KTM 125 SX User guide

125 / 200 / 250 / 300 / 380
125 / 200 / 250 / 300 / 380
SX / MXC / EXC / EGS
SX / MXC / EXC / EGS
‘99
‘99
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
OWNER’S HANDBOOK
OWNER’S HANDBOOK MANUEL D’UTILISA
MANUEL D’UTILISATION TION
MANUAL DE INSTRUCCIONES
MANUAL DE INSTRUCCIONES
MANUALE D’USO
MANUALE D’USO AR
ART T. NR. 3.205.51 . NR. 3.205.51
6.98
6.98

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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
Frame number
Engine number
Stamp of dealer
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 mainten-
ance, 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.
COMSUMER INFORMATION FOR AUSTRALIA ONLY

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2
Introduction
We would like to congratulate you on your purchase of a KTM motorcycle. Let us also
take this opportunity to thank you for putting your trust in us; we will not let you down.
You are now owner of a sporty and modern motorcycle which you are bound to have a
great time with provided you care for it properly. Your owner’s handbook will furnish you
with important information on how to operate and maintain your new KTM motorcycle.
At the time of printing, the handbook covered the most up-to-date models in this series.
It is, however, possible that we may have made slight modifications in the meantime due
to development in our motorcycle design.
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 mainten-
ance 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 by *
found in the chapter entitled “Maintenance Work on Chassis and Engine” of this
manual.
Take special care to follow the recommended run in, inspection, and maintenance inter-
vals. Heeding these guidelines will significantly increase the life of your motorcycle. Be
sure to have any maintenance jobs performed by an authorized KTM dealer.
Address your special requests to an authorized KTM dealer who, should the need arise,
will be supported by the KTM importer.
Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we cer-
tainly hope that you will enjoy it to the full. However, this enjoyable outdoor activity can
cause environmental problems or lead to conflicts with other people. Responsible use of
the motorcycle will prevent such problems and conflicts. You can contribute to securing
the future of motorcycling by making sure that you only use the motorcycle within the
limits established by the applicable laws, making environmental protection one of your
top priorities and never violating other people’s rights.
We wish you a lot of fun when driving !
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments : 1 spare parts manual chassis 1 owner handbook for telescopic fork
1 spare parts manual engine 1 owner handbook for shock absorber
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
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.

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3
Page
SERIAL NUMBER LOCATIONS.............................................4
Chassis number................................................................4
Engine number, engine type (125/200)............................4
Engine number, engine type (250/300/380)....................4
OPERATION INSTRUMENTS ...............................................4
Clutch lever .....................................................................4
Hand brake lever..............................................................4
Speedometer, indicator lamp (EXC)..................................5
Odometer (EXC USA).......................................................5
Speedometer, indicator lamps (EGS).................................5
Ignition lock.....................................................................5
Short circuit button (SX)...................................................6
Combination switch (EXC)................................................6
Headlamp switch (EXC USA)............................................6
Flasher switch...................................................................6
Emergency OFF switch (Australia)....................................6
Filler cap...........................................................................7
Refueling, fuel..................................................................7
Fuel tap............................................................................7
Choke knob .....................................................................8
Shift lever.........................................................................8
Kickstarter........................................................................8
Foot brake pedal..............................................................8
Compression damping of fork..........................................8
Rebound damping of fork................................................9
Compression damping of shock absorber.........................9
Rebound damping of shock absorber...............................9
Steering lock ....................................................................9
Center stand ....................................................................9
DRIVING INSTRUCTIONS ..................................................10
PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE .....12
MAINTENANCE WORK ON CHASSIS AND ENGINE ..........13
Changing the original position of the clutch lever ..............13
Checking and adjusting the steering head bearing..........13
Pivot bearing..................................................................14
Check chain tension ......................................................14
Correct chain tension ....................................................14
Chain maintenance ........................................................14
Chain wear ....................................................................15
General informations about KTM disc brakes ................15
Adjusting of free travel at the hand brake lever..............15
Checking of brake fluid level - front brake......................16
Refilling the front brake fluid reservoir............................16
Page
Checking the front brake pads .......................................16
Replacing the front brake pads.......................................16
Changing the basic position of the brake pedal..............17
Checking rear brake fluid level .......................................17
Refilling the rear brake fluid reservoir.............................17
Checking the rear brake pads.........................................18
Replacing the rear brake pads ........................................18
Dismounting and mounting the front wheel...................18
Dismounting and mounting the rear wheel ....................19
Tires, air pressure ...........................................................19
Checking spoke tension..................................................19
Fuse (CH, Singapore) .....................................................20
Battery (CH, Singapore) .................................................20
Replacing head light lamp (H4)......................................20
Cooling system...............................................................20
Checking the coolant level .............................................21
Bleeding the cooling system...........................................21
Cleaning the air filter......................................................22
Exhaust system...............................................................22
Cleaning the spark arrestor (EXC USA)...........................22
Carburetor adjustment...................................................23
Checking the float level..................................................24
Checking the oil level of the hydraulic clutch..................24
Bleeding of the hydraulic clutch......................................24
Check transmission oil level (125/200)...........................25
Changing the transmission oil (125/200)........................25
Check transmission oil level (250/300/380) ...................25
Changing the transmission oil (250/300/380)................25
CLEANING..........................................................................26
CONSERVATION FOR WINTER OPERATION ....................26
STORAGE...........................................................................26
Use after period of storage .................................................26
TECHNICAL SPECIFICATIONS - CHASSIS (125/200)..........27
TECHNICAL SPECIFICATIONS - ENGINE (125/200)
...................28
TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)
Only USA
........................................................................30
TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)
All models out of USA
.......................................................32
TECHNICAL SPECIFICATIONS - CHASSIS (250/300/380).....34
WIRING DIAGRAMME, CARBURETOR SETTING.......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 (125/200)
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.
Engine number, engine type (250/300/380)
Engine number and engine type are stamped on the right hand side of the
engine in front of the kickstarter. Write this number into the relevant area
on page 1.
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 angine).
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.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1
A

