denotes additional information or tips.
Denotes the result of a test step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The typographical and other formats used are explained in the following.
Own name Indicates a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

SET‑UP 3
2.1Unpacking and setting up the vehicle
B00095-01
Packaging 2
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Carefully loosen and remove the tensioning belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
–Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
–Together with an assistant, take the vehicle off of the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
600811-10
Package 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Together with an assistant, take the vehicle off of the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
B00094-01
–Install the shock absorber. ( p. 7)
600814-01
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp
(EXC EU/AUS)
M8 20 Nm
(14.8 lbf ft)
Screw, bottom triple clamp
(EXC EU/AUS)
M8 15 Nm
(11.1 lbf ft)
Screw, top triple clamp
(EXC SIX DAYS, XC‑W)
M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp
(EXC SIX DAYS, XC‑W)
M8 12 Nm
(8.9 lbf ft)

SET‑UP 4
Info
The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws toward the front.
0
0
22
0
0
11
0
0
22
0
0
11
400223-10
–Remove screws . Remove the handlebar clamp.
–Remove screws . Remove the handlebar support.
–Place the handlebar support in the required position. Mount and tighten screws .
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
600824-10
–Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
B00096-10
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
600817-10
–Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.

SET‑UP 5
600818-10
(EXC, EXC SIX DAYS)
–Attach the retaining bracket for the connector, the turn signal bracket with the
turn signal and the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Connect the connector.
600819-10
(XC-W)
–Attach the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Connect the connector.
–Install the front fender. ( p. 9)
–Correctly mount the fuel tank breather.
B00539-01
–Secure the handlebar cushion with two cable binders.
(EXC, EXC SIX DAYS)
–Refit the headlight mask with the headlight. ( p. 10)
(XC-W)
–Install the start number plate. ( p. 10)
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
800035-10
(All 250/300 models)
Warning
Risk of injury Battery acid and battery gases cause serious cauteriza-
tion.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well
ventilated rooms.
–Flush with copious amounts of water in case of skin contact. If bat-
tery acid comes into contact with the eyes, flush the eyes with water
for at least 15 minutes and consult a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 8)
–Install the battery. ( p. 9)

SET‑UP 6
B00097-01
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts installation instructions.
–Apply the label included in the delivery (optional).
101037-01
(EXC, EXC SIX DAYS)
–Mount the mirror clamps on both sides.
101038-01
–Mount and tighten the rear mirror adapter and rear mirror on both sides.
–Mount the reflector.
–Position all controls exactly on the handlebar. Tighten all screws.
–Refuel. ( p. 11)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 7
3.1Removing the seat
500080-10
–Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
3.2Mounting the seat
500068-01
–Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear
and simultaneously push forward.
–Make sure that the seat is correctly locked in.
500080-10
–Mount and tighten screw of the seat fixation.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.3Installing the shock absorber
601156-11
(All 125/200 models)
–Push splash protector to the side and position the shock absorber. Mount
and tighten screw .
Guideline
Screw, top shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®2701
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®2701
Info
The heim joint for the shock absorber at the swing arm is Teflon coated.
It must not be lubricated with grease or with other lubricants. Lubri-
cants dissolve the Teflon coating, thereby drastically reducing the ser-
vice life.
303393-11
(All 250/300 models)
–Push splash protector to the side and position the shock absorber. Mount
and tighten screw .
Guideline
Screw, top shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®2701
–Mount and tighten screw .

WORK 8
Guideline
Screw, bottom shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®2701
Info
The heim joint for the shock absorber at the swing arm is Teflon coated.
It must not be lubricated with grease or with other lubricants. Lubri-
cants dissolve the Teflon coating, thereby drastically reducing the ser-
vice life.
–Remove the motorcycle from the lift stand.
3.4Installing the front wheel
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
500086-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing.
–Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 14)
–Insert the spacers.
500084-11
–Lift the front wheel into the fork, position it, and insert the wheel spindle.
–Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
–Operate the hand brake lever several times until the brake linings are lying correctly
against on the brake disc.
–Remove the motorcycle from the lift stand.
–Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
3.5Recharging the battery (All 250/300 models)
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–Flush with copious amounts of water in case of skin contact. If battery acid comes into contact with the eyes, flush the
eyes with water for at least 15 minutes and consult a physician.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
–Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.

