KTM 125 EXC EU 2012 Manual

SETUP INSTRUCTIONS 2012

125 EXC EU

125 EXC SIX DAYS EU

200 EXC EU

200 EXC AUS

200 XC‑W USA

250 EXC EU

250 EXC AUS

250 EXC SIX DAYS EU

250 XC‑W USA

300 EXC EU

300 EXC AUS

300 EