KTM 125 EXE 2001 User guide

OWNERS HANDBOOK
MANUAL DE INSTRUCCIONES
2001
BEDIENUNGSANLEITUNG
Art.Nr. 3.205.96 3/2001
125 EXE, SUPERMOTO

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1
IMPORTANT
WE STRONGLY SUGGEST THAT YOU 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:

WARNING

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR
BODY AND YOUR LIFE.
!
CAUTION
!
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE
IS NOT ROAD-SAFE ANYMORE.
Please insert the series numbers of your motorcycle in the boxes below
Chassis number
Engine number
Stamp of dealer
KTM S PORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT , TECHNICAL SPECIFICATI -
ONS , 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
. I T SHALL BE ACCEPTABLE TO STOP
MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT
. I N THE EVENT OF SUCH MODIFI -
CATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION . W E SHALL NOT BE HELD LIABLE FOR
ANY PRINTING ERRORS
.

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2
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
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 there may exist minor discrepancies 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.
Many motorcyclists have a good working knowledge of motorcycle mechanics; if
this is true in your case, you will be able to use this manual to carry out most of
the maintenance steps yourself. If, on the other hand, you are not very familiar
with motorcycles, it might be better to have a professional KTM dealer perform
those steps marked *described in the chapter entitled “Maintenance Work on
Chassis and Engine” of this manual.
For your own safety use only KTM-approved parts and accessories. 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.
We wish you a lot of fun when driving !
KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the
beginning of an on-going total re-engineering quality plan for a brighter tomorrow.
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

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3
Page
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Speedometer, indicator lamps . . . . . . . . . . . . . . . . . . . . .5
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Center stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Baggage carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of fork . . . . . . . . . . . . . . . . . . . . .8
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of shock absorber . . . . . . . . . . . .9
Rebound damping of shock absorber . . . . . . . . . . . . . . .9
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .10
PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE
. .13
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .14
Dismounting and mounting of seat . . . . . . . . . . . . . . . .14
Checking and adjusting the steering head bearing . . . . .15
How to change the handlebar position . . . . . . . . . . . . .15
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .16
Cleaning the dust sleeves of the telescopic fork . . . . . . .16
Changing the spring preload of the shock absorber . . . .16
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .17
Page
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
General informations about KTM disc brakes . . . . . . . .18
Adjusting of free travel at the hand brake lever . . . . . .19
Checking of brake fluid level - front brake . . . . . . . . . .19
Refilling the front brake fluid reservoir . . . . . . . . . . . . .19
Checking the front brake pads . . . . . . . . . . . . . . . . . . .19
Changing the basic position of the brake pedal . . . . . .20
Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .20
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .20
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .20
Dismounting and mounting the front wheel . . . . . . . . .21
Dismounting and mounting the rear wheel . . . . . . . . .21
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .22
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Replacing head light lamp (H4) . . . . . . . . . . . . . . . . . .23
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . .23
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .24
Changing the original position of the clutch lever . . . . .24
Checking the oil level of the hydraulic durch . . . . . . . .25
Adjusting the idle speed . . . . . . . . . . . . . . . . . . . . . . . .25
Check transmision oil level . . . . . . . . . . . . . . . . . . . . . .25
Changing the transmission oil . . . . . . . . . . . . . . . . . . .25
Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
CONSERVATION FOR WINTER OPERATION . . . . . . . . .28
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Use after period of storage . . . . . . . . . . . . . . . . . . . . . .28
TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . .29
TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . .30
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . . . .Appendix
INDEX

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4
Chassis number
The chassis number is stamped on the right side of the steering head tube.
Write this number into the field on page no 1.
Engine number, engine type
The engine number and the engine type are stamped into the left side of
the engine below the engine sprocket. Please note this number down on
page 1.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
Clutch lever
The clutch lever 1is located on the left side of the handlebar. The adju-
sting screw Ais used to change the original position of the clutch lever (see
maintenance work on chassis and engine).
Hand brake lever
The hand brake lever is mounted on the handle bars on the right and actua-
tes the front wheel brake.

