Instruction/ maintenance manual of the product EXC-E KTM
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 5/2007 FOTO: MITTERBAUER 125 EXC, EXC SIX DAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXC SIX DAYS 300 XC, XC-W, EXC-E, EXC-E SI.
ENGLISH 1 INTRODUCTION » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation.
ENGLISH 2 IMPORTANT » INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations.
ENGLISH 3 IMPORTANT » The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void.
ENGLISH 4 TABLE OF CONTENTS » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS .
ENGLISH 5 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.
ENGLISH 6 OPERATION INSTRUMENTS » TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly dis- played in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires).
ENGLISH 7 OPERATION INSTRUMENTS » SPEED / LAP (lap time) display mode Y ou can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds.
ENGLISH 8 LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds. Press the + button to access the next lap time.
ENGLISH 9 Kilometers or miles The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly . The TR1, A1, S1, TR2 and A2 figures will be cleared. T o select the unit, select the SPEED/H mode and hold the | button for 3 sec- onds to access the SETUP menu.
ENGLISH 10 OPERATION INSTRUMENTS » If the CLK, LAP , TR1, TR2 A1, A2, S1 and S2 figures are suddenly cleared, the battery in the electronic speedometer is empty an d must be replaced (see: Replacing the battery in the electronic speedometer).
ENGLISH 11 OPERATION INSTRUMENTS » Combination switch (EXC/EXC Six Days) The light switch has 2, respectively 3 switch positions. [A] = Light off (this function is not available in all models) [B] = Low beam on [C] = High beam on Y ou may use button [2] to actuate the horn.
ENGLISH 12 Fuel tap OFF In this position the fuel tap is closed. No fuel can 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.
ENGLISH 13 OPERATION INSTRUMENTS » 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 between first and second gear . Kickstarter The kickstarter is mounted on the left side of the engine.
ENGLISH 14 OPERATION INSTRUMENTS » Compression damping of fork (XC-W, EXC, EXC-E) Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.
ENGLISH 15 OPERATION INSTRUMENTS » Rebound damping of shock absorber By using the adjusting screw [4] , the degree of damping of the rebound can be adjusted. T urn the knob to the right side to increase damping, turn it to the left side to reduce damping during rebounding.
ENGLISH 16 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for your first ride – Make sure the work for the "pre-delivery inspection" was per- formed by your authorized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle.
ENGLISH 17 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start.
ENGLISH 18 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap 2 T urn on emergency OFF switch 3 Swing up the side stand 4 Put the gear in neutral 5 Activate cold-starting aid (choke) 6 Leave throttle closed or open it no more than 1/3 and kick down kick- starter vigorously all the way .
ENGLISH 19 DRIVING INSTRUCTIONS » Shifting/Riding Y ou are now in first gear , referred to as the drive or uphill gear . Depending on the conditions (hill size, etc.), you can shift to a higher gear . T urn down the throttle, at the same time pull the clutch lever in and shift to the next higher gear .
ENGLISH 20 PERIODIC MAINTENANCE SCHEDULE » 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Before each race 1st service after 10 hours ever.
ENGLISH 21 PERIODIC MAINTENANCE SCHEDULE » 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Every 20 hours.
ENGLISH 22 PERIODIC MAINTENANCE SCHEDULE » 250/300 XC/XC-W/EXC/EXC Six Days/EXC-E/EXC-E Six Days 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Before each race 1st service aft.
ENGLISH 23 250/300 XC/XC-W/EXC/EXC Six Days/EXC-E/EXC-E Six Days 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Every 20 hours Every 40 hours Ev.
ENGLISH 24 MAINTENANCE WORK ON CHASSIS AND ENGINE » Maintenance and adjusting work marked with an asterisk * requires expert skills and technical know-how . For your own safety , always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified, skilled staff.
ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the fork, shock absorber , swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight.
ENGLISH 26 Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs [2] a few turns in order to relieve excess pressure from the inside of the fork. T o do this, place the motorcycle on a stand with the front wheel lifted off the ground.
ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » 3 3 3 2 5 4 4 6 8 7 7 9 Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [2] are to remove dust and coarse dirt particles from the fork tube. However , after some time, dirt may also get in behind the dust-protection bellows.
ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the fork offset (caster) XC/EXC Six Days * The fork offset [A] in the XC/EXC Six Days models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the handling to match the race course.
ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw . T ighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages.
ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The dis- tance between the chain and the swing arm should be approx.
ENGLISH 31 Chain maintenance Maintenance of the X-ring chain is reduced to a minimum. Rinse off any heavy dirt with plenty of water . Residual used grease must be removed prior to lubri- cation (Motorex Chain Clean 611). After drying, use a chain spray specially designed for X-ring chains (Motorex Chainlube 622).
