=MOTORCYCLES 125 Sting ‘97 BEDIENUNGSANLEITUNG OWNER’S HANDBOOK ART. NR. 3.205.22 MANUEL D/’UTILISATION 5.97IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS HANDBOOK CAREFULLY AND COMPLETELY BEFORE YOU TAKE YOUR FIRST RIDE. IT CONTAINS INFORMATION AND TIPS THAT WILL ENABLE YOU TO OPERATE AND HANDLE YOUR MOTORCYCLE PROPERLY. PAY ATTENTION ESPECIALLY TO THE FOLLOWING INSTRUCTIONS: WARNING IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE. —__i CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORBIKE OR THAT THE MOTORBIKE IS NOT ROAD SAFE ANYMORE. Please insert the series numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealerIntroduction We would like to congratulate you on your purchase of a KTM motorcycle. You ate now owner of a sporty and modem motorcycle which you are bound to have a | great time with, provided you care for it properly. This manual 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. Itis, 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 * descr bed 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. Have services carried out by a KTM dealer so that your warranty claim remains intact. ‘We wish you a lot of fun when driving ! rate FOR QUALITY SYSTEM iso 9001 REG.NO. 12 100 6061 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.LOCATING THE SERIAL NUMBERS Frame pumber Engine number, engine type .. OPERATION INSTRUMENTS Cute lever Choke lever . Hand brake lever Speedometer, tachometer Indicatr amps liton loc, steering lock Combination switch - Starter tip swatch, emergency OFF switeh Fler cap Fuel. Fuel tp Of ank shift lever Foot brake pedal Passenger handles DRIVING INSTRUCTIONS PERIODIC MAINTENANCESCHEDULE MAINTENANCE WORK ON CHASSIS AND ENGINE Toolkit .. - _ Dismounting and mounting of seat ck and adjust stecring head bearing ‘Changing the spring preload of the shock absorber (Check chain teasion Readjusting chat tension - (Chain maintenance Coxin wear CGenetal informations about dise brakes (Checking of brake fuid level - front brake Reflling the front brake reservoir Checking te font brake pads Changing the basic position ofthe brake pedal (Checking the rear brake fu level. Reflling the rear brake reservoir (Checking the reer brake pads 2 213 213 13 4 4 4 15 15 15 1S 16 16 16 7 17 17 17 INDEX Dismounting and mounting the front whee] Dismounting and mounting the rear whee! “Tires, alr pressure Checking spoke tension Main fuse Batterie (Charging the battery Cooling system (Checking the cooling liquid level. . Adjusting the clutch cable Adjusting the choke cable ‘Adjusting tne throtl cable Adjust the ide speed... Checking the gear ol evel Changing gear oi Bleeding tne ol pump Removing the headlight mask Replacing the headlight amo Replacing the instrument light Replacing the indicator lames TROUBLE SHOOTING . CLEANING ‘CONSERVATION FOR WINTER OPERATION . STORAGE Resnitation afer time of storage ‘TECHNICAL SPECIFICATIONS - CHASSIS TECHNICAL SPECIFICATIONS - ENGINE WIRING DIAGRAME 18 18 19 wld 19 20 2 a1 valll 2 22 22 2a 2a 2B 23 23 2A a 2d 25 aa aa aa 2 28 29 append,LOG: ING THE SERI POA Frame number ‘The frame number is swamped on the right side ofthe steering head tube, Write the number into the box on page I Engine number, engine type Engine oumer and engine type are stamped into the engine housing underneath ‘he carburetor. Write this mmbee into the box on page OPERATION INSTRUMENTS Clutch lever ‘The clutch ever @ is fited on the left hand side of the handle bar. When engine {s cold, there should bea play of 19 mm (0.4 in} (measured at outer edge t ‘CAUTION I IP wear iso piav ow Tae curren uve, THE CLUTCH WIL START TO Su. THE Cl WiLL THEN OVERIEAT, DESTROYING THE CLUTCH LININGS Choke lever When the choke lever @ Is pulled backwards, a bore is opened In the earbure tor-which enables the engine to draw in addtional fuel. This produces 2 gtieh* ‘ue/alr mixture necessary for cold start. When the choke lever Is pushed forward 2 far as It will go, the bore will be closed again. ln this pasition the choke cable ‘must have a play of approx, 21am (0.8 in) 1 ‘CAUTION If Tutat i wo TINY BU THE GHOKE CABLE, THE BORE OF THE OOLD STARTER STEN caw Not BE COMPLETELY cLomeD, THs RESULTS I MGM FUEL CONSUMPRON, THE ENGINE UNS UNTVENLY WITH EXTREME WEAR OF STON AND CXLINDER. Hand brake lever The hand breke lever is mounted on the right side ofthe handle: a ‘WARNING "THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE FEDAL FELS “SEONGE” [NOT [ENOUGH SEISTANCE), THIS SAN INDICATION THAT SOMETHING 15 WRONG WITHTHE BRAKE systiat, Don'r RDE YOUR MOTORCYCLE ANYMORE WITHOUT FRST HAVING THE BRAKE SYSTEM LOOKED Owe, & KTM. DEALER.Speedometer, tachometer The mileage indicator @ in the speedometer @ indicates overall mileage, The day mileage indicator @ can be sotto 0 by means ofthe setting wheel @, Tum the serting wheel forward untl only zeros can be seen inthe display. The tachometer © shows the engine speed in revolulons per minute (rpm. Da not push the engine into the orange zone, which begs at 10.500 zp, T CAUTION t "Mabini RECOWMTNDED ROTATION RATE W 10.5DD HP, ROTATION RATES EXCEE Ding 10-500 ness wait SHORTEN YOUR ENGINE'S LIFE. REFER ALSO TO THE SECTION ON AUNNING IN YOUR aTOROYELE TO BF FOUND 18 TE “DATING INSTRUCTIONS” CHAPTER = SPIEDOMETER AND TACHOMETER ARE NOT SUPFOSED TO GET IN CONTACT WITH \WIPe OFF SPLASHED FUEL ON THE PLASTIC ARTS IMMIEDISTELY, OTHERNISE THE. PL Si PaaS MUGHT GET DAMAGED. Indicator lamps GS) Tere ove wag amp @ ths up when he lgnion sshd =) on, indicating thatthe ol level warning system works propery. Ifthe two-stroke of level in the oll lank is sulicentiy high, the oil level war ring lamp wil go out after approximately two seconds, Ifthe il level has decreases to approximately 300 cem, the ol evel warning lamp will stay on, reminding you that che oll tank must be refilled with two- stroke oil within the next 100 kilometers. T CAUTION i [Gack FINCTION OF OL LVL WARNING LANE EEEORE EVERY RIDE THERE NO TWO STROKE OLIN THE OM. TANK, THE ENGINE 8 BOUND TO BREAK = Of. PUMP AND Ol, LANES MUST BE BLED WHENEVER THE OIL TANK WAS COMPLETELY EMPTIED (SEE BLEEDING THE CLL PLM), OTHERWISE THE O1. PUMP WiLL NOT DELIVER ‘The green indicator lamp fashes when the flasher ight Is working in the same rhythm as the fase ligt @ ‘The red cooling liquid temperature warning lamp lights up at 2 cooling liquid temperature of 110 r CAUTION Bay ATTENTION 9 TE DIRECTIONS INTHE CHAPTER {COOLING