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”
(TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE
BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE
BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.
1
A

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5
A
1
23
4
5
A
B
8
7
6
Speedometer, indicator lamps
The mileage indicator Ain the speedometer 1indicates overall mileage.
When the turn indicator is on, the green indicator lamp 2will be flashing in
the same rhythm.
The blue indicator lamp 3will be lit when the high beam is on
Ignition lock
Switch positions of ignition lock 4
= Ignition off
= Ignition on, parking light on (only for models with battery)
!
CAUTION
!
DONT TURN THE PARK LIGHT FOR MORE THAN 90 MINUETS, WHEN THE MOTOR IS NOT
RUNNING, BECAUSE THE BATTERY WILL BE COMPLETLY EMPTIED AND DESTRYED.
The ignition key 5can be removed when in its position.
The red oil level warning lamp 6lights up when the ignition is swit-
ched on, indicating that the oil level warning system works properly.
– If the two-stroke oil level in the oil tank is sufficiently high, the oil level
warning lamp will go out after approximately two seconds.
–
If the oil level has decreased to approximately 300 ccm, the oil level war-
ning lamp will stay on, reminding you that the oil tank must be refilled with
two-stroke oil (e.g. Shell Advance Ultra 2) within the next 100 kilometers.
!
CAUTION
!
–C
HECK FUNCTION OF OIL LEVEL WARNING LAMP BEFORE EVERY RIDE
–ONCE THERE IS NO TWO-STROKE OIL IN THE OIL TANK, THE ENGINE IS BOUND TO
BREAK DOWN.
Combination switch
The light switch has 2 switch positions.
A= Low beam on
B= High beam on
You may use button 7to actuate the horn.
The red short circuit button 8serves to switch off the engine. Leave the
switch pressed until the engine stops.
Flasher switch
Flasher left
Flasher right

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6
Filler cap
To open it: turn filler cap counter-clockwise.
To close it: put filler cap back on and tighten it by turning it clockwise.
Install tank breather hose 1without kinks.
Fuel
This motorcycle is equipped with separate lubrication. This means that the
two-stroke oil required for engine lubrication is not admixed to the fuel but
contained in a separate oil tank (see below). An oil pump is used for con-
trolled admixing of two-stroke oil into the fuel in the carburetor.
Besides, the motorcycle is equipped with a catalytic converter. Therefore, it
is absolutely necessary to fill in unleaded fuel.
Fuel:
UNLEADED REGULAR GASOLINE WITH AT LEAST 91 OCTANES (RON)
Fuel expands when its temperature rises. Therefore do not fill the tank to
the top (see fig.). Fuel tank capacity 11,0 liter

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED
WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR
BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE
CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS
HOT. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES,
SEEK A DOCTOR’S ADVICE IMMEDIATELY.
!
CAUTION
!
NEVER FILL IN LEADED FUEL. LEADED FUEL WILL DESTROY THE CATALYTIC CONVERTER.
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the carbure-
tor.
ON When using the motorcycle, the twist grip must be set to the ON
position. Now fuel may flow to carburetor. In this position the tank
empties down to the fuel reserve of approx. 3 liters.
RES The reserve tank, approximately 3 liters, cannot be tapped until the
twist grip is turned to the RES position. Fill the tank as soon as possible
and remember to turn the twist grip back to the ON position so that
you will have backup fuel next time, too.
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.
ON RESOFF
35 mm
1

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7
Oil tank
The oil tank 1is mounted on the right side in front of the fuel tank. Here,
the two-stroke oil for separate lubrication of the engine must be filled in.
The oil level can easily be checked through the transparent material of the
oil tank. Engine oil:
2-stroke engine oil suitable for a mixing ratio of 1:50
and for separate lubrication
KTM recommends SHELL ADVANCE Ultra 2
To open it: pull vent hose out of the frame and turn closure cap counter-
clockwise.
To close it: apply closure cap and turn it clockwise. Stick vent hose into
frame and install it without kinks.
Tank volume: 1.3 liters
!
CAUTION
!
–O
NCE THERE IS NO TWO-STROKE OIL IN THE OIL TANK, THE ENGINE IS BOUND TO
BREAK DOWN.
–T
HE VENT HOSE MUST ALWAYS BE INSTALLED WITHOUT KINKS.
Choke
When tilting the choke lever 2upwards, a bore is opened in the carbure-
tor, which enables the engine to take additional fuel. This creates a rich fuel
air mixture, that is needed for a cold start.
Tilting the choke lever downwards closes the bore again.
Shift lever
The shift lever is mounted on the left side of the engine. The position of the
gears is shown in the illustration. Neutral, or the idle speed, is located bet-
ween first and second gear.
Kickstarter
The kickstarter is mounted on the left side of the engine. Its upper part can
be swivelled.