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5
Speedometer, indicator lamp (EXC)
The mileage indicator Ain the speedometer 1indicates overall mileage.
For further adjustment options and handling, see the appended user’s guide
of the SIGMA SPORT BASELINE 500 speedometer.
On default factory models, a wheel circumference of 2150 mm (standard
tires) is adjusted on the speedometer.
The blue indicator lamp 2is lit when the high beam is on.
Odometer (EXC USA)
The odometer is a mileage indicator and can be set to 0 by means of the
adjustment wheel 3.
Speedometer, indicator lamps (EGS)
The mileage indicator Bin the speedometer 4indicates overall mileage.
When the turn indicator is on, the green indicator lamp 5will be flashing in
the same rhythm.
The blue indicator lamp 6will be lit when the high beam is on
Ignition lock
Switch positions of ignition lock 7
= 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 8can be removed when in its position.
1
A
2
B
3
4
56
7
8

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6
Short circuit button (SX)
The short circuit button 1turns off the engine. When pressing this button,
the ignition circuit is short-cicuited.
Combination switch (EXC)
The light switch has 2, respetively 3 switch positions.
A= Light off (this function is not available in all models)
B= Low beam on
C= High beam on
You may use button 2to actuate the horn.
The red short circuit button 3serves to switch off the engine. Leave the
switch pressed until the engine stops.
Headlamp switch (EXC USA)
In this model the headlamp is switched on with the pull switch 4.
Flasher switch
Flasher left
Flasher right
Emergency OFF switch (Australia)
The emergency OFF switch 5is located next to the throttle grip. Primarily
designed as safety or emergency OFF switch, it should normally not be in its
activated state.
In this position, the ignition circuit is shorted; if the engine is running,
it will stall immediately, if it is at standstill, it will not start.
In this position, the ignition circuit is enabled; the engine should start.
1
23
A
B
C
5
4

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7
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.
Refueling, fuel
125: Unleaded premium gasoline RON 98 mixed with high grade two
stroke oil. Mixture ratio 1:40
200-380: Unleaded premium gasoline RON 95 mixed with high grade two
stroke oil. Mixture ratio 1:40 – 1:60
Fuel and engine oil should only be mixed immediately before use.
KTM recommends SHELL ADVANCE RACING X.