SISTEM™ ON PA blue indicator lamp lights up when the high beam ison, Ignition lock, steering lock ‘Thee are four postions to his lock. They at: (§Q = tatton of, ght oot Q) = teton on, eng turd f us puigt on —engine running: — parking light and headlight on = igiton off ght of, handlebar locked r CAUTION i Baier PRES THE KEY IN THE OB POSTON me ORDER TO TURN THE LONITON ocr To Gon PS. Ta HANDLSBAR CAN BE LOCKED 8 TURNING IT ERST INTO THE EXTREME LEFT OR RIGHT POSTION AND THEN TURNING THE IGNITION KY TO vite Fosmon, IMPORTANT: Do not push the ignition key into the Keytiole wile swi ching postions. ition of, parking light on, handlebar locked. CAUTION t DDO NOT LEAVE THE PARKING LIGHT ON FoR MORE THAN THREE HOURS Wind Tl ENGINE OFF, OLMAWISE YOU WILL NUT BE ABLE TO START THE ENGINE TH THE ELECTR STARTER, ADDITIONALLY, THE BATTERY IS DISCHARGED BELOW THE NORMAL LEVEL AND ‘THEREBY DAMAGED. IX THIS CASE, THE RATTERY SHOULD BE RECHARGED AS SOON ‘The ignition key can be removed in the positions ®, @, and PS.Combination switch ‘The rocker switch @ actuate the high beam and low beam, ED = Hignbeam phe 2D = Lowbeam gee ‘The switch @ retums to central position after actuation. Press flasher swit towards switch housing to switch off the fashr. © = Assert > = Rasher sight Peo = The homis sounded with button @. = The light signal (high beam} is actuated with bution @, NOTE: The engine must be running tn onder toe able fo check that all curent consumes are functioning correctly Starter tip switch, emergency OFF switch Q athe sane ipowteh @ wo opts te ace sae I CAUTION r Naxpan PERIOD FOR CONTINUOUS STARTING. 5 SHOONDS. WAIT AT LEAST S SECONDS BEFORE TRYING AGAIN The emerpency off switch @ is mainly a safety and emergency switch and should normally be on, If this symbol is visible on the switch, the engine can be started (Le. the ‘ignition circuit and the starter cieuit are switched on}, If this symbol is visible on the switch, the engine can not be started (Le. the igniion clue and the starter circuit are interropted) Filler cap To open filler cap: Turn the filler cap counterclockwise To close filler cap: Screw on the filer cap clockwise. Place the tank venting hose @ in positon, avoiding any kinks Fuel This motorcycle is equipped with separate lubrication. This means that the two stroke oll required for engne lubrication is not admixed to the fue! but contained ina soparate ol tank (see page 7). An oll pump is used for controled admixing of two-stroke oil into the fuel in the carburetor Besides, the motorcycle Is equipped with a catalytic converter. Therefore, itis absolutely necessary to Min unleaded foe R UNLEADED REGULAR GASOLINE WITH AT LEAST 91 OCTANES (RON) uel expands when it temperature rises, Therefore do not fll the tanto the top (see fig). Fuel tank capacity 8.5 Itera WARNING a CGASOUNE f HIGIEY FAKGABLE AnD rosoxOUS. BXIREME CAUTION SHOULD BF USED [WIEN HANDING GaSOUNE. DO NOT SEFUEL TRE MOTORCYCLE NAAR OPEN FLAMES OR TURNING CIGARETTES. ALWAYS SWITCH OFF TAR ENGINE BEFORE REFUELING. BE CAREUL NOT TO SPL GASOLINE ON THE ENGINE OR EXHAUST Pie Wau THe ENGINE 1S HoT. WIPE PSUELS PROMITLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE FYE, SEEK A DOC TORS ADVICE IMMEDIATELY r CAUTION t Nevin FLW LEADED FUEL, LEADED FUEL WL DESTROY THE GNTALYTTC CONVERTER. Fuel tap (OFF In this position the fuel tp is closed, No fuel may Now tothe carburetor. (ON Wien using the motorcycle, the twist pip must be set ro the ON positon. Now fuel may flow to carburetor. In thls postion the tank empties down © the fuel reserve of approx. 3 liters. RES The reserve tank, approximately 3 liters, cannot be tapped uml the twist grip is tumed to the RES position Fil the tank as soon as possible and remember to turn the twist grip back to the ON postion so that you will have backup fuel next time, too. r CAUTION t The Fit TAP SHOULD BE CRED w CNCLE 9 PARKED, IF THE TAPS NOT CLOSED THE CARBRETOR MAY OVERTION AND RIEL GE IO THE ENGINE Oil tanic “The oll tank @ is mounted on the right side in font of the fuel tank. Here, the ‘vo stroke oll fr separate lubrication ofthe engine must be filed in, The ol fevel can east be checked through the transparent material ofthe ol tank Engine oil: 2-stroke engine oll stable for a mixing ratio of ‘and for separate lubrication KTM recommends SHELL ADVANCE VSX2 To open it: pull vent hose out ofthe frame and turn closure cap counterclockwise To close it apply closure cap and turn it clockwise, Suick vent hose into frame and tnsal It without kinks. Tank volume; 1.3 ters (teem OEE etree ior: TONGE THERE NO TWO-STROKE OIL INTHE OIL TANE, THE ENGINE 1 BOUND TO BREAK THE VENT Hose Must Atiays Be nistataeD WITHOUT KS. (On. PUM AND OWL LINES MUST RE RLED WHENEVER THE CL TANK WAS COMPLETELY ‘Moric (SEE BLEEDING THE OIL PUM). OTHERHASE THEO MP YALL NOT DELIVER Ol THUS CALAING ENGINE DAMAGE, 0 da!m v4 (9) fs 4) Be A Shift lever ‘The shift lever ls mounted on the left side of the engine, The postion of the gears is shown in the fllustration. Neutral, or the ide speed, i located hetween first and second geet Foot brake pedal The oot brake pedals located in front ofthe right footrest. The basic positon cam be adjusted tothe seat postion (see maintenance work a ‘WARNING x JT RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEIS “SFONGY™ [NOT [ENOUGH RESSTANCE), THIS AN INDICATION THAT SOMETHING Is WRONG WITH THE RARE stsTen DON'T RDE YOUR MOTORCYCLE ANYMORE WITHOUT FST HAVING THE BRAKE SYSTEM LOOKED OVER AY KTM DESL. Passenger handles (On the tall ofthe motoreycle you wil find two handles which a passenger can use to hold on to,pe aN IN! Check the following before each start ‘When you start off, che motorcycle must be In a perfect technical contition. For safety reasons, you should make a hablt of performing an overall check of your motorcycle before each start. ‘The fallowing checks should be performed: 1 OWL LEVELIN OIL TANK nee there is no twestoke oil In the oll tank, the engine is bound to break down. The vent hose of the oll tank must be installed without xinks. 2 GEAR OIL LEVEL Tnsuffelent amounts of olin the transmission wil lead to prema ture wear and subsequent to transmission fallure. 