Instruction/ maintenance manual of the product XC-W KTM
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 4/2006 FOTO: MITTERBAUER 125 EXC SIX DAYS, EXC 200 XC, XC-W, EXC 250 XC, XC-W, EXC SIX DAYS, EXC 300 XC, XC-W, EXC SIX DAYS, EXC OWNER’S MANUAL 2007 ART.
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 » Setting the clock T o set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the | button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the | button to move to the next digit.
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 Filler cap (EXC/EXC Six Days) T o open it: turn filler cap counter-clockwise. T o close it: put filler cap back on and tighten it by turning it clockwise. Filler cap (XC, XC-W) To open the filler cap: T urn the filler cap 45 ° counter -clockwise.
ENGLISH 13 OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. 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).
ENGLISH 14 OPERATION INSTRUMENTS » 3 3 2 2 1 Compression damping of fork 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 » Compression damping of shock absorber (XC-W, EXC) The compression damping (during compression) can be adjusted for the XC-W and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [2] with a screwdriver .
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 ignition or 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 2007 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 2007 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 SIX DAYS/EXC 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Before each race 1st service after 10 hours every 20 .
ENGLISH 23 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER Every 20 hours Every 40 hours Every 60 hours Every 80.
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 MAINTENANCE WORK ON CHASSIS AND ENGINE » According to our experience, the damping rate of the compression stage can remain unchanged. The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring.
ENGLISH 27 Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs [1] 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 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 » How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper triple clamp [1] includes 2 bores arranged at a distance of 15 mm (0.
ENGLISH 31 Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water , but never use brushes or solvents. After letting the chain dry , you can use a special X-ring chain spray (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 Adjusting the 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 resis-tance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size.
ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 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). At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.
ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground.
ENGLISH 37 Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motorcy- cle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle.
ENGLISH 38 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check/set distance of the magnetic sensor The distance between the magnet [2] and the sensor [1] must be 2-4 mm, otherwise malfunctions on the speedometer might occur . This distance can be corrected by screwing the sensor [1] in or off.
ENGLISH 39 Cooling system The water pump in the engine circulates the cooling liquid. However , the cool- ing liquid can only circulate properly if the cooling circuit contains no air bubbles. Bleeding of the cooling system is therefore required a) after adding more than 0.
ENGLISH 40 MAINTENANCE WORK ON CHASSIS AND ENGINE » Refilling/Bleeding the cooling system The cooling system must be bled as described below after draining the cooling liquid or after adding more than 0.25 l (0.06 US gallons) cooling liq- uid. Make sure that the drain screw [1] is fastened.
ENGLISH 41 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 42 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 43 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 [2] and the air control screw [3] .
ENGLISH 44 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 45 MAINTENANCE WORK ON CHASSIS AND ENGINE » 3 1 2 3 4 5 6 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 46 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 47 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 48 CHASSIS 125 EXC SIX DAYS/EXC 200 XC/XC-W/EXC Frame Central chrome-moly-steel frame Fork WP Suspension – 4860 MXMA (WP – 4860 MXMA + P A: 200 XC, EXC 125 Six Days) Wheel travel front/rear 300/335 mm (11.
ENGLISH 49 TECHNICAL SPECIFICATIONS – CHASSIS 125 EXC/SIX DAYS, 200 XC/XC-W/EXC 2007 » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Locti.
ENGLISH 50 TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007 » 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 51 TECHNICAL SPECIFICATIONS – ENGINE 125 EXC/EXC SIX DAYS, 200 XC/XC-W/EXC 2007 » BASIC CARBURETOR SETTING 125 EXC EU 4,2 KW 125 EXC SIX-DAYS 200 XC USA 200 XC-W USA 200 EXC ZA 200 EXC AUS .
ENGLISH 52 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 » CHASSIS 250/300 XC/XC-W 250/300 EXC SIX DAYS 250/300 EXC (EXC ZA) Frame Central chrome-moly-steel frame Fork WP Suspension – 4860 MXMA (-P A; 250/300 XC/EXC SIX DA YS) Wheel travel front/rear 300/335 mm (11.