WARNING

–I
F YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY
MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICK-
STARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH
GREAT VEHEMENCE.
–A
LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.
KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED
THROTTLE GRIP INCREASE THE KICK-BACK HAZARD.
Foot brake pedal
The foot brake pedal is disposed in front of the right foot rest. Its basic posi-
tion can be adjusted to your seat position (see maintenance work).

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”
(TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE
BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE
BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.
2
2,3,4,5,6
1
N
1

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8
Steering lock
The handlebar can be locked by means of the lock located on the steering
head. Fully turn handlebar to right to lock, insert key, turn to left, press in,
turn to right and withdraw.
!
CAUTION
!
NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK. IF YOU TURN THE HANDLE BAR
TO THE LEFT THE KEY COULD GET DAMAGED.
Center stand
Push center stand with your foot to the ground and pull your bike back-
wards. Make sure that you put your bike on solid ground and in a secure
position. For off-road riding, you can use the rubber band 1to additionally
secure the center stand in its folded-up position.
!
CAUTION
!
ALWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE CENTER
STAND AS FAR AS POSSIBLE. IF THE STAND TOUCHES THE GROUND WHILE YOU ARE
DRIVING, YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE.
Baggage carrier
The baggage carrier may be loaded with up to 10 kg. The two lateral
brackets serve as handles for the passenger
Compression damping of fork
The compression damping mechanism is built into the left fork tube. It only
regulates the degree of damping during compression.
By turning the adjusting screw 2(COM), the degree of damping of the
compression can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during compression.
STANDARD ADJUSTMENT
– turn adjusting screw clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of
fork
WP 0618T777A..................10 clicks
Rebound damping of fork
The rebound damping mechanism is built into the right fork tube. It only
regulates the degree of damping during rebounding.
By turning the adjusting screw 3(REB), the degree of damping of the
rebound can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during rebounding.
STANDARD ADJUSTMENT
– turn adjusting screw clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of
fork
WP 0618T777A....................9 clicks
1
3
2

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9
Compression damping of shock absorber
The damping force of the compression damping can be adjusted with
knob 1The higher the number the higher the damping force.
STANDARD ADJUSTMENT:
WP 1218T715......................3 clicks

WARNING

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION
NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN-
ANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
Rebound damping of shock absorber
By using the adjusting screw 2, the degree of damping of the rebound can
be adjusted. Turn the knob to the right side to increase damping, turn it to
the left side to reduce damping during rebounding.
STANDARD ADJUSTMENT:
– Turn the adjusting screw clockwise to the stop.
– Then turn the adjusting screw counterclockwise, counting the number of
clicks that corresponds to the respective type of shock absorber.
WP 1218T715....................14 clicks
1
2

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10
DRIVING INSTRUCTIONS
– Read the entire manual carefully before your first drive.
– Familiarize yourself with the operating elements.
– Adjust the foot brake pedal to the most comfortable positi-
ons for you.
– Get used to handling the motorcycle on an empty car park,
before starting on a longer drive. Also try to drive as slowly
as possible and in standing position, to improve your feeling
for the vehicle.
– Hold the handlebar with both hands and leave your feet on
the foot rests while driving.
– Remove your foot from the foot brake pedal when you are
not braking. If the foot brake pedal is not released the brake
pads rub continuously and the braking system is overhea-
ted.
– You may only be accompanied by a passenger if your
motorcycle is fitted and registered for such purposes. The
passenger must hold tight to the brackets or hold on to the
driver during the drive, with his feet on the passenger
foot rests.
– Do not make any alterations to the motorcycle and always
use ORIGINAL KTM SPARE PARTS. Spare parts from other
manufacturers can impair the safety of the motorcycle.
– Motorcycles are sensitive to alterations in the distribution of
weight. If you are taking luggage with you, this should be
secured as close as possible to the middle of the vehicle; dis-
tribute the weight evenly between the front and rear wheel.
Never exceed the maximum permissible laden weight and
the axle weights. The maximum permissible laden weight is
made up of the following components:
– Motorcycle ready for operation and tank full
– Luggage
– Driver and passenger with protective clothing and
helmet.
– Pay attention to running in instructions.
Running in
–EVEN VERY PRECISELY MACHINED SECTIONS OF ENGINE COMPONENTS
HAVE ROUGHER SURFACES THAN COMPONENTS WHICH HAVE BEEN SLI-
DING ACROSS ONE ANOTHER FOR QUITE SOME TIME. THEREFORE,
EVERY ENGINE NEEDS TO BE BROKEN IN. FOR THIS REASON, DURING ITS
FIRST 500 KILOMETERS (300 MILES) OR 5 HOURS THE ENGINE MUST
NOT BE REVVED UP TO ITS PERFORMANCE LIMITS.
–A
PPLY LOW BUT CHANGING LOADS FOR RUNNING-IN.
– DO NOT DRIVE AT FULL LOAD FOR THE FIRST 500
KILOMETERS (300 MILES) OR 5 HOURS!
Check the following before each start
When you start off, the motorcycle must be in a perfect tech-
nical condition. For safety reasons, you should make a habit of
performing an overall check of your motorcycle before each
start.
The following checks should be performed:
1 OIL LEVEL IN OIL TANK
Once there is no two-stroke oil in the oil tank, the engine is
bound to break down. The vent hose of the oil tank must
be installed without kinks.
2 GEAR OIL LEVEL
Insufficient amounts of oil in the transmission will lead to
premature wear and subsequently to transmission failure.
3 FUEL
Check that there is sufficient fuel in the tank.
4 CHAIN
A loose chain can fall off; an extremely worn chain can tear,
and insufficient lubrication can result in unnecessary wear to
the chain and rear sprockets.
5 TIRES
Check for damaged tires. Tires showing cuts or dents must
be replaced. The tread depth must comply with the legal
regulations. Also check the air pressure. Insufficient tread
and incorrect air pressure reduce the driving performance.
6 BRAKES
Check correct functioning of the braking system. Check for
sufficient brake fluid in the reservoir. If the level of brake
fluid falls below the minimum value, this indicates a leak in
the braking system or completely worn out brake pads.
Arrange for the braking system to be checked by a KTM
specialist garage, as complete failure of the braking system
can be expected.
Also check the state of the brake hoses and the thickness of
the brake linings. Brake linings measured at their thinnest
point should not be less than 1 mm since extremely worn
linings can lead to brake failure.
7 CABLES
Check correct setting and easy running of all control cables.
8 COOLING LIQUID
Check the level of cooling liquid when the engine is cold.
9 ELECTRICAL SYSTEM
Check correct functioning and adjustment of headlights,
parking light, tail-lights, brake lights, flashers, indicator
lamps, horn and emergency OFF switch while the engine is
running.
10LUGGAGE
If you are taking luggage with you, check that this is secu-
rely fastened.

WARNING

–WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER
KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A
JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A
SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY
COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS
EARLY AS POSSIBLE. YOUR PASSENGER OF COURSE WILL ALSO NEED
SUITABLE PROTECTIVE CLOTHING.
–D
O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–O
NLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR
EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF
THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT
DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE’S DRIVING PRO-
PERTIES.
–T
HE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.

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11
3
2
1
4
Starting when the engine is cold
a) Open the fuel tap
b) Turn on the ignition (ignition key 1position: ).
c) Switch the gear to NEUTRAL
d) Operate the choke lever 2.
e) Swing up the stand.
f) Push the kick starter 3right the way down without accelerating.
g) When the engine has started but does not run smoothly, the choke lever
should be tilted to its downward position.

WARNING

–IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON
STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF
THE KICKSTARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT
UPWARD WITH GREAT VEHEMENCE.
–A
LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE
THROTTLE. KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN
OPENED THROTTLE GRIP INCREASE THE KICK-BACK HAZARD.
–D
O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST
FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN
COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLIN-
DER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS KEEP IN MIND THAT THE ENGINE SHOULD
BE WARMED UP WITH SMALL LOAD AT MEDIUM R.P.M.
Starting when the engine is warm
a) Open the fuel tap
b) Turn on the ignition (ignition key 1position: ).
c) Switch the gear to NEUTRAL
d) Swing up the stand.
e) Turn up the throttle a bit and actuate the kick-starter 3hard ALL THE
WAY.
What to do when the engine is „flooded”
The throttle must be fully opened when starting.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly release the clutch
lever and open throttle at the same time.