3 FUEL ‘Check that there is sufficient fuel in the tank 4 CHAIN Aloose chain can fal off; an exmemely worn chain can tear and Ingufcient lubrication can result in unnecessary wear ta the chain and rear sprockets 5 TIRES Check for damaged tre, Tires showing cuts or dents must be replaced, The wead depth must comply with the legal regulations. Also check the alr pressure. Insufficient tread and incorrect air pressure reduce the driving performance 6 BRAKES Check correct functioning ofthe braking system. Check cient brake fluid In the reservoir. Ifthe level of rake Ould falls below the minkmum value, this indicates a leak in the braking system of completely wore out brake pads. Acrange for the bra ‘cng system to be checked by 2 KTM specklst garage, as com: plete failure of the balding system can he expected ‘sa check the state of the brake hoses and the thickness of the Drake linings. Brake linings measured at their thinnest point should not be less than Imm since extremely worn linings can. lead to brake failure, 7 CABLES ect selling and easy running of all control cables. iG LIQUID Check the level of cooling Higuid when the engine scold > ELECTRICAL SYSTEM CCaeck corsect functioning and adjustment of headlights, parking light, talighs, brake ight, fashers, indicator lamps, horn and emergency OFF switch while the engine is running, TOLUGGAGE I you are taking luggage with you, check that ths is securely fastened, a WARNING WEAR SiTTARin GLOWING WHEN DANISG A MOTORCYCLE, CLEVER KTM ovens at A IELMET, 3007S, GUNES AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR SHORT HP THE PROTECTIVE CLOTHING SHOUID BE BRIGHTLY COLOURED SO THAT (OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS OSSILE. YOUR PASSENGER OF COURSE WIL ALSO NEED SUITABLE PROTECTNE CLOTHING ~ Do Nor DRIvE AFTER HAVING CONSUMED ALCOLO ONLY USE ACCESSORIES THAT HAGE BEAN HELEASED BY KTML Fo Eka TLE, ONT PANELING CAN IMPAIR THE DARING PROPERTIES oF MOTOREHGLE, CASES EXTRA TANES ETC, GAN ALTER THE WHORT DISTR IRITON aND TS ALSO DMPA THE VEHICLES DRIVING PROPERTIES ‘TWE FRONT AND REAR WHEEL ARE ONLY ALLONED TO BE TIRED WIT THRES THAT AVE THE SAM PROME TE Instructions for initial operation ~ Read the entice manual carefully before your fist drive Familiarize yourself withthe operating elements. ~ Adjust the foot brake peda tothe most comfortable postions for you Get used to handling the motorcycle on an empty car park, Leone starting ona lager drive, Also ty to drive as slowly a8 possible and in standing pation, to improve yout feting forthe vehicle — Hold the handlebar with both hands and leave your feet on the foot rests while diving — Remove your foot from the foot brake pedal when you are not byaldng I Ue fot brake pedal isnot released the brake pads rob continuously and the braking system is overheated — You may only be accompanied by a passenger if Your motoreycie Is fied and regstered for such purposes. The passenger must hold taht to the brackets or hold on to the driver during the ve, wh his feet onthe passenger fot cess Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS, Spare pat from other mance turers can inipair the safer of the motoreyce — Motorcycles are sensitive to alterations in the distrbuton of weight. Ifyou are raking luggage with you, this should be secured 4 close a posible to the mle of the vehicle; distribute the ‘weight evenly between the front and rear wheel. Never exceed the maximum permis laden welfht and the axle weighs ‘maximum permissible laden weight 's made up of the wing components: ~ Motorcyle ready for operation and tank full ~ Loagige ~ Driver and passenger with protective clothing and helmet. Pay attention to running in instructions Running in Even finely machined surfaces of engine parts have rougher surfaces parts that slide on each othe fr a long time. Therefore, every engine must be run in. For tis reason, do not demand maximum petformance from the engine for the frst 100 kilometers. The Yehicle must be rum in at iow, changing performance level for the sist 1000 KM [620 ries). The maximum number of revolutions pee minute must not go exceed 7500 rpm. Once you have run yout engine in for 1000 kim (620 mil, you may push x to its 10500 rpm init. upto the orange zone indicated in te tachometer, Excee ding the above isted rotations aswell as pusing high rpm when the ‘engine is cold will have an averse effect onthe life of your engine.Starting when the engine is cold 4] Open the fuel tep >) Turn on the ignition (ignition key position: C)). Switch the gear to NEUTRAL (green lamp N @ on} di) Switch on the emergency OFF switch {symbol @ must be visite). 2) Operate the choke lever @. 4) Swing up the stand, 8) Operate the starter tip switch @ without accelerating. ‘the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. & ‘WARNING & Do NOT START THE ENGINE AND ALLOW IT TO IDLE IN A GLOSED AREA. EXHAUST FUMES ‘ARE POISONOUS AMD CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADBOIIATE VENTILATION WHILE THE ENGINE IS RUNING 1 GAUTION t ‘= Misawa renioo For CONTINOUS STARTING: 5 SECONDS, WATT AT TEAST 5 SECONDS BBRORE TRYING AGAIN. ‘= DoW’ RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON'T REV ENGINE WHEN co, BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, 1T ‘CAN CAUSE ENGINE DAMAGE. ALWAYS KEEP IN|MIND THAT THE ENGINE SHOULD’ BE WARMED UP WET SMALL LOAD AT MEDIUM RPM. IF THE ENGINE 1S DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH: = Check f the transmission is switched to idle = Check ft ignition is on — Check ifthe emergency OFF switeh Is on ~ Check ifthe parking ligt and the coc tghts are on If this not the case, the battery is discharged Irthe lights are on, proceed a described inthe , Trouble shooting” section or contact a KTM dealer. IFTHE ENGINE CRANKS BUT DOES NOT START, WHEN YOU ACTUATE THE STARTER TIP SWITCH: Check if the fuel tap is open = Checkif the choke lever has been operated ~ Check if sofcint fuel sin the tae ~ If this not the case, rfl the tank ifsuliient fuel Is i the tank, proceed as described in the ,Troubleshoo- ting* section or contact a KTM dealer. NOTE: = When you turn on the Ignition, you: wil hear a bref whirring sound. While you hear this sound, a cleaning cycle of the control roller in the cinder i executed. Check ifthe all evel warning lamp works properiy (see .Contol lamps") Starting when the engine is warm a) Open the fuel tap bb) Turn on the ignition (tmition key position: Cj ¢) Switch the pear to NEUTRAL (green lamp N @ on) 4) Switch on the emergency OFF switch (symbol @ must be visible} e} Swing up the stand. {Turn up the throttle @ bit, and actuate starter tp switch ©, ‘What to do when the engine is , flooded” ‘The toile must be fully opened when starting. Starting off Pall the clutch lever. Pur the engine into ist gear, slowly release the clutch lever an open throtle at the same time, a WARNING. a Deron vou START OFF, GHOCK THAT THE STAND @ HAS BEEN SWUNG RIGHT UP To AND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL.Shifting/Riding You are nove in fist goat, refered to as the dive or uphill gear. Depencing on the condiins (ual, ved gradient, etc}, you can shift to a higher gear. Close throtle, atthe same time pl cluteh iver and shift tothe next higher gat. Lt clutch lever go agaln and open trot. IF you tumed on the choke, make sure you tun i off again as soon as engine swarm Sen you reach fall speed through turing the cron gxp all he wa ta thre back 1a 3/4; the speed hardy Gereasesaithough the engine wl use less gas. Never open the throttle wider than the ecgine can Handle. Excesve turning ofthe thot grip wil increase {ul consumption. By ating dow, use the brakes if necessary and close thot atthe same time, Pol teh lever and shit down to the cest gear Let Clute lover a slowly and open trot or sit down aga. Ifthe engine fs kled tex. at a crossing simply pl the cute lever anil statis not necessary to site the pear to NEUTRAL, a WARNING a ‘OnStRVE THE TARR HEGITATIONS, DRNE DEFERSNELY AND THVING TO {OOK AUEAD AS TAR AS PCSSIBLE 0) THAT A2e MAZADS CN RE RECO ‘ONIZD AS EARLY AS FOSSLLE. = ADIUST YOUR DRIVING PEED ACCORDING TO THE CONDITIONS AND SOUR Danan ss. — Dawe CARETULE ON UNKNOWN ROADS — REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY ‘OF TM, WAEN LICHT SHINES DIRICTLY ON SCAATCHED visoR O8 OGG 1s, YOU WILL BE PRACTICALLY BL. ASIIR FLUNG WITH THE MOORCYCLE, CHECK ALL FUNCTIONS THKROUGHLY #BHORE STARTING UP OPEBATIONS AGAIN, 1 CAUTION T [Hilt Rew RATES WIEN THE ENGINE 1S GOLD HAVE AN ADVEISE ERECT (ON THE LIFE OF YOUR ENGINE, We: RECOMMEND YOU RUN THE ENGINE IN ‘A-MODERATE RM RANGE FOR A TIA MILES GING CT & CHANCE TO ‘ARO UE. AFTER THAT MO FORTHER THECANIIONS I TS ASPECT NEED be rast. ‘Siar To THe NEXT HGHER GEAR 8 {0500 ara a Tt LATEST — NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A TOWER Cran, Tie ENGINE WILL OVERSPEED, DAMAGING THE VALYES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT TAE MOTORCYCLE CAN ESL GET OT OF CONTROL — JF DURING EXTENDED DOWNITL RIDES THE ENGINE 1S BUNNING ALONG [WITHOUT ANY ACTUATION OF THE THROTTLE, YOU HAVE TO TURN UP TH "THROTTLE A BIC ONCE LN WALE TO MAKE SURE THAT ENOUGH ENGINE OILS FED To THE ENGINE. IF THE RED OO, LEVEL. WARNING LAMP CAG UIP, TT WILL BE NECESSARY TO REFLL THE OIL TANK WITH TNO-STKOKE ENGINE OL DURING THE Next 100 xiLoMETeRs (8: PAGE 7} = O11 MUNG AND OIL LINES MUST RE ALED WHENEVER THE OL TANK WAS ‘COMPLETELY EMPTIED (SEE BLEEDING THE OM. FMP). OTHERS: THE (1c FMP Wn NOT DEENER Of, THUS CAISSNG ENGINE DAMAGE = INTHE BvENT THAT, WHILE RING ON YouUR MOTORCYCLE, YoU NOTICE ANY UNISIIAL OPERATIONABLATED NOME, STOP DMMEDIATELY, TURN THE ENGINE OFT, AND CONTACT AN ALTHOMZED KTM DEALER, NOTE TO THE COOLING SYSTEM If que to slow trafic in eles or waiting a trafic light, for example, Title oF no relative wind is blowing through the radiators, it may happen that the cooling water temperature rises end the red cooling liquid temperature wazning lamp lights up appr. 110°C, 2387). Lo thls case, you should try to drive on briskly, Hf possible, for generally the lamp wll stop being lit soon ifenough relative wind ges into the radiators, However, you should check the cooling liquid level later matter the engine has cooled down again, t CAUTION, r HOWEVER, WF THE SED COOUNGHOUID TEMPERATURE WARNING LAMP LIGHTS UP WHILE YOU ARE DAIING ALONG BRISELY, THES WL INDICATE. & DEC IN THe COOLING SISTER, IN THIS CASE, STOP IMMEDIATELY, SINCE COTERWISE YOU MAY DAMAGE YOUR ENGINE, LET YOUR NGF COOL DOWN, CHECK THE COOLING SYSTEM FOR LFAES, AND CHECK THE COOLANT vit. CAUTION - SCALDING HAZARD! 'Do sor pave ox, UNTL TERE 6 SUFFICIENT OLD IN THE COOLING SYSTEM ‘WARNING a TP wr RADIATOR CAP 5 REMOVED WHEN THE ENGINE IS HOT, HOT COOCING LUOUTD, THKT IS UNDER PRESSE, CAN SPRAY OUT AND CAUSE SEVERE URS. ALLOW YOUR ENGINE TO COOL DOWN AND, IN THE MEANTIME, (CHECK THE CooUNG SYSTEM FOR LEAS. Braking Cicse tht and apply he hand ana foot takes a the same tne ‘When diving on sandy, wet o sppery ground ace many the eat ‘ee bres Always brake wih felng, blocking Whee Gn cose You to skid or fal Ao change down fo lower gears depencing on your speed __ a WARNING Wie v0 ase, TE FAKE SCS, BART PS, BE CALERA Bae UTD Nea CP THe HOTTER THES ARTS Oy TH WEARER BRA fine fic, I baREMe AMS TH NTEE GENE SEN CAN Stopping and parking Apply the brakes fully and put the engine Into neutral. To sop the engin, switch off the Ignition, Close fuel tap. Park on solid ground and lock the vehicle, a WARNING a [NER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISON AS LONG AS THE ENGINES RUNNING, ‘MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN TiN. THE ENGINE, THE RADIATOR, EXHAUST SISTEM, MUFFLER, BRAKE DBCS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. Do NoT TOUCH ANY OF THESE FARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE ‘CAE TD PARK 1T WHERE PEDESTRIANS ARE NOT LAKBLY TO TOUCH IP AND (GET BURNED, — NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EIST FRE TWAZARDS DUE TO DRY GRASS OR OTHER EASY FAMOHABLE MATERIALS. i ‘CAUTION r TT RiwNS OSE THE GRITION COCK TO TURN OFF THE ENGINE, IF YOU TSE Tit EMERGENCY OFF SWITCLTO TURN QFE THE ENGINE WITHOUT SMI CHING OFF THE IGNITION, THE PARKING LGHT WIL STAY ON, THUS DISCHARGING THE BATTERY SO THAT THE ENGINE GAN'T RE STARTED WITH THE ELECTHC STARTER ANY LONGER, WHEN Pat YOUR MOTORCYCLE AsVaYS CLOSE FUEL Tap, Weta THE FL TAP OPEN, THE CARBURETOR MIGHT OVERFLOW AND RIEL COULD LOW INTO THE ENGINE. — ALWAYS TAKE QUI THE (ONION KEY WHEN PARKING YOUR MOTORCYCLE ‘0 THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS, — PaRk YOUR MOTORCHCLE, S0 THAT IT RESTS STABLY ON THE STAND [HaRD GROUND, (VEL SURFACE] AND CAN'T TIP OVER ENGLISHPERIODIC MAINTENANCE SCHEDULE 125 Sting KTM rider 102, Sing 5.97 Ki EiimM eck oll level in ol tank (Check gear oil evel Deore each start ater vasting (Change gear oll (Check extaus control function heck spark plug, replace iti necessary, adjust electrode distance CChecic intake manifold for leaks and cracks Drain and clean float chamber (Check ile setting and emission values when engine Is warm ‘Check vent