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 REFUELING. 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
!
–
O NLY USE PREMIUM - GRADE GASOLINE ROZ 98 RESPECTIVELY 95 MIXED WITH HIGH -
GRADE TWO - STROKE ENGINE OIL . O THER TYPES OF GASOLINE CAN CAUSE ENGINE FAI -
LURE .
–DO NOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD ENGINES OR NOR-
MAL ENGINE OIL TO PREPARE THE MIXTURE.
–D
O NOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN ONE WEEK. THE
LUBRICATION PROPERTIES OF SOME TWO-STROKE OILS CAN DETERIORATE VERY
RAPIDLY.
–O
NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL.
–N
EVER MIX SYNTHETIC OILS AND MINERAL OILS.
–N
OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. WHEN
USING TOO MUCH OIL, THE ENGINE MAY START SMOKING AND FOUL THE SPARK
PLUG.
–F
UEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL THE TANK TO
THE TOP. (SEE FIG.)
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the carbure-
tor.
ON During operation the twist grip must be turned to ON. This means
that the fuel can flow to the carburetor. With the twist grip in this
position the tank will be emptied until only the reserve is left.
RES The reserve tank cannot be tapped until the rotating handle is turned
to the RES position. Fill the tank as soon as possible and remember to
turn the rotating handle back to the ON position so that you will have
backup fuel next time, too.
Reserve of the 9,5 l tank: 1.3 l (0,35 US gallons)
Reserve of the 12 l tank: 1.7 l (0,45 US gallons)
!
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.
35 mm
ON RESOFF
SX
MXC
EXC
EGS
1

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8
Choke knob
When pulling the choke knob 1fully towards the top, a bore is opened in
the carburetor. Through this bore the engine can take in additional fuel.
This encoure the rich fuel-air mixture, that is needed for a cold start.
When pressing the choke knob downward in the carburetor, the bore is
closed 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 right side of the engine. Its upper part
can be swivelled.

WARNING

WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJU-
RIES. YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN
KICKING NOT VEHEMENTLY ENOUGH.
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.
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(C, 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
Type Marzocchi 91...............................15 clicks
Type White Power 918T767 ................12 clicks
Type White Power 918T768 ................12 clicks
Type White Power 918T769 ................12 clicks
2,3,4,5 (6)
1
N
1
2
2

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9
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 1(R, 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
Type Marzocchi 91...............................15 clicks
Type White Power 918T767 ................12 clicks
Type White Power 918T768 ................12 clicks
Type White Power 918T769 ................12 clicks
Compression damping of shock absorber
The damping force of the compression damping can be adjusted with knob 2
The higher the number the higher the damping force.
STANDARD ADJUSTMENT:
Type White Power 1218T711..................5
Type White Power 1218T712..................5
Type White Power 1218T713..................6
Type White Power 1218T714..................6

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 3, 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.
Type White Power 1218T711.......14 clicks
Type White Power 1218T712.......14 clicks
Type White Power 1218T713.......14 clicks
Type White Power 1218T714.......12 clicks
Steering lock
The handlebar can be locked by means of the lock located on the steering
head. To lock it, turn handlebar all the way to the right, insert key, turn it to
left, press it in, turn it to right, and remove it.
!
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 4to 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 DRI-
VING, YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE.
1
1
2
3
4

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10
Instructions for your first ride
– Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
– Thoroughly read the whole instruction manual before star-
ting for your first tour. Additionally, you should also read
the enclosed operating instructions for the spring elements.
– Familiarize yourself with the controls.
– Adjust the clutch lever, the hand brake lever and the foot
brake pedal to the most comfortable position.
– Get used to handling the motorcycle in an empty parking
lot or open space, before going for a longer ride. Also try to
ride as slowly as possible while standing upright, to improve
your feeling for the vehicle.
– Do not drive along off-road trails which go beyond your
ability and experience.
– Hold the handlebar with both hands and leave your feet on
the foot rests while driving.
– Remove your foot from the foot brake lever when you are
not braking. If the foot brake lever is not released the
brake pads rub continuously and the braking system is
overheated.
– You may only take a passenger along if your motorcycle is
fitted and registered for such purposes. During the ride, the
passenger must hold on the straps or to the driver, 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, it should be
secured as close as possible to the middle of the vehicle; dis-
tribute the weight evenly between the front and the 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.

