KTM 125 EXC EU User Manual

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18 SERVICE WORK ON THE ENGINE 117

– Start the engine and check that it is oil-tight.

Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual9
3 Important Notes10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Service10
- Figures10
- Customer Service10
4 View of Vehicle11
- View of Vehicle, Front Left (Example)11
- View of Vehicle, Rear Right (Example)12
5 Serial Numbers13
- Chassis Number13
- Type Label13
- Key Number (All EXC Models)13
- Engine Number13
- Fork Part Number13
- Shock Absorber Part Number14
6 Controls15
- Clutch Lever15
- Hand Brake Lever15
- Throttle Grip15
- Kill Switch (All EXC Models)15
- Kill Switch (All XC-W Models)16
- Horn Button (All EXC Models)16
- Light Switch (All EXC Models)16
- Light Switch (All XC-W Models)16
- Turn Signal Switch (All EXC Models)16
- Emergency off Switch (EXC AUS)17
- Electric Starter Button (200/250/300 EXC EU, 250/300 SIX DAYS, XC-W)17
- Electric Starter Button (EXC AUS)17
- Overview of Indicator Lamps (EXC EU/AUS)17
- Overview of Indicator Lamps (SIX DAYS EU)17
- Overview of Indicator Lamps (300 XC-W SIX DAYS USA)18
- Opening the Filler Cap18
- Closing the Filler Cap18
- Fuel Tap19
- Choke19
- Shift Lever19
- Kick Starter20
- Foot Brake Lever20
- Side Stand20
- Steering Lock (All EXC Models)20
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)21
7 Speedometer22
- Exc, XC-W22
- Speedometer Overview22
- Activation and Test22
- Setting Kilometers or Miles22
- Adjusting the Speedometer Functions23
- Setting the Clock23
- Querying Lap Time23
- Display Mode SPEED (Speed)24
- Display Mode SPEED/H (Service Hours)24
- Setup Menu24
- Unit of Measurement Menu25
- Display Mode SPEED/CLK (Time)25
- Setting the Clock25
- Display Mode SPEED/LAP (Lap Time)26
- Viewing the Lap Time26
- Display Mode SPEED/ODO (Odometer)26
- Display Mode SPEED/TR1 (Trip Master 1)26
- Display Mode SPEED/TR2 (Trip Master 2)27
- Setting TR2 (Trip Master 2)27
- Display Mode SPEED/A1 (Average Speed 1)27
- Display Mode SPEED/A2 (Average Speed 2)28
- Display Mode SPEED/S1 (Stop Watch 1)28
- Display Mode SPEED/S2 (Stop Watch 2)28
- Table of Functions28
- Table of Conditions and Menu Activation29
- Six Days29
- Speedometer Overview29
- Activation and Test30
- Setting Kilometers or Miles30
- Setting the Speedometer Functions30
- Setting the Clock31
- Viewing the Lap Time31
- Display Mode SPEED (Speed)32
- Display Mode SPEED/H (Service Hours)32
- Setup Menu32
- Setting the Unit of Measurement33
- Display Mode SPEED/CLK (Time)33
- Setting the Clock33
- Display Mode SPEED/LAP (Lap Time)34
- Viewing the Lap Time34
- Display Mode SPEED/ODO (Odometer)34
- Display Mode SPEED/TR1 (Trip Master 1)34
- Display Mode SPEED/TR2 (Trip Master 2)35
- Setting TR2 (Trip Master 2)35
- Display Mode SPEED/A1 (Average Speed 1)35
- Display Mode SPEED/A2 (Average Speed 2)36
- Display Mode SPEED/S1 (Stop Watch 1)36
- Display Mode SPEED/S2 (Stop Watch 2)36
- Table of Functions37
- Table of Conditions and Menu Activation38
8 Preparing for Use39
- Advice on First Use39
- Running in the Engine40
- Preparing the Vehicle for Difficult Riding Conditions40
- Preparations for Riding on Dry Sand41
- Preparations for Riding on Wet Sand41
- Preparations for Riding on Wet and Muddy Surfaces42
- Preparations for Riding at High Temperatures and Low Speeds42