ENGLISH 53 TECHNICAL SPECIFICATIONS - CHASSIS 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 » STANDARD ADJUSTMENT – SHOCK ABSORBER 250/300 EXC/XC-W WP 5018 PDS MCC 12187C04 Compression adjuster 15 Rebound .
ENGLISH 54 TECHNICAL SPECIFICATIONS – ENGINE 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 » ENGINE 250 XC 250 XC-W/EXC SIX DAYS/EXC 300 XC 300 XC-W/EXC SIX DAYS/EXC 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 293.
ENGLISH 55 TECHNICAL SPECIFICATIONS – ENGINE 250/300 XC/XC-W/EXC SIX DAYS/EXC 2007 » BASIC CARBURETOR SETTING 250 XC USA/EU 250+300 EXC EU 300 EXC-E EU 250+300 EXC AUS 250+300 XC-W USA, 300 XC USA .
ENGLISH 56 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 Adjusting the free travel at the hand brake lever .
ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAMM 7 0 0 2 0 0 3 - 5 2 1 C X E m a r g a i d g n i r i w s s e n r a h n i a m 6 / 1 h c t i w s r e h s a l f 3 / T B _ C 3 / .
ANHANG – APPENDICE APPENDIX – APÉNDICE 2 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 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAMM 7 0 0 2 0 5 2 - 0 0 2 W - C X m m a r g a i d g n i r i w 0 0 0 . 5 7 0 . 1 1 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 4 SCHALTPLAN » WIRING DIAGRAMM 7 0 0 2 0 0 3 W - X C m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 1 .
SCHALTPLAN » WIRING DIAGRAMM ANHANG – APPENDICE APPENDIX – APÉNDICE 5 ENGLISH DEUTSCH IT ALIANO Capacitor Kondensator Condensatore CDI CDI CDI Driving light lamp Fernlichtkontrolle Spia abbaglia.
SCHALTPLAN » WIRING DIAGRAMM ANHANG – APPENDICE APPENDIX – APÉNDICE 6 ENGLISH FRANCAIS ESP ANOL Capacitor Condensateur Condensador CDI CDI CDI Driving light lamp T emion feu route Lampara aviso .
VERGASERTABELLE » CARBURETOR TABLE ANHANG – APPENDICE APPENDIX – APÉNDICE 7 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.
VERGASERTABELLE » CARBURETOR TABLE ANHANG – APPENDICE APPENDIX – APÉNDICE 8 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.
VERGASERTABELLE » CARBURETOR TABLE ANHANG – APPENDICE APPENDIX – APÉNDICE 9 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 200 EXC, XC 2007 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE .
ANHANG – APPENDICE APPENDIX – APÉNDICE 10 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250+300 XC-W USA, 300 XC USA, 250+300 EXC EU/AUS 250+300 EXC SIX DAYS, 250+300 EXC ZA MEERESHÖH.
VERGASERTABELLE » CARBURETOR TABLE ANHANG – APPENDICE APPENDIX – APÉNDICE 11 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36S AG 250 XC USA/EU 2007 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATU.
KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 4/2006 FOTO: MITTERBAUER 125 EXC SIX DAYS, EXC 200 XC, XC-W, EXC 250 XC, XC-W, EXC SIX DAYS, EXC 300 XC, XC-W, EXC SIX DAYS, EXC BEDIENUNGSANLEITUNG 2007 ART.
An important point after buying a device KTM XC-W (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 XC-W 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 XC-W - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM XC-W you will learn all the available features of the product, as well as information on its operation. The information that you get KTM XC-W will certainly help you make a decision on the purchase.
If you already are a holder of KTM XC-W, 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 XC-W.
However, one of the most important roles played by the user manual is to help in solving problems with KTM XC-W. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM XC-W 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