WARNING

BEFORE YOU START OFF, CHECK THAT THE STAND 4HAS BEEN SWUNG RIGHT UP TO
THE TOP. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF
CONTROL.

ENGLISH
12
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you
can shift to a higher gear. Close throttle, at the same time pull
clutch lever and shift to the next higher gear. Let clutch lever
go again and open throttle. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through turning the throttle grip all
the way, turn throttle back to 3/4; the speed hardly decreases
although the engine will use less gas. Never open the throttle
wider than the engine can handle. Excessive turning of the
throttle grip will increase full consumption.
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.
If the engine is killed f.ex. at a crossing, simply pull the clutch
lever and start. It is not necessary to switch the gear to
NEUTRAL.

WARNING

–O
BSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING
TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE.
–A
DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND
YOUR DRIVING SKILLS.
–D
RIVE CAREFULLY ON UNKNOWN ROADS
–R
EPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY
OF TIME. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR
GOGGLES, YOU WILL BE PRACTICALLY BLIND.
–AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
!
CAUTION
!
–H
IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE
EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN
THIS RESPECT NEED BE TAKEN.
–NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE VAL-
VES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCY-
CLE CAN EASILY GET OUT OF CONTROL.
–IF DURING EXTENDED DOWNHILL RIDES THE ENGINE IS RUNNING
ALONG WITHOUT ANY ACTUATION OF THE THROTTLE, YOU HAVE TO
TURN UP THE THROTTLE A BIT ONCE IN A WHILE TO MAKE SURE THAT
ENOUGH ENGINE OIL IS FED TO THE ENGINE.
–I
F THE RED OIL LEVEL WARNING LAMP LIGHT UP, IT WILL BE NECESSARY
TO REFILL THE OIL TANK WITH TWO-STROKE ENGINE OIL DURING THE
NEXT 100 KILOMETERS (SEE PAGE 5).
–O
IL PUMP AND OIL LINES MUST BE BLED WHENEVER THE OIL TANK
WAS COMPLETELY EMPTIED (SEE BLEEDING THE OIL PUMP). OTHER-
WISE THE OIL PUMP WILL NOT DELIVER OIL, THUS CAUSING ENGINE
DAMAGE.
–I
N THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU
NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIA-
TELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM
DEALER.
NOTE TO THE COOLING SYSTEM
If little or no air blows through the radiator, for example when
riding through slow traffic or waiting at traffic lights, the coo-
lant temperature will rise and the cooling liquid will discharge
from the radiator overflow. If possible, you should ride on fai-
rly fast so that enough air blows through the radiators. If this
is not possible however, the engine should be turned off. Let
the engine cool down before you check the cooling system.
!
CAUTION
!
IF THE COOLING SYSTEM OVERHEATS IT MOST LIKELY SUGGESTS A DEFECT
IN THE SYSTEM. IN THIS CASE, STOP IMMEDIATELY, SINCE OTHERWISE YOU
MAY DAMAGE YOUR ENGINE. LET YOUR ENGINE COOL DOWN, CHECK THE
COOLING SYSTEM FOR LEAKS, AND CHECK THE COOLANT LEVEL. CAU-
TION - SCALDING HAZARD! DO NOT DRIVE ON, UNTIL THERE IS
SUFFICIENT LIQUID IN THE COOLING SYSTEM.

WARNING

IF THE RADIATOR CAP IS REMOVED WHEN THE ENGINE IS HOT, HOT COO-
LING LIQUID, THAT IS UNDER PRESSURE, CAN SPRAY OUT AND CAUSE
SEVERE BURNS. ALLOW YOUR ENGINE TO COOL DOWN AND, IN THE
MEANTIME, CHECK THE COOLING SYSTEM FOR LEAKS.
Braking
Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.