- Preparing for Riding at Low Temperatures or in Snow43
9 Riding Instructions44
- Checks and Maintenance Work When Preparing for Use44
- Starting44
- Start off45
- Shifting, Riding45
- Braking45
- Stopping, Parking46
- Transport46
- Refueling47
10 Service Schedule48
- Service Work (as Additional Order)49
11 Tuning the Chassis50
- Checking the Basic Chassis Setting with the Rider's Weight50
- Compression Damping of Shock Absorber50
- Adjusting the Low-Speed Compression Damping of the Shock Absorber50
- Adjusting the High-Speed Compression Damping of the Shock Absorber51
- Adjusting the Rebound Damping of the Shock Absorber51
- Measuring the Sag of the Unloaded Rear Wheel52
- Checking the Static Sag of the Shock Absorber52
- Checking the Riding Sag of the Shock Absorber53
- Adjusting the Spring Preload of the Shock Absorber53
- Adjusting the Riding Sag54
- Checking the Basic Setting of the Fork54
- Adjusting the Compression Damping of the Fork55
- Adjusting the Rebound Damping of the Fork56
- Adjusting the Spring Preload of the Fork (EXC, XC-W)57
- Handlebar Position57
- Adjusting the Handlebar Position58
12 Service Work on the Chassis59
- Raising the Motorcycle with the Lift Stand59
- Removing the Motorcycle from the Lift Stand59
- Bleeding the Fork Legs59
- Cleaning the Dust Boots of the Fork Legs60
- Loosening the Fork Protection60
- Positioning the Fork Protection61
- Removing the Fork Legs61
- Installing the Fork Legs61
- Removing the Fork Protector62
- Installing the Fork Protector63
- Removing the Lower Triple Clamp (EXC, XC-W)63
- Removing the Lower Triple Clamp (SIX DAYS)64
- Installing the Lower Triple Clamp (EXC, XC-W)64
- Installing the Lower Triple Clamp66
- Six Days)66
- Checking the Play of the Steering Head Bearing68
- Adjusting the Play of the Steering Head Bearing68
- Greasing the Steering Head Bearing69
- Removing the Front Fender69
- Installing the Front Fender69
- Removing the Shock Absorber70
- Installing the Shock Absorber70
- Removing the Seat71
- Mounting the Seat71
- Removing the Air Filter Box Lid72
- Installing the Air Filter Box Lid72
- Removing the Air Filter72
- Installing the Air Filter72
- Cleaning the Air Filter and Air Filter Box73
- Sealing the Air Filter Box73
- Removing the Main Silencer74
- Installing the Main Silencer74
- Changing the Glass Fiber Yarn Filling of the Main Silencer74
- Removing the Fuel Tank75
- Installing the Fuel Tank76
- Checking the Chain for Dirt77
- Cleaning the Chain77
- Checking the Chain Tension77
- Adjusting the Chain Tension78
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide79
- Checking the Frame80
- Checking the Swingarm81
- Checking the Routing of the Throttle Cable81
- Checking the Rubber Grip82
- Additionally Securing the Rubber Grip82
- Adjusting the Basic Position of the Clutch Lever82
- Checking/Correcting the Fluid Level of the Hydraulic Clutch83
- Changing the Hydraulic Clutch Fluid83
- Removing the Engine Guard (SIX DAYS)84
- Installing the Engine Guard (SIX DAYS)85
13 Brake System86
- Checking the Free Travel of the Hand Brake Lever86
- Adjusting Free Travel of Hand Brake Lever (All EXC Models)86
- Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)86
- Checking the Brake Discs87
- Checking the Front Brake Fluid Level87
- Adding Front Brake Fluid87
- Checking the Front Brake Linings88