WARNING

IMPORTANT INSTRUCTIONS FOR MODELS SX, MXC, AND EXC:
– THE ABOVE MODELS WERE DESIGNED AND BUILT FOR
ONE PERSON ONLY - NO ADDITIONAL PASSENGER
ALLOWED!
– NEITHER DO THESE MODELS MEET THE APPLICABLE
STATUTORY REGULATIONS AND SAFETY STANDARDS.
USING THEM ON PUBLIC ROADS, HIGHWAYS, FREE-
WAYS ETC. IS AGAINST THE LAW.
– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN
MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY
EXCESSIVE NOISE.
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.
–APPLY LOW BUT CHANGING LOADS FOR RUNNING-IN.
– DO NOT DRIVE AT FULL LOAD FOR THE FIRST 500
KILOMETERS (300 MILES) OR 5 HOURS!
What you should check before each start
When you start off, the motorcycle must be in a perfect
technbical condition. For safety reasons, you should make it a
habit to perform an overall check of your motorcycle before
each start.
The following checks should be performed:
1 CHECK TRANSMISSION OIL LEVEL.
Too little transmission oil leads to premature wear and will
ultimately destroy gear wheels and parts of the shift
mechanism.
2 FUEL
Check that there is sufficient fuel in the tank; when closing
the filler cap, check that the tank venting hose is free of
kinks.
3 CHAIN
A loose chain was fall off the chain wheels; an extremely
worn chain may tear, and insufficient lubrication may result
in unnecessary wear of chain and chain wheels.
4 TIRES
Check for damaged tyres. 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 deteriorate the driving perfor-
mance.
5 BRAKES
Check correct functioning of the braking system. Verify that
there is sufficient brake fluid in the reservoir. The reservoirs
have been designed in such a way that brake fluid does not
need to be refilled even when the brake pads are worn. 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 an authorized KTM dealer, as complete failure
of the braking system can be expected.
Also check the state of the brake hose and the thickness of
the brake linings.
Check free travel at hand brake lever and foot brake lever.
6 CABLES
Check correct adjustment and easy running of all control
cables.
7 COOLING FLUID
Check the level of cooling fluid when the engine is cold.
8 ELECTRICAL SYSTEM
Check correct functioning of headlamps, tail-lights, brake
lights, turn indicators, indicator lamps and horn while the
engine is running.
9 LUGGAGE
If you are taking luggage with you, check that it is securely
fastened.

WARNING

– W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE . SMART
KTM DRIVERS ALWAYS WEAR A HELMET , BOOTS , GLOVES , AND A
JACKET
, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST GO FOR A
SHORT RIDE
. T HE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLO -
RED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS
POSSIBLE
. O F COURSE YOUR PASSENGER WILL ALSO NEED SUITABLE
PROTECTIVE CLOTHING
.
–DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–
O NLY USE ACCESSORY PARTS RECOMMENDED BY KTM. F OR EXAMPLE ,
FRONT PANELLING CAN IMPAIR THE DRIVING CHARACTERISTICS OF THE
MOTORCYCLE
.C ASES , EXTRA TANKS ETC . CAN ALTER THE WEIGHT
DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE
’ S DRIVING CHA -
RACTERISTICS .
–FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING
THE SAME TREAD LAYOUT. - ONLY USE HOLOGATED TIRES
DRIVING INSTRUCTIONS

ENGLISH
11
–DRIVE CAREFULLY ON UNKNOWN ROADS OR IN UNKNOWN TERRITORY.
–W
HEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND
MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH
OTHER SHOULD DIFFICULTIES ARISE.
–R
EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH.
WHEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES,
YOU WILL BE PRACTICALLY BLIND.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL ITS FUNCTIONS
THOROUGHLY BEFORE USING IT 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.
–N
EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO
A LOWER GEAR. THE ENGINE WILL OVERREV, DAMAGING THE VALVES.
IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE
CAN EASILY GET OUT OF CONTROL.
–I
F THE ENGINE RUNS WITHOUT THROTTLE DURING LONGER DOWNHILL
TRAVEL, THE ENGINE SHOULD BE ACCELERATED OCCASIONALLY TO
ENSURE THAT IT IS SUPPLIED WITH SUFFICIENT LUBRICANT WHICH IS
MIXED IN THE FUEL.
–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.
Braking
Turn off gas 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
BREAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN
FAIL.
Stopping and parking
Brake motorcycle and shift gears to idling. To switch off the
engine, depress short circuit switch until the engine stops or
switch off ignition. Close fuel tap.

WARNING

–N
EVER 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, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND
SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF
THESE PARTS AFTER STARTING THE MOTORCYCLE, AND TAKE CARE TO
PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET
BURNED.
!
CAUTION
!
–C
LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE. OTHERWISE THE
CARBURETOR MAY GET FLOODED AND FUEL WILL ENTER THE ENGINE.
Starting when the engine is cold
1 Open fuel tap
2 Turn on ignition or emergency OFF switch
3 Put the gear in neutral
4 Activate cold-starting aid (choke)
5 Leave throttle closed or open it no more than 1
/3and kick
down kickstarter vigorously all the way.