WARNING

WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND
BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE
BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN
FAIL.
Stopping and parking
Apply the brakes fully and put the engine into neutral. To stop
the engine, switch off the ignition. Close fuel taps. Park on
solid ground and lock the vehicle.

WARNING

–NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS
THE ENGINE IS RUNNING.
–M
OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE
RUNNING. THE ENGINE, THE RADIATORS, EXHAUST SYSTEM, MUFFLER,
BRAKE DISCS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO
NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCY-
CLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY
TO TOUCH IT AND GET BURNED.
–N
EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE
HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE
MATERIALS.
!
CAUTION
!
–A
LWAYS USE THE IGNITION LOCK TO TURN OFF THE ENGINE. WHEN
YOU TURN OFF THE ENGINE WITH THE SHORT CIRCUIT BUTTON AND
LEAVE THE IGNITION ON, THE PARKING LIGHT WILL LIGHT UP.
–W
HEN PARKING YOUR MOTORCYCLE ALWAYS CLOSE FUEL TAP. WITH
THE FUEL TAP OPEN, THE CARBURETOR MIGHT OVERFLOW AND FUEL
COULD FLOW INTO THE ENGINE.
–A
LWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR
MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED
PERSONS.
–P
ARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE STAND
(HARD GROUND, LEVEL SURFACE) AND CAN’T TIP OVER.

ENGLISH
13

ENGLISH
14
PERIODIC MAINTENANCE 2001
2. Service after
4000 km
1. Service after
1000 km
every
4000 km
or
once a year
SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM!
MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
A washed motorcycle can be checked more quickly which saves money!
Check oil level in oil tank and verify kink-less arrangement of bleeder hose ●●●
Change transmission oil ●●●
Check spark plug, set electrode gap, replace plug if necessary ●
Check carburetor connection boots for cracks and leaks ●●
Check idle setting and emission values ●●●
Check bleeder hoses for damage and kink-free arrangement ●●●
Check cooling system for leaks, antifreeze protection ●●●
Check exhaust system for leaks and suspension ●●
Check actuating cables for damage, smooth operation, and kink-less arrangement, ●●●
and adjust and lubricate
Check oil level in master cylinder of hydraulic clutch ●●●
Clean air filter and air filter box ●●
Check cables for damage and kink-less arrangement ●●
Check headlamp adjustment ●●
Check electrical system for proper operation ●●●
(low/high beams, stop light, turn indicators, tell-tale lamps,
speedometer illumination, horn, battery holder, and connections)
Check brake fluid level, lining thickness, and brake discs ●●●
Check brake lines for damage and leaks ●●●
Check/adjust smooth operation, free travel of handbrake/footbrake levers ●●●
Check screws of brake system for tight fit ●●●
Check suspension strut and fork for leaks and proper function ●●●
Clean fork dust sleeves ●●
Bleed fork legs ●●
Check swinging-fork pivot ●●
Check/adjust steering-head bearing ●●●
Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, ●●●
swinging-fork pivot, suspension strut)
Check spoke tension and rim joint ●●
Check tire condition and inflation pressure ●●●
Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension ●●●
Lubricate chain ●●●
Check wheel bearings for play ●●●
IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER
Verify proper function of exhaust control ●
Perform complete fork maintenance ●
Perform complete suspension strut maintenance ●
Clean and lubricate the steering-head bearing and sealing elements ●
Clean and adjust the carburetor ●
Replace the glass-fiber yarn packing of the main silencer ●
Treat the electrical contacts and switches with contact spray ●
Replace the oil of the hydraulic clutch ●
Replace the brake fluid ●
WHEELS CHASSIS BRAKES ADD-ON-PARTS
CARBURATOR
ENGINE
125 EXE
125 SUPERMOTO
at least
once a year
every 2 year
or 20000 km

ENGLISH
15
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Check oil level in oil tank and bleeder hose for its kink-less arrangement ●
Check transmission oil level ●
Check brake fluid level ●
Check brake pads for wear ●
Check lighting system for proper operation ●
Check horn for proper operation ●
Lubricate and adjust actuating cables and nipples ●
Bleed fork legs in regular intervals ●
Remove and clean fork dust sleeves in regular intervals ●
Clean and lubricate chain, check tension and readjust it if necessary ●●
Clean air filter and filter box ●
Check tire inflation pressure and wear ●
Check coolant level ●
Check fuel lines for leaks ●
Drain and clean float chamber ●
Verify smooth operation of all controls ●
Check brake performance ●●
Treat exposed metal components (except for brake and exhaust systems) with ●
wax-based anti-corrosion agents
Treat ignition/steering lock and light switch with contact spray ●
Check all screws, nuts, and hose clamps for their tight fit in regular intervals ●
For cross- country use Once a year After every cleaning
Before each start