- Changing the Front Brake Linings89
- Checking the Free Travel of Foot Brake Lever90
- Adjusting the Basic Position of the Foot Brake Lever90
- Checking the Rear Brake Fluid Level91
- Adding Brake Fluid for the Rear Brake91
- Checking the Rear Brake Linings92
- Changing the Brake Linings of the Rear Brake92
14 Wheels, Tires95
- Removing the Front Wheel95
- Installing the Front Wheel95
- Removing the Rear Wheel96
- Installing the Rear Wheel96
- Checking the Tire Condition97
- Checking the Tire Air Pressure98
- Checking the Spoke Tension98
15 Electrical System100
- Removing the Battery (All 200/250/300 Models)100
- Installing the Battery (All 200/250/300 Models)100
- Recharging the Battery (All 200/250/300 Models)101
- Changing the Main Fuse (All 200/250/300 Models)102
- Removing the Headlight Mask with the Headlight103
- Refitting the Headlight Mask with the Headlight103
- Changing the Headlight Bulb103
- Changing the Turn Signal Bulb (All EXC Models)104
- Checking the Headlight Setting105
- Adjusting the Headlight Range105
- Changing the Speedometer Battery105
16 Cooling System107
- Checking the Antifreeze and Coolant Level107
- Checking the Coolant Level108
- Draining the Coolant108
- Refilling with Coolant109
17 Tuning the Engine111
- Checking the Play in the Throttle Cable111
- Adjusting the Play in the Throttle Cable111
- Carburetor - Idle111
- Carburetor - Adjusting the Idle Speed112
- Emptying the Carburetor Float Chamber113
- Checking the Basic Position of the Shift Lever114
- Adjusting the Basic Position of the Shift Lever114
- Engine Characteristic - Auxiliary Spring (All 250/300 Models)114
- Engine Characteristic - Setting the Auxiliary Spring X (All 250/300 Models)114
18 Service Work on the Engine116
- Checking the Gear Oil Level116
- Changing the Gear Oil116
- Draining the Gear Oil117
- Refilling with Gear Oil117
- Adding Gear Oil118
19 Cleaning, Care120
- Cleaning the Motorcycle120
- Checks and Maintenance Steps for Winter Operation121
20 Storage122
- Preparing for Use after Storage122
21 Troubleshooting123
22 Technical Data125
- Engine125
- All 125 Models125
- All 200 Models125
- All 250 Models126
- All 300 Models126
- Engine Tightening Torques127
- All 125/200 Models127
- All 250/300 Models128
- Capacities129
- Gear Oil129
- Coolant129
- Fuel129
- Chassis129
- Electrical System130
- Tires131
- Fork131
- EXC EU, All 200 Models131
- 250/300 Exc Eu/Aus, XC-W Usa131
- Exc Six Days Eu132
- 250/300 Six Days132
- Shock Absorber133
- All 125/200 Models133
- All 250/300 Models133
- Chassis Tightening Torques134
- Carburetor135
- 22.10.1 All 125 Models135
- 22.10.2 200 Exc Eu135
- 22.10.3 200 Exc aus135
- 22.10.4 200 XC-W Usa135
- 22.10.5 250 Exc Eu, 250 Exc Six Days Eu136
- 22.10.6 250/300 Exc aus136
- 22.10.7 250 XC-W Usa136
- 22.10.8 300 Exc Eu, 300 Exc Six Days Eu137
- 22.10.9 300 XC-W Usa, 300 XC-W Six Days Usa137
- Carburetor Tuning (All 125 Models)137
- Carburetor Tuning (All 200 Models)138
- Carburetor Tuning (All 250 Models)139
- Carburetor Tuning (All 300 Models)140
- General Carburetor Tuning141
23 Substances142
24 Auxiliary Substances144
25 Standards146
- Index147

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KTM 125 EXC EU Specifications

General

Brand	KTM
Model	125 EXC EU
Category	Motorcycle
Language	English

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