hoses of oil ank and transmission for kink free installation (Clean ait ter and ai iter box, check carburetor connection boot | Check sprockets, chain guides and chain (Clean and lubricate chain (Check chain tension (Check cooling liquid level Check quay of antoezet Check coling et for els Val croc [ Chanecootng tad Chesnais stem fr ake cs of exhaust brackets Check silent Boe Ghecic brake fluid level in reservoirs | Change brake Aud ‘Check brake pad thickness Check brake dics ‘Check condition and correct instalation of brake hoses ‘Check treeplay and easy operation of hand brake lever and foot brake pedal ‘Check elescopic fork for function and tightness : Service telescopic fork completely | Check steering head bearing clearance (Clean and grease steering head bearings aod It sealing elements e e e e ‘Check shock absorber for function and tightness Disassemble the Pro Lever suspension system Inking and hubricate Servicing swingarm pivots Check spoke tension and rim join Check wineel bearings for clearance Check tie condition and air pressure ‘Check cables for damage and smooth operation (Oi and acjust cabs (Check the electrical system (Check battery rack and connections [ Check anjustmenc of bead light Spray lgnllon lock, emergency OFF switch and tight switch with contact spray (Oil center stand or side stand and check function (Check all screws, nuts and hase lamps fr eight ft | Grease of otal pit points and sing componentsMAINTENANCE WORK ON CHASSIS AND ENG! a WARNING & ‘ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SAFETY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER ! I GAUTIGN r TT Wee CLEANING THE MOTORGYCLE, DD NOT UNE A WIGH PRESSURE CLEANING UNIT F FOSSIBIE, OTHERW/SE WATER WILL FENETRATE THE BEARINGS, CARRE “oR, ELECTRIC CONNECTORS FIC = LET Youre MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK I GRDER TO a Disrast oF om, GREASE, FILTERS, #15, CLEANING AGENTS ETC. ACODRDING TO YOU — UNpen No CHCURSIANCES MAY USED OIL BF DSPOSED OF IN Te 1,000,000 ures ware. 0D GETTING RURNED. LOCAL RIGIIATION SEWAGE SYSTEM OR THE OFEN COUNTRYSIDE, 1 LITER USED Of, CONTARUNATES Tool kit The too kit @ is located inthe tool box under the let sie cover, Dismounting and mounting of seat Remove let and right screws @, Lift rar potion of seat, pul it backwards, and isengage it atthe oval head screw @. Mounting the seat ~ Hook the seat onto the oval head screw — Slice it forward to let the retaining plate @ engage in the seat. = Sle retaining shackles of seat under the side covers and mount screws | JCheck and adjust steering head bearing* Check steering head bearing for play periodically. To check ths support the rotoreyele so that the font whee is off the ground. Nowr try to move the fork forward and backward - no play should be discernable For readjustment, release the 5 clamp serews @ ofthe top triple clamp and tum the top screw @ withthe ‘wrench from the tol set until no play is left at all. Don’ tighten the stering stem holt all the way, otherwise the bearings willbe damaged. Wit a pastic Rammer, light rap on the top triple clamp to release tension. Retight the fve clamp sc. es to 25 Nm (18 ft) a ‘WARNING a IF Tae STERN HEAD ENING NOT ADIUSTED TO BE FREE OF PLAY, THE WoTORGYCAE ‘SHOW AN LNSTEADY ORING PERFORMANCE AND CAN GET OUT OF CONTROL. 1 CAUTION i TF You bane WT PLAY INTHE STEERING HEAD BEARING FOR LONGER PERIODS, FRSTIV The BEARDS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED. ‘The steering head bearings shouldbe regreased alter 2 years at the latest. Changing the spring preload of the shock absorber KTM sets the shock absorber for driver only, weighing approximately 75 kg (165 1) Ifyou Want take a passenger wth you, of you weigh considerably moe or Jes than 75 ka (165 ih, Fou should change he spring preloed accordingly. This s easiy done. NOTE ~ Before changing the sping preload note dowa the base seting eg. now many coisa isle sbove te adjusting ing ~ One ration of he acting ring @ changes the spring preload by approxima ‘ay 5mm Use te oak wrenches included in the vehicle oot to Toosen the counter ing ©. Charge sving preload as desied by means of the assing ring ®, and relighten counter tng Check chain tension = To check the chain tension, tum off the motorcycle. ~ Press chain upward at the end of the chain sling component. The distance Derween chain and swing arm should be approx. 10 mn. In the course of this procedure, the upper chain porton @ must he tensioned (see drawing) ~ necessary, readjust chain tension, a WARNING a Tr GHAI TENSION 1S TOO GREAT, PARTS (iON THE SECONDARY POWER TRANSMISSION [osamy, CHa SeROCKETS, HANSYASSION AND REAR WHEEL SEARIGS) WIL BE SUBJECTED To UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AKD EVEN CHAIN BREAEACE. Too MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT INTHE CHAIN JUMt YING OFF THE CHAIN WHEL, IP THIS HAPPENS, THE CHAIN COULD AISO BLOCK THE BEAR WHEEL OR DAMAGE TE ENGINE In En case THe OPERATOR 1 LKELY TO LOSE CONTROL OFTHE MOTORCYCLE.Readjust chain tension = Loosen elit mt @, losen counter nuts screws @ equally fa. Tighten counter nuts @. ~ Before tghtening the colar nut, verify that the chain tensoners © are siting close othe adjusting screws and that the rear wheel has been aligned wit the front whee! “Tighten collar nut @ with 100 Nim (74 fb). and tum right and let adjusting Chain maintenance ‘Oring chains require only modest maintenance. The best way isto use lots of ‘water, but never use brushes or solvents. After leting the chain dry, you can use a special ing chain spray. a WARNING a INO WoBwCATION & aLLOWID 1 REACH THE REAR TIE OR THE BRAKE DISS, RTBERWASE THE ROAD ADHERENCE AND THE REAR WHEEL BEARING EFTECTS WOULD AE STRONGLY EDU (ED AND THE MOTORCYCLE COULD EASY GET OAT OF CONTROL T CAUTION r ‘Wien OUTING THE CAAINTOINT, THE CLOSED SIDE OF THE SAFETY DEVICE MIST FONT Also check sprockets and chain guides for wear, and replace if necessry. Chain wear In onder to check the chain wear, regard the following instructions: Shift the gear into Idng and pull the upper chain strand with approx. 