WARNING

–T
O AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR
BOOTS!
–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 VENTILA-
TION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
DO NOT RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DO NOT REV
UP THE ENGINE WHEN COLD. SINCE THE PISTON IS WARMS UP AND
EXPANDS FASTER THAN THE WATER COOLED CYLINDER, THIS MIGHT CAUSE
ENGINE DAMAGE. ALWAYS LET ENGINE IDLE UNTIL WARM OR DRIVE IT
WARM AT LOW R.P.M. SPEEDS.
Starting when the engine is warm
1 Open fuel tap
2 Turn on ignition or emergency OFF switch
3 Put the gear in neutral
4 Open throttle to 1
/2and kick down kickstarter vigorously
What to do when the engine is „flooded”
1 Close fuel tap
2 Start engine with full throttle. If necessary, unscrew spark
plug and dry it.
3 Once the engine is running, open fuel tap again.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly
release the clutch lever and accelerate at the same time.

WARNING

–B
EFORE YOU START OFF, CHECK THAT THE MAIN OR SIDE STAND HAS
BEEN SWUNG RIGHT UP TO THE TOP. IF THE STAND DRAGS ON THE
FLOOR, YOU MAY LOSE CONTROL OF YOUR MOTORCYCLE.
–B
EFORE STARTING FOR AN OFF-ROAD TOUR, IT IS RECOMMENDED TO
ADDITIONALLY SECURE THE SIDE STAND WITH THE RUBBER BAND ON
THE AIR FILTER BOX.
Shifting/Riding
You are now in first gear, referred to as the drive or uphill gear.
Depending on the conditions (traffic, hill size, etc.), you can
shift to a higher gear. Turn down the throttle, at the same time
pull clutch lever in and shift to the next higher gear. Let clutch
lever go again and open the 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 opening the throttle all the
way, turn throttle back to 3/4; the speed hardly decreases alt-
hough the engine will use less gas. Only give as much gas as
the engine can handle. Through quick and high revving of
throttle, the gas consumption increase. When shifting down,
use the brakes if necessary and turn down at the same time.
Pull clutch lever and shift down to the next lower gear. Let
clutch lever go slowly and open throttle or shift down again.

WARNING

–O
BSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRY TO
LOOK AHEAD AS FAR AS POSSIBLE SO THAT YOU RECOGNIZE ANY
HAZARDS AS EARLY AS POSSIBLE.
–A
DJUST YOUR DRIVING SPEED TO THE CONDITIONS AND YOUR DRIVING
SKILLS.

ENGLISH
12
PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE
Check transmission oil level ●
Change transmission oil ●●●
Check spark plug and electrode gap ●●●
Change spark plug ●
Functional testing of the exhaust control system ●
Check intake manifold for leaks and cracks ●●
Drain and clean carburetor float chamber ●●
Adjust idling ●●
Check breather hoses of engine case and gas tank for correct position without buckles ●
Clean and check airfilter element, box and carburetor connection boot ●●●
Check chain, sprockets, guides and chain wear ●●●
Clean and oil chain ●●
Check chain tension ●●●
Check coolant level ●●●
Check quality of antifreeze ●
Check cooling system for leaks - visual inspection ●●●
Check exhaust system for cracks and leaks ●
Replace glass fiber yarn of silencer ●
Check of the exhaust suspension system ●
Check brake fluid level front and rear ●●●
Change brake fluid ●
Check thickness of disc brake pads ●●
Check brake discs ●
Inspect condition and installation of front and rear brake hoses ●●●
Check free travel and free movability of hand brake lever and foot brake lever ●●●
Check the oil level in the master cylinder of the hydraulic clutch ●●
Change the oil of the hydraulic clutch ●
Check telescopic fork action ●●
Check telescopic fork for leaks ●
Push up the protective bellows and remove the dirt; the drain holes must be free of obstructions (Marzocchi fork) ●●●●
Clean the dust scrabbers of the telescopic force (WP Extreme fork) ●●●
Undo the bleeder screws at the fork legs ●
Change oil of telescopic fork ●
Service telescopic fork completely ●
Check steering head bearing free play ●●
Clean and regrease steering head bearing ●●
Check setting and damping of shock absorber ●●
Service shock absorber completely ●
Grease swingarm needle bearings (dont grease the pivot bearing for the shock absorber) ●
Check for even spoke tension and rim alignment ●●●
Check wheel bearings ●●
Check tires for cuts and air pressure ●●
Check cables for damage and free movement ●●
Adjust and oil control cables ●● ●
Check electrical system ●●●
Check battery holder and connections (CH, Singapore) ●
Check adjustment of headlight ●
Apply contact spray to light switches, flasher switches and ignition lock ●●
Check all bolts, nuts, screws and clamps for proper tightness ●●●
Clean and lubricate control lever pivot points ●●●●
AT A REGULAR COMPETITION USE OF THE BIKE, THE 4000 KM (2500 MILES)
SERVICE IS TO BE DONE AFTER EVERY RACE
KTM
rider KTM dealer
before each start after washing
after 2000 km (1250 miles) or 20 hours after 4000 km
(2500 miles) or once a year
at least once a year
1st service after 1000 km (600 miles) or 10 hours
125-380 6.98