ENGLISH 32 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 33 Changing the basic position of the hand brake lever Y ou can change the basic position of the hand brake lever with the adjusting screw [1] . The position of the pressure point (the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disk) can be adjusted for any hand size.
ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 A B 5 1 1 2 3 4 Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips [1] and pull out bolt [2] . Remove brake pads from the brake caliper .
ENGLISH 35 MAINTENANCE WORK ON CHASSIS AND ENGINE » 3-5mm 4 3 2 1 min. 1 mm 5 7 6 6 Changing the basic position of the foot brake pedal * T o change the basic position of the foot brake lever , loosen the counternut [1] and turn the stop screw [2] as needed.
ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » A B 2 1 3 2 3 2 2 1 Before remounting the front wheel, clean and grease the shaft seal rings [A] and the bearing surface [B] of the distance bushings and mount the distance bushing. T o install the front wheel, lift it into the fork, position and mount the axle shaft [3] .
ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 2 3 Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Remove the collar nut [1] , remove the chain tensioner [2] and pull out the wheel spindle [3] until you can push the rear wheel forwards.
ENGLISH 38 Replacing the headlight lamp/parking light lamp Loosen both rubber bands and tilt the headlight mask to the front. Pull the parking light lamp with holder [3] carefully out of the reflector . Pull connector [4] off the headlamp and remove rubber cap [5] .
ENGLISH 39 MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 3 1 Battery The battery is located under the seat and is maintenance-free. Maintenance-free means you will not need to check the acid level. Clean the battery terminals regularly and grease with acid-free grease if necessary .
ENGLISH 40 MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 A 1 3 2 1 1 Fuse The fuse [1] is located in the starter relay of the E-starter [2] underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover [A] , you will be able to see the fuse.
ENGLISH 41 MAINTENANCE WORK ON CHASSIS AND ENGINE » 10 mm when engine ist cold 1 1 2 2 3 4 3 Bleeding the cooling system By removing the screw [1] at the water pump cover you can drain the coolant. T o bleed the cooling system, add coolant up to approx.
ENGLISH 42 Exhaust system * If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to “burn out”.
ENGLISH 43 Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ).
ENGLISH 44 MAINTENANCE WORK ON CHASSIS AND ENGINE » Definitions Mixture too rich: T oo much fuel in proportion to air . Mixture too lean: Not enough fuel in proportion to air . Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw [1] and the idle adjusting screw [2] .
ENGLISH 45 Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. W ater in the float chamber leads to engine malfunction.
ENGLISH 46 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the engine characteristic via the auxiliary spring (250/300) * The engine characteristic can be modified through various thicknesses of the auxiliary spring [1] .
ENGLISH 47 Check transmission oil level (125/200) In order to check the transmission oil level the control screw [1] on the clutch cover is to be removed. Oil should just barely escape from the inspection open- ing when the motorcycle is in an upright position.
ENGLISH 48 CLEANING » CONSERVATION FOR WINTER OPERATION » STORAGE » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.
ENGLISH 49.
ENGLISH 50 CHASSIS 125/200 XC/XC-W/EXC/EXC SIX DAYS Frame Central chrome-moly-steel frame Fork 125/200 XC-W/EXC/EXC Six Days 200 XC WP Suspension – 4860 MXMA P A (Open Cartridge) WP Suspension – 4860 MXMA CC (Closed Cartridge) Wheel travel front/rear 300/335 mm (11.
ENGLISH 51 TECHNICAL SPECIFICATIONS – CHASSIS 125 EXC/SIX DAYS, 200 XC/XC-W/EXC 2008 » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 (10.
ENGLISH 52 TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 » ENGINE 125 EXC/EXC SIX DAYS 200 XC-W/EXC 200 XC Design Liquid-cooled, single-cylinder , two-stroke engine with intake and exhaust control Piston displacement 124.
ENGLISH 53 TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2008 » BASIC CARBURETOR SETTING 125 EXC EU 4.4 KW 125 EXC SIX-DAYS Carburetor Keihin PWK 36S AG Keihin PWK 36S AG .
ENGLISH 54 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC-E/EXC-E SIX DAYS 2008 » CHASSIS 250 XC/XC-W/EXC/EXC SIX DAYS 300 XC/XC-W/EXC-E/EXC-E SIX DAYS Frame Central chrome-moly-steel frame F.