10-15 kllo- sramm (33 To) upwards (see gure). Now one can measure a space of 18 chain reels atthe lowe chaln strand. The chain should be replaced at the latest when a space of 272 cm (10,70 in) is measured. Chains do not always wear off evenly, ‘therefore repeat the measurement at diferent places on the chain, NO If you mount a new chaln, the sprockets should aso be replaced. New chains ‘ea faster if used on old used sprockets General informations about KTM disc brakes BRAKE CALIPERS: The front whee! brake system has a disc measuring 320 mm in dlameter and fouppiston brake caliper whica is mounted rigidly on the fork. The rear wheel brake system consists of 2 220 mm diameter disc and a “float mounted” one: piston brake caliper BRAKE FLUID RESERVOIRS: The brake fui reservoirs on the front and rear wheel brakes have been designed Jn such a way that even if he brake pads are worn it is not necessary to top up the broke did. 1 the brake fluid level drops below the minimum either the brake system has @ leak ofthe brake pads are completely worn down, In this case, consult an authorized KTM dealer immediate BRAKE FLUID: KTM fil the brake sysems with CASTROL DOT 5.1 breke Lui on ofthe best rake us that is currendyavaabie. We recommen that you coatinue ose i DOT 5.1 brake ful is based on alycol ether and ofan amber color. I you do not lave any DOT 5.1 for relling, you may use DOT 4 brake fiid, However, you sould repiace ita soon as possible by DOT 5.1.Checking of brake fluid level - front brake ‘The brake fluid reservoirs nked with the hand brake cylinder atthe handlebar and the reserviis provided with an inspection gla. With the eservol ina hr zontal poston, the brake uid level should not go below middle ofthe alas. a ‘WARNING JF Tae BRAKE LIND UBER DROPS BELOW THE MONI EITHER THE BRAKE STEN HAS A {LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN IN THIS CASE, CONSULT AN ALT onze KTM DEALER IMMEDIATELY Refilling the front brake reservoir* Loosen screws @ and remove ld @ and membrane @. Place hand brake inde in 2 horizontal position and fl the brake uid reservoir to 5 mm (02) below the rim with brake fuld DOT 5.1. Replace membrane and lg tighten Screws. Rinse of spilled or overowing brake fu wit water. a ‘WARNING a NEVE Use DOTS oiane RUUD! IT BSED OW SCONE OL AND OF A PUIPE (oLOR, SEALS AND BAO HOSES ALS Bj ESFECALLY ADAPTED OF STORE seaKE LD OUT OF REACK OF CADRE ~ BRAKE FID CAN CAISE SKIN TRITATION. AVON CONTACT WITH SKIN AND BYES, Tr YOU CET 3K ND IN YOUR HES, RSE WIT PLENTY OF WATER AND CONSULT A CAUTION r = Don'T GFT BRAKE LUND GET by OONTACT WITH FAINT, ITS AN HFREGTIVE PAINT REMOVER = USE ONLY CLEAN BRAKE FLIID TAKEN E804 TIGHTLY SEALED CONTAINER. Checking the front brake pads ‘he brake pads can be inspected from behind. Always inspect the brake pad linings before taking of on your motorjee. They should not be inner than 1 zim whichis the case when the notch @ is no longer discernable a ‘WARNING a [ATER MOST WOR FORT BRAKE PAD UNDNGS SHOULD NOT BE THINNER THAN To (OTAERWISE THEY COIND LEAD TO BRAKE FAILIBE, FOR YORR OWN SAFETY DON'T PTF DAVING YOUR BRAFE Pas CHANCED, 7 CAUTION t [Tie BRAKE 1A05 ARE REPLACED TOO CATE SO THAT TE LINNG B PARTLY OR ENTRY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE FAD WIL. RUB AGAINST THE BRAKE D'S IGNTIARTLYIMFAHING THE BRAKING ERECT AND DESTROYING THE BRAKE DISChanging the basic position of the foot brake pedal* The hasic poston ofthe foot brake pedal can be altered by turing the stop screw © The fice play at the foot brake pedal must then be adjusted by means of the push rod @. Measured on the oulside, the foot brake pedal must have $5 mm (0,12-0,20 in) of free play, before the pish rod can move the plston in the brake cylinder tobe recognised from the resistance on the foot brake pedal), i CAUTION t IF THs FARE PAYS NOT FAESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM [WHEN ORWING, CAUSING CONSTANT FRICTION OF THE BRAKE PADS THE BRAKING SYSTEM (EEBIEATS AND CAN FAL COMPLETELY IN EXTRENE CASES. Checking rear brake fluid level ‘The reservar forthe rear dsc brake Is located on the lefthand sie of the vehicle next to the carburetor connecting boot. The brake Mui level may not drop below the .MIN" marking when the vehicle isin an uptight postion, a WARNING a ITH WRAKe FLD LEVEL DROPS BELOW THE MIMIMOMC EITHER THE BRAKE SYSTEM HAS A TEAR OR THE BEAKE TADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUT [pono KTM DEALER IM@EDIATE. Refilling the rear brake reservoir* ‘When the brake fd level has dropped to the MIN mari, you need to refill the brake fluid reservoir. This is done by first unscrewing the cap @ and rubber boot ©. Ad brake fluid DOT 5.1 unt) It reaches the MAX mark, then screw ruber hoot and cap back on. Rinse off spilled or overflowing brake Muid with water. z ‘WARNING. a NEveR ise DOT 5 ORAKE FLMD! [TS BASED ON SILIGONE OL AND OF A FURIE ‘coloa, SEALS AND BRAKE HOEES MUST BE ESPECIALLY ADAPTED 10 IT ‘STORE BRAK. FLUID OUT OF REACT OF CHT.DREN. ~ BRAKE FLUID ca CAUSE SKE IRRITATION. AVOID CONTACT WITH SQN AND EVES. I YOU GET RAKE FLD ON YOUR EVES, RINSE PUTS PLENTY OF WATER AND CONSULT A DOCTOR T GAUTION DONT LET BARE TOD GFT CONTACT WITH PAINT TIS AN EFECITVE PANT MOVER, LUst ONLY GLEAN BRAKE FLD TAKEN FROMM A NGMILY SEALED CONTARNTR Checking the rear brake pads The brake pads can be inspected from the rear. The thickness ofthe linings may aot be less than ra (004 i ‘WARNING [AT TREIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE TRINNEK THAN T nM, COTWERWISE THEY COULD LEAD TO BRAKE FALLRE, FOR YOUR ON SAFETY DON'T FUT OFE ING YOUR BRAKE PADS CTANGED, t ‘CAUTION TF Tae WAKE PADS ARE REPEAGED 100 LATE SO THAT THE UNG 1S PARTLY OR ENTIRELY WORN AKAY, THE STEEL COMPONENTS OF THE BRAKE PAD BTL RUB AGAINST THE BRAKE DISC, IMPARING THE BAKING EFFECT AND DESTROVING THE BRAKE DIS ENGLISH SIDismounting and mounting the front wheel* = To remove the font whee, jack the motoreycle up bythe frame so thatthe {font wine! no longer touches the ground. = Take out both allan head screws @ and remove brake caliper ftom brake dis = Screw speedometer cable @ ftom speedometer drive ~ Loosen the clamp screws @ on the rghit fork leg axle passage (leave the clamp screws on the lft fork fis tightened!) — Loosen wheel spindle ®. — Hold the ront whesl, pul the wheel spindle out, remove the front wheel from the forc by pulling ic forward 1 ‘CAUTION i DO NOT OPEHATE THE HAND BEAKE WHEN THE FRONT WFEL RAS BEEN REMOVED, ~ Prior to mounting the front wheel, clean and grease the shaft seal ring @ and running surface @ atthe speedometer aive. = To mount the front wheel insert speedometer drive into the bub, ~ Ralse the front wheel into the fork, insert the tongue @ of the retaining ‘bracket into the sot ofthe right fork leg axle