ENGLISH
13
Changing the original position of the clutch lever
The adjusting screw 1can be used for individual adjustment of the original
position of the clutch lever, thus allowing adjustment to an optimal position
for every hand size.
Turning the adjusting screw clockwise reduces the distance between the
clutch lever and the handlebar. Turning the adjusting screw counterclock-
wise increases the distance between the clutch lever and the handlebar.
!
CAUTION
!
ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS.
ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE.
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 2of 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 triple
clamp to release tension. Retighten the five pinch bolts to 15 Nm (11 ft.lb).

WARNING

IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE
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
(e.g. Shell Advance Grease).

WARNING

ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST KNOW-
LEDGE. FOR YOUR OWN SECURITY, 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.
–WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT
THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK
–O
NLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR
LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.
–D
O NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING
LOOSE. INSTEAD, USE SELF-LOCKING NUTS.
–LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–R
EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.
–UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL CONTAMINATES
1.000.000 LITERS WATER.
MAINTENANCE WORK ON CHASSIS AND ENGINE
1
2
3

ENGLISH
14
Pivot bearing
The pivot bearing 1for PDS suspension struts at the swinging fork is
Teflon-coated and must not be lubricated with either grease or other lubri-
cants. Grease and other lubricants cause the Teflon coat to dissolve, whe-
reby the bearing’s lifecycle will be reduced dramatically.
When cleaning your bike with a high-pressure cleaner, do not aim the high-
pressure spray directly at the pivot bearing.
Check chain tension
– To check the chain tension, park the motorcycle.
– Press chain upward at the end of the chain sliding component. The
distance between chain and swing arm should be approx. 15 mm (0.6 in).
In the course of this procedure, the upper chain portion Amust be taut
(see drawing).
– If necessary, correct chain tension.

WARNING

–IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY TRANSMISSION
(CHAIN, CHAIN WHEELS AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO UNNE-
CESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE.
–T
OO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN
JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK
THE REAR WHEEL OR DAMAGE THE ENGINE.
–I
N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correct chain tension
– Loosen collar nut 2, loosen lock nuts 3, and turn right and left adju-
sting screws 4equally far. Tighten lock nuts.
– Before tightening the collar nut, verify that the chain adjusters 5are sit-
ting close to the adjusting screws and that the rear wheel has been aligned
with the front wheel.
– Tighten collar nut 2to 80 Nm (60 ft.lb).

WARNING

–IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU
HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS
POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF
YOUR MOTORCYCLE.
–T
IGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE
MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.
Chain maintenance
For long chain life, good maintenance is very important. Chains with-
out O-rings should be cleaned in fireproof solvent regularly and after-
wards treated with hot grease or chain spray (Shell Advance Bio
Chain).
O-ring chains on the other hand are very simple to clean. The best
way is to use lots of water, but never use brushes or cleaning liquids.
After letting the chain dry, you can use a special O-ring chain spray
(Shell Advance Bio Chain).
15 mm
A
1
2
3
4
5
3
4