WORK 9
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 7)
–Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.
400240-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid .
Charge the battery with at most 10% of the capacity specified on the bat-
tery .
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
–Mount the seat. ( p. 7)
3.6Installing the battery (All 250/300 models)
500069-11
–Place the battery in the battery holder.
Battery (YTX4L-BS)
–Reconnect the rubber band .
–Attach the plus cable and replace the plus pole cover .
–Attach the minus cable .
–Mount the seat. ( p. 7)
3.7Installing the front fender
500092-10
–Ensure that the spacers are mounted in the fender.
–Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the start number plate.

WORK 10
3.8Refitting the headlight mask with the headlight (EXC, EXC SIX DAYS)
303402-11
–Connect the electric plug connector .
303401-11
–Position the headlight mask and fix it with the rubber band .
Info
Ensure that the holding lugs engage in the fender.
–Position the brake line and wiring harness. Put on the clamp and mount and
tighten screw .
–Check the headlight setting.
3.9Installing the start number plate (XC-W)
500123-11
–Position the start number plate. Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Ensure that the holding lugs engage in the fender.
–Position the brake line. Put on the clamp and mount and tighten screw .
3.10Opening the filler cap
303520-10
–Press release button , turn the filler cap counterclockwise and lift it free.
3.11Closing the filler cap
303521-10
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Run the fuel tank breather hose without kinks.

WORK 11
3.12Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
–Switch off the engine.
–Open the filler cap. ( p. 10)
AA
400382-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Total fuel tank
capacity, approx.
(EXC EU,
EXC SIX DAYS)
9.5 l
(2.51 US gal)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 13)
Total fuel tank
capacity, approx.
(XC-W, EXC AUS)
11.5 l
(3.04 US gal)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 13)
2-stroke engine oil ( p. 13)
–Close the filler cap. ( p. 10)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 12
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Screw, frame protector M5 3 Nm (2.2 lbf ft) –
Screw, spoiler on fuel tank (XC-W) M5x12 1.5 Nm (1.11 lbf ft) –
Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) –
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, shock absorber adjusting ring M6 5 Nm (3.7 lbf ft) –
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp
(EXC EU/AUS)
M8 15 Nm (11.1 lbf ft) –
Screw, bottom triple clamp
(EXC SIX DAYS, XC‑W)
M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, side stand attachment M8 40 Nm (29.5 lbf ft) Loctite®2701
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®2701
Screw, top steering stem
(EXC EU/AUS)
M8 20 Nm (14.8 lbf ft) –
Screw, top steering stem
(EXC SIX DAYS, XC‑W)
M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top triple clamp (EXC EU/AUS) M8 20 Nm (14.8 lbf ft) –
Screw, top triple clamp
(EXC SIX DAYS, XC‑W)
M8 17 Nm (12.5 lbf ft) –
Engine bracket screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite®2701
Screw, top shock absorber M12 80 Nm (59 lbf ft) Loctite®2701
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

SUBSTANCES 13
2-stroke engine oil
According to
–JASO FC ( p. 15)
Guideline
–Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex®products.
Fully synthetic
Supplier
Motorex®
–Cross Power 2T
Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)
According to
–DIN EN 228
–JASO FC ( p. 15) (1:60)
Mixture ratio
1:60 2-stroke engine oil ( p. 13)
Super unleaded (ROZ 95 / RON 95 / PON 91)

AUXILIARY SUBSTANCES 14
Long-life grease
Guideline
–KTM recommends Motorex®products.
Supplier
Motorex®
–Bike Grease 2000

STANDARDS 15
JASO FC
JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

*3211693en*
3211693en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
08/2010
Photo: Mitterbauer