passage. = Replace the whee spindle and tighten it with 50 Nm (37 fb = Put the brake caliper back in place and tighten the alan head screw with 40 Nm (30 fb) = Avtach speedometer drive cable and replace dust cap. ~ Jack the motoreycle back down, work the front brake and bounce the foxk hard afew times to align the fork bes. — Now you can tighten the clamp screws on the right fork leg ale pasage to 7 Nm (5 fe) a WARNING a TUTE YOU DON'T HAPPEN TO AVE A TORQUE WRENCH AT HAND, NARE SURE YOU HAVE ‘THE TIGHTENING TORQUE CORRECTED BY a KTM DEALER AS SOON aS FOSSIL, Iris vagy nePoRTANt To KEEP THE BRAKE DISK FREE FROM OL AND GREASE, OTHERWISE ‘THE BRAKING EFFECTS WOULD DE STRONGLY REDUCED. Dismounting and mounting the rear wheel* Jack the motorcycle up by the frame so that the reer wheel no longer touches the ground, Loosen the colar nut @, remove chain tensioner @, hold the rear wheel pul out the whee! spindle @ until the rear whee! is fee butte brake caliper su- ports stil hel Push the rear wheel as far forward as posible, take the chain from the chain sprocket and carefully take the rear wheel out of the swing arm, I CAUTION r [Do NOT OPERATE TE FOOT BRAKE WHEN THE REAR WHEEL HAS BEEN DIMOUNTED. = WGN THE WHEEL SPINDLE 1S DBMOUNTED, CLEAN THE THREADS OF THE WHE. SMINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO FRE \VENTTHE THREAD FROM INOAING ‘The cear wheel Is remounted in reverse order. Before tightening the collar nut with 100 Nm (74 Rb), push the rear whee! forwards so that the chain tensioners lie on the tension screws. a WARNING a TTF YOU DON'T HAPPEN TO HAVE A TOROUE WRENCH! AT HAND, MARE SURE YOU AVE THE TIGHTENING TORQUE CORRECTED BY A KTML DIALER AS SOON AS OSSILE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR ~_ AVTIR MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE UNTIL THE PRES SURE ROOST RETUR = Tris vray ueroarAnc To KEEP TE BRAKE DSK FREE FROM OL AND CREASE, OTHERWISE "THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.Tires, air pressure ‘Tire type, tire condition, and how much alr pressure the tires have in them affect the way your motorcycle rides, and they must therefore be checked whenever You geting ead o go anywhere on your moore ‘Tre type and size can be found inthe technical specifications and in the homo- logation cersitcate ~ Tire condition has to be checked everytime you want to ride your motorcycle Before leaving check for punctures and nails or other sharp objects that might have become embedded inthe tire Refer to the specific regulations in your country for minimum tre tread requ ements. We recommend replacing ties atthe latest when the tread is down. to2ma. Tire pressure should be checked regularly on a “cold” tte. Proper pressure ensures optimum driving comfort and extends the life of your tres, ——_4__WARNING A [Do NOT MOUNT TRES WIIG HAVE. NOT BEEN APPRENED BY KTM. OTR THES ‘COULD KAVE ADVERSE FECTS ON THE WAY YOUR MOTORCSCIE RIDES, = "THE OMT AND REAR WHEEL ARE ONLY ALLOWED TO RE TRED WITH TIRES THAT 14 Tie SAME PROBE YP. ~ Fo youn ov SAFETY REPLACE DANAGED TIES (Wom TRS CAN GAVE A NEGAUIVE ESRECT ON HOW YOUR MOTORCYCLE ERIORNS, CUALY OM WET STRPAC IF AIR PRESSURE I TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE TIE CM front tye air pressure | Tear tye air pressure | iver only 1.8 bar (26 pal) 2.1 bar (31 ps) diver plus passenger 2.0 bar (29 pa) 2.3 bar (34 pal) Checking spoke tension The correct spoke tension is very important for the stably of the wheels and thus for riding safety. A loose spoke causes the wheel to become untalanced and belore long other spokes will hve come loose. Caeck spoke tenson, especially on a new motorcycle, in regular intervals For checking, tap on each spoke with the blade of a screw driver (see flustration). A clear tone must be the result. Dull tones indicate loose spokes. If necessary, have the spokes retihtened and the ‘wheel centered by a KTM dealer Main fuse ‘The main fuse ©, which Is located above the carburetor, protects the fllowing "Hlecue starter system ~ Parking ight Flasher lights = Hon = Ol evel warning lamp NEUTRAL lamp Rated fuse current is 10 amperes r ‘GAUTION Uspee no arcu ED 10 9 "REF INSTANCES & A STRONGER FUSE ALLOWED TO BESET IN OR A FISE ALLO 1D", AN INERPERT TREATMENT COULD DAMAGE THE WHOLE HCTRCALBattery The battery is mounted under the seat (remove te eat, ee page 13) ‘The battery has a closed system and therefore rues no maintenance, Its not necessary to check the eleccoyte level orto rfl water. Simply keep the battery poles clean and sight grease them with an aces grease If necessary When removing the battery cum of ll power consumers and then disconnect the negative pole fist. When reinsaling the batry the negative pole f connected last a WARNING = TF ELECTROLYTE (SULPHURIC ACD) LEAKS FROM THE BATTER, PROGSED WIT GREAT CARE TH ELECTROLYTE CAN CAUSE SEVERE BLINS INTE CASE OF SN CONTACT HOSE THOROUGATY WE WATER, = IN tHe CASE OF CONTACT WOTH THE EYES, THOROUGHLY RSE EVES WIHT WATER FOR {a asst 15 nuNUTES, oneDuaretyconsuLr a boctoal ‘Ta BATTERY 15 4 CLOSED MODEL RUT CAN NEVERTHELESS SRT EXPLOSIVE CASS AVOID SPARKS AND OPEN FIR NEAR THE BATTERY ~ DEFEcr ERs MUST BE STORED OUT OF THE REACH OF CHILDREN. ENSURE eRoRER DSO OF DSCARDED RATERS, t ‘CAUTION NOW THE SANG SR @®, TH SE Do vor REMOVED. — NEVER DISCONNECT THE AATTERY WHILE THE ENGINE IS RUNNING, This WiLe DESTROY ‘THE RECTIER REGULATOR © STRIP WiLL DAMAGED IF BATTERY STORAGE: ‘When preparing the motorcycle for a longer period of standstil, nemove the bat tery and recharge it. Storage temperature: 0 - 35° C, Do not expose to dict sun radiation. Charging the battery Remove the batery and check the charging level, Use a volumeter to measute the vollage between the batty poles (ood voage). ‘Accurate resus can only be obtained {the batery has nelther been charged not alscharped during period of 30 nutes preceding the measring GToad volage | crargnalevel_) charging tine charging wehage ott % oga | 127 100 = “125 7 an “122 50 7h a -120 25 Ma _— “1g 0 lah If the battery is empty, it can be recharged for a maximum period of 10 hours at 0.3 Aand 2 maximum of 14.4V, i CAUTION i [Do NOT REMOVE THE SEALING STP. ALWAYS CONNECT THE BATTSRY TO THE CHARGING UNIT AEFORE TURNING THE CHAR ‘ING UNT ON, \WHEN RECHARGING THE BATTERY a CLOSED ROOMS ENSURE SUFFICIENT VENTHLATION [EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCES, CHARGING Tv AND CHARGING WOLTAGE SHOULD NOT EXCEED THE STATED VAL (Ores ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES. — AVOID Quick CHARGING IF POSSRLE,‘when engine Is cold Cooling system The cooing liquid is circulated by the water pump @ in the engine. When the engine js col the cooling liqud circulates ony through the cylinder andthe cin: der head, Ater the engine has reached it operating temperature aprox. 