ENGLISH
15

WARNING

NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS, EITHER-
WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRON-
GLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL.
!
CAUTION
!
WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK
CLIP MUST POINT IN RUNNING DIRECTION.
Also check sprockets and chain guides for wear, and replace if necessary.
Chain wear
In order to check the chain wear, regard the following indications:
Shift the gear into idling and pull the upper chain strand with approx. 10-15
Kilogramm (33 lb) upwards (see figure). Now one can measure a space of
18 chain reels at the lower chain strand. The chain should be replaced at the
latest when a space of 272 mm (10.70 in) is measured. Chains do not
always wear off evenly, therefore repeat the measurement at different pla-
ces on the chain.
NOTE:
If you mount a new chain, the sprockets should also be replaced. New
chains wear faster if used on old used sprockets.
!
CAUTION
!
WHEN YOU ASSEMBLE A REAR SPROCKET WITH 14T, THE COLLAR MUST BE ON THE INSIDE
General information about KTM disc brakes
BRAKE CALIPERS:
The brake calipers of this series use a „floating” mount. This means that the
brake calipers are not solidly attached to the caliper support, which enables
them to „float” for maximum braking contact.
BRAKE PADS:
The motorcycles are delivered with organic brake pads and have also been
type-coded with these pads. Said pads are suitable for almost the entire
range of application of these motorcycles.
It is only for competitive racing in extremely dirty conditions (e.g., water in
combination with sand and mud) that we recommend brake pads that have
sintered linings. However, take notice of the fact that brake pads with sinte-
red linings have not been type-coded! Besides, they may cause greater wear
on the brake discs.
BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on front and rear wheel brakes have been desi-
gned in such a way that even if the brake pads are worn it is not necessary
to top up the brake fluid. If the brake fluid level drops below the minimum
level either the brake system has a leak or the brake pads are completely
worn.
In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake system with ”Shell Advance Brake DOT 5.1”, one of the
best brake fluids currently available. We recommend that you continue to
use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.
If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake
fluid. However, you should replace it as soon as possible by DOT 5.1.
Adjusting of free travel at the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjustment
screw 1. In this way, the position of the point of pressure (i.e., the resi-
stance you feel on the hand brake lever when the brake pads are pressed
against the brake disc) can be adjusted for any hand size.
!
CAUTION
!
AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN). ONLY
THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY
THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF THIS FREE TRAVEL IS NOT PRO-
VIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE
MAY FAIL DUE TO OVERHEATING.
15 KG
33 lbs
max. 272 mm
1 2 3 16 17 18
DOT
5.1 DOT
5
✓✕
min. 3 mm
✓
1

ENGLISH
16
Checking of brake fluid level - front brake
The brake fluid reservoir is linked with the hand brake cylinder at the hand-
lebar and the reservoir is provided with an inspection glass. With the reservoir
in a horizontal position, the brake fluid level should not drop below the
middle of the glass. The reservoir should be kept completely full at all times
for best performance.

WARNING

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A
LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHO-
RIZED KTM DEALER IMMEDIATELY.
Refilling the front brake fluid reservoir *
When the brake fluid falls to the middle of the inspection glass, new brake
fluid has to be added.
Loosen screws 1and remove lid 2and membrane 3.
Place hand brake cylinder in a horizontal position and fill the brake fluid
reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1
(Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws.
Rinse off spilled or overflowing brake fluid with water.

WARNING

–N
EVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE
COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.
–S
TORE BRAKE FLUID OUT OF REACH OF CHILDREN.
–B
RAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF
YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A
DOCTOR
!
CAUTION
!
–D
ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER.
–USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
Checking the front brake pads
The brake pads can be inspected from below. The linings nust be at least
1 mm (0.04 in) thick.

WARNING

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,
OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT
OFF HAVING YOUR BRAKE PADS CHANGED.
!
CAUTION
!
IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY
WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,
THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.
Replacing front brake pads *
Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips 4and pull out bolt 5. Remove brake pads
from the brake caliper. Clean the brake caliper and the brake caliper support
with compressed air. Check the sleeves of the guide bolts for damage, and
grease guide bolts if necessary.
min.
1 mm
5 mm
12
3
44
5

ENGLISH
17
Mount the right brake pad and fix it with the bolt. Mount the left brake pad
and insert the bolt until it stops. Mount the clips.
When mounting the brake pads, be sure to check for correct fit of the sli-
ding metal-sheet 3in the caliper support and of the leaf spring 4.