ENGLISH
16
Dismounting and mounting of seat
Remove left and right screws 1. Lift rear portion of seat, pull it backwards,
and disengage it at the oval head screw 2.
Mounting the seat:
Hook the seat onto the oval head screw 2.
Slide it forward to let the retaining plate 3engage in the seat.
Slide retaining shackles of seat under the side covers and mount screws 1
23
1

WARNING

ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST KNOW-
LEDGE. FOR YOUR OWN SAFETY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER
!
CAUTION
!
–W
HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-
BURETOR, ELECTRIC CONNECTORS ETC.
–L
ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–D
ISPOSE OF OIL, GREASE, FILTERS, FUELS, CLEANING AGENTS ETC. ACCORDING TO YOUR LOCAL REGULATIONS.
–U
NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER USED OIL CONTAMINATES
1.000.000 LITERS WATER.
MAINTENANCE WORK ON CHASSIS AND ENGINE

ENGLISH
17
Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. For check put motorcycle
on stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. For readjusting, loosen the five pinch bolts 2
of the top triple clamp and turn steering stem bolt clockwise 3until there is
no more play. Don’t tighten the steering stem bolt all the way, otherwise
the bearings will be damaged. With a plastic hammer, lightly rap on the tri-
ple clamp to release tension. Retighten the five pinch bolts to 20 Nm
(15 ft.lb).

WARNING

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-
CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.
!
CAUTION
!
IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE
BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
The steering head bearings should be regreased at least once a year
(i.e. Shell Advance Grease).
How to change the handlebar position
The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar to the position that is the most convenient for you. The upper tri-
ple clamp 4includes 2 bores arranged at a distance of 15 mm (0,6 in) from
one another. The bores at the handlebar support 5are offset from the cen-
ter by 3.5 mm (0,13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws 6of the handlebar clamps and screws 7
of the handlebar support. Position handlebar support, and tighten screws 7
to 40 Nm (30 ft.lbs). Mount handlebar and handlebar clamps, and tighten
screws 6to 20 Nm (15 ft.lbs). The gap between handlebar support and
handlebar clamps is to be of equal size in the front and in the rear.
2
3
4
5
6
7
15 mm
3,5 mm

ENGLISH
18
Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather
plugs 1a few turns in order to relieve excess pressure from the inside of
the fork. To do this, place the motorcycle on a stand with the front wheel
lifted off the ground. When riding the motorcycle mainly on street, it will be
enough to have this job performed in the course of the periodical mainten-
ance service.!
CAUTION
!
EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF
YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE
HAVING THE SEALS REPLACED.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows 2are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind
the dust-protection bellows. If this dirt is not removed, the oil sealing rings
located behind it may start to leak.
Use a screwdriver to lever the dust-protection bellows from the outer tubes
and slide them downward.
Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with silicone spray or engine oil. Then, push dust-pro-
tection bellows into the outer tubes by hand.
Changing the spring preload of the shock absorber *
KTM sets the shock absorber for driver only, weighing approximately 75 kg
(165 lb). If you want to take a passenger with you, of if you weigh consi-
derably more or less than 75 kg (165 lb), you should change the spring pre-
load accordingly. This is easily done.
NOTE:
– Before changing the spring preload note down the basic setting, e.g.
how many coils are visible above the adjusting ring.
– One rotation of the adjusting ring 3changes the spring preload by
approximately 1.5 mm.
Use the hook wrenches included in the vehicle tool kit to loosen the counter
ring 4. Change spring preload as desired by means of the adjusting ring 3,
and retighten counter ring.
ADJUSTMENT VALUES - SPRING PRELOAD:
Minimum preload...............................................................10 mm
Preload driver only 75 kg BASIC SETTING..........................23 mm
Preload with passenger.......................................................28 mm
A= spring preload
1
34
A
2