65 °C), the thermostat @ opets and cooling gui purped aso through the alminam radiator ‘Az blowing in through the radiators coos the colin liquid. The slower the speed fof the motorcycle, the les the cooling liquid is cooled down. Dirty radiator nbs aso reduce the cooing efficiency. tf due to slow trafic in cles or walting ata talc ight, for example, ite oF no relative wind is blowing through the radlatos, it may happen that the cooling ‘water temperature rises and the red cooling guid temperature warning amp @ lights up (appr. 110°C, 238°F) inthis case, you shoul try to drive on bese, I posible fr generally the lamp will stop being lit soon if enough relative wiod bes into the radietors. However, you should check the cooling liquid level later im ater the engine has cooled down again i ‘CAUTION H Howeves, F TWE RED COOUNGLOUTD TelersaTiRe WARNING LAMP LIGHTS UP Wake SOU A DRIVING ALONG BRSKLY, THIS WILL INDICATE a DEFECT INTHE COOLNG SYSTE Tie 71s CASE STOP IMMEDIATELY, SINCE OTHEANUSE YOU MAY DAMAGE YOUR ENGINE, LET {OUR ENGINE COOL, DOW CHICK THE COOUING SYSER FOR LEAR, AND CHECK THE COO xe Laub Levit. CAUTION - SCALDING HAZARD! Do NOT ome ON, uN. HHRE 1 SUFFICIENT ULI INTHE CROUING SSTEN a WARNING IF Tee RADATOR OP IS : UNDER PRES (O01 DONS AND IN THE MEANTIME, CHECK AA mixture of 40% antireezerlquld and 60% wate s used as cooling liquid, How: ever, the antl-teeze protection must beat least-25° C (13°F). Aside from ante ezing protection, this mixture also provides great corrosion protection which Is must not be replaced by pure water. t CAUTION i AE OOOUNG SISTEM, USE ONLY HIGHGRADE ANTIFFEZER, USING LOWERGRADE 12 ACENTS, CAN CAUSE CORKOSEON AND COOLANT FOAMING. ie Pressure induced by heating of the cooting liquid in the cooling system is contol led by a valve in the radiator cap @; a water temperature rising up to 120° C (248° F| is admissible, without fear of problems. Checking the cooling liquid level The cooing liquid should be 10 mm (0,4) above the cooling elements when the engine i cold (¢t. dlagram). Inthe event of the cooling iguld being drained, aways ilthe sytem before han, then top off while the engine is running & ‘WARNING a IF POSSE, ALKATS GREK TBVEL OF COOUNG LOUD WHEN ENGINE IS ODID. TF YOU HAVE TO OF TE RAKIATOR CAP HHEN ENGINE IS HOT, OSE A RAG TO CONER THE CAP AND OPEN SLOWLY TO RELEASE PRESSUREAdjusting the clutch cable When the engine is cold, the play at the clutch lever should be 10 mm (0.4 in} [measured atthe outer edge} ‘To adjust the clutch cable turn the adjusting nut @ accordingly. Adjusting the choke cable* AL the choke cable, there must always exist a play of approx. 2 sam (0.1 in). To check thls, pus coke lever fuly forward and pull protective cover @ trom the adjuster piece @. Now, it must be possible to lit the outer covering ofthe cable by approx. 2 mm from the adjuster pioce unt feeling a resistance. If necessary, Joosen counter nut and readjust play by turing the adjuster piece, Tighten coun ter nut, and slide on protective cover Adjusting the throttle cable* There must always be a 3-5 am (0.1-0.2 in) ply n the teotle cable, To check ths, move back the protective cover @ on the tote pip. You must be abe to tthe outer covering ofthe cable 55 mm fom the adjusting screw @, unl res stance if ‘To adjust, loosen the counter nut @ and tun the adjusting screw accordingly Frallyghten counter nut and ade the proactive cover back on Adjusting the idle speed* ‘The dle speed can be adjusted with Idle screw @, Turning in clockwise direction wil increase th idle spec, Checking the gear oil level “To make checking te gear oll level easy, an inspection pass @ Is dispose atthe Hla ide ofthe engine. =" Warm up engine, then turn it of and wait for 2 minutes so thatthe oil may flow back into th transmission case. ~ Hold motoreyce in a stright postion ona horizontal surface do not put i on the site stand), and read the ol level ~ The oll level stoud be ln the upper half of e inspection gas NOTE: placing the motoreyele in another than a fully upright postion wil fa sity the measuring result ~_Hnecossary, illin 10WV30 engine oi H ‘CAUTION I ‘Too UTTIE OIL OR & POOR OI, GHALITY WIL, CAUSE PREMATURE WEAR OF TRANSMISSION NO CLIT, ONLY USE BRANDED on.Changing gear oil* Warm up engine. — Remove screw @, and drain old oil into an appropriate container. — Tit your motoreyce to the right to ensure that the entire oll is discharge. = Mount screw with paske, and tighten it with 1S Nm (11 fb). ~ Unsceew closure cap @, and fil in 0.75 titers of 1OW30 engine ol Mount closure cap and check engine for possible ol loss. T ‘CAUTION i Too UTE OR OR A POOR ON GUALTY WHEL CAUSE FRENATORE WEAR OP TRARSH ‘xb CLUTCH, ONLY USE BRANDED Ot Bleeding the oil pump COIL PUMP AND OIL LINES MUST BE BLED WHENEVER THE OIL TANK WAS ‘COMPLETELY EMPTIED (SEE BLEEDING THE OWL. PUMP). OTHERWISE THE OIL PUMP WILL NOT DELIVER OIL, THUS CAUSING ENGINE DAMAGE. Remove cover of ol pump. — Remove bleeder screw @. Do not close bleeder screw until oil without air bubbles is discharged ~ Disconnect ol jne from oll pump to carburetor and fil it with ol Reconnect all line. Sart the engine and set oil pump to maximum capacity by pling the cable @ but, Let engine run at 2000 r.pm. for approx. 2:3 minutes. This is the only ‘way how to fly blees the lubricating syste, I-pump cover together with new gasket T CAUTION RABY UP THE ENGINE DURING BLEEDING, BECALSE TH DOES NOT WET SF NOUGH OM. TO A LIRIGATING POINTS. Removing the headlight mask* The headlight mask must be removed whenever you want to change the head ight or instrument lamps Removing he font fashers, = Remove the lens @ by inserting a screw driver inthe lateral slot to separate the lens from the fasher housing. Remove the reflector from the housing and remove the flasher cables Remove the HH screw @ and remove the Lasher housing | Removing the knob ofthe day mileage indicator. ~Pop off the cap © with a small screxedriver use a Philip screw driver (size I| to remove the screw inside the knob @ remave the knob and the rubber ring,