WARNING

–I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.
OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
–A
FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
–
H AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM , ONE MUST ALLWAYS
ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER
, RESPECTIVELY SO AS TO
ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE
POINT IS ESTABLISHED
.
Changing the basic position of the foot brake pedal *
The basic position of the foot brake pedal can be altered by turning the stop
screw 5. The free play at the foot brake pedal must then be adjusted by
means of the piston rod 6.
Measured on the outside, the foot brake pedal must have 3-5 mm
(0.12–0.20 in) of free play, before the piston rod can move the piston in the
brake cylinder (to be recognised from the resistance on the foot brake
pedal). !
CAUTION
!
IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM
WHEN DRIVING, CAUSING THE REAR WHEEL TO BRAKE.THE BRAKING SYSTEM OVERHEATS
AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES.
Checking rear brake fluid level
The brake fluid reservoir of the rear disc brake is located on the right side of
the motorcycle next to the kickstarter. The brake fluid level must not drop
below the „MlN” marking when the vehicle is in an upright position.

WARNING

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A
LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHO-
RIZED KTM DEALER IMMEDIATELY.
Refilling the rear brake fluid reservoir *
For this purpose, it is recommended to remove screw 7and to pull the
brake fluid reservoir outwards. Now the screw cap 8and the rubber boot
9can be removed. Add brake fluid DOT 5.1 (Shell Advance Brake DOT
5.1) until the brake fluid level reaches the ”MAX” mark, then mount the
screw cap together with the rubber boot. Restore the brake fluid reservoir
to its original position and fix it with the screw. The connecting hose bet-
ween the reservoir and the foot brake cylinder must be carefully positioned,
preventing kinks and keeping a safe distance between the hose and the
exhaust pipe. Spilled brake fluid must be rinsed off with water.

WARNING

–N
EVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE
COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.
–S
TORE BRAKE FLUID OUT OF REACH OF CHILDREN.
–B
RAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF
YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A
DOCTOR
!
CAUTION
!
–D
ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMO-
VER.
–USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.
34
1
2
3-5mm
8
9
5
6
7

ENGLISH
18
Checking the rear brake pads
The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).

WARNING

AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM,
OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT
OFF HAVING YOUR BRAKE PADS CHANGED.
!
CAUTION
!
IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY
WORN, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,
THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.
Replacing the rear brake pads *
Press brake caliper 1in direction of chain wheel for the brake piston to
reach its basic position. Remove safety device 2, knock out the guide pin
3from the brake caliper with a drift towards the chain wheel and remove
brake pads. Carefully clean the brake caliper with compressed air and check
sleeves of the guide pins for damage.
Slide left brake pad into the brake caliper and fix it with the pin. Slide in the
right brake pad and knock the bolt in as far as it will go. Mount safety
device 2.

WARNING

–I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.
OTHERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
–A
FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.
–H AVING PERFORMED ANY WORK ON THE BRAKING SYSTEM , ONE MUST ALLWAYS
ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER
, RESPECTIVELY SO AS TO
ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE
POINT IS ESTABLISHED
.
Dismounting and mounting the front wheel
– To remove the front wheel, jack the motorcycle up on its frame so that
the front wheel no longer touches the ground.
– Loosen the collar screw 4
– Loosen the 4 clamping screws 5on the fork fists.
– Hold the front wheel, pull out the wheel spindle 6
NOTICE: the wheel spindle may be pulled out more easily, if you slide an
open-end wrench (17mm) onto the flat portion Aof the wheel spindle.
– Remove front wheel carefully from the fork and take the speedometer
drive 7off the hub.
!
CAUTION
!
DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED.
– Prior to mounting the front wheel, clean and grease sealing ring 8and
running surface 9at the speedometer drive.
– To mount the front wheel, lift it into the fork. Insert speedometer drive
into the hub. Make sure that the driving tabs bk engage with the slots of
the drive.
– Position front wheel and speedometer drive, and mount wheel spindle.
– Mount collar screw 4, turn speedometer drive in a way that the flexible
speedometer shaft will curve upwards in a slight bow and tighten collar
screw to 40 Nm (30 ft.lb).
– Take the motorcycle off the stand and bounce the fork hard a few times
to align the fork legs
– Then tighten clamping screws 5to a max. torque of 7 Nm (5 ft.lbs)

WARNING

–IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU
HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSI-
BLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR
MOTORCYCLE.
–A
FTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE
PRESSURE POINT RETURNS.
–I
T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,
EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.
min.
1 mm
1
2
3
7
A
5
64
5
7
8
9
10