ENGLISH 55 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC-E/EXC-E SIX DAYS 2008 » STANDARD ADJUSTMENT – FORK 250/300 XC-W/EXC/EXC-E 250/300 EXC-E EXC-E SIX DAYS 250/300 XC WP 4860 MXMA P A WP 4860 MXMA P A WP 4860 MXMA CC 14.18.7D.04 14.18.
ENGLISH 56 TECHNICAL SPECIFICATIONS – ENGINE 250 XC/XC-W/EXC/EXC SIX DAYS 2008 » ENGINE 250 XC 250 XC-W ZA 250 EXC 250 EXC SIX DAYS 250 XC-W USA Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve Control exhaust system and KTM T orque Chamber Piston displacement 249 ccm Bore / stroke 66.
ENGLISH 57 TECHNICAL SPECIFICATIONS – ENGINE 250 XC/XC-W/EXC/EXC SIX DAYS 2008 » TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M 8 27 Nm Nuts-cylinder base M 10 35 Nm Flywheel collar nu.
ENGLISH 58 TECHNICAL SPECIFICATIONS – ENGINE 300 XC/XC-W/EXC-E/EXC-E SIX DAYS 2008 » ENGINE 300 XC 300 XC-W 300 EXC-E 300 EXC-E SIX DAYS Design Liquid-cooled single-cylinder two-stroke engine with KTM T win V alve Control exhaust system and KTM T orque Chamber Piston displacement 293 ccm Bore / stroke 72 / 72 mm (2.
ENGLISH 59 TECHNICAL SPECIFICATIONS – ENGINE 300 XC/XC-W/EXC-E/EXC-E SIX DAYS 2008 » TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head M 8 27 Nm Nuts-cylinder base M 10 35 Nm Flywheel colla.
ENGLISH 60 SCHALTPLAN » WIRING DIAGRAMM.
ENGLISH 61 SCHALTPLAN » WIRING DIAGRAMM.
ENGLISH 62 SCHALTPLAN » WIRING DIAGRAMM.
ENGLISH 63 SCHALTPLAN » WIRING DIAGRAMM.
ENGLISH 64 SCHALTPLAN » WIRING DIAGRAMM e r r b e l b a c r o l o c h c t i w s n r o h N R O H F F O h c t i w s e k a r b - n g e y l b l b h w d e h s u p d e h s u p n u e l b a c h c t i w s s s.
ENGLISH 65 SCHALTPLAN » WIRING DIAGRAMM ENGLISH DEUTSCH IT ALIANO Battery Batterie Batteria Cooling fan Lüftermotor Motorino ventola Driving light lamp Fernlichtkontrolle spia abbagliante Flasher co.
ENGLISH 66 SCHALTPLAN » WIRING DIAGRAMM ENGLISH FRANCAIS ESP ANOL Battery Batterie Batería Cooling fan V entilateur Motor del ventilador Driving light lamp temoin feu route lampara aviso luces larga.
ENGLISH 67 VERGASERTABELLE » CARBURETOR TABLE LSO = Luftregulierschraube offen LD = Leerlaufdüse POS = Nadel Clip Position von oben HD = Hauptdüse NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 95 EXC Modelle: Die oben angeführten V ergaserregulierungen gelten nur für entdrosselte Motorräder.
ENGLISH 68 VERGASERTABELLE » CARBURETOR TABLE LSO = Luftregulierschraube offen LD = Leerlaufdüse POS = Nadel Clip Position von oben HD = Hauptdüse NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 95 EXC Modelle: Die oben angeführten V ergaserregulierungen gelten nur für entdrosselte Motorräder.
ENGLISH 69 VERGASERTABELLE » CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250 XC 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C .
ENGLISH 70 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250 XC-W/EXC/EXC-SIX DAYS 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C bis 5°C 19°F to.
ENGLISH 71 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 300 XC/XC-W/EXC/EXC-SIX DAYS 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C bis 5°C 19°F.
INDEX » Page Activating and deactivating display modes . . . . . . . . .7 Adjusting the engine characteristic via the auxiliary spring .45 Adjusting the engine characteristic via the ignition curve . .44 Basic suspension setup for the weight of the driver .
KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 5/2007 FOTO: MITTERBAUER 125 EXC, EXC SIX DAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXC SIX DAYS 300 XC, XC-W, EXC-E, EXC-E SI.
An important point after buying a device KTM EXC-E (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM EXC-E yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM EXC-E - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM EXC-E you will learn all the available features of the product, as well as information on its operation. The information that you get KTM EXC-E will certainly help you make a decision on the purchase.
If you already are a holder of KTM EXC-E, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM EXC-E.
However, one of the most important roles played by the user manual is to help in solving problems with KTM EXC-E. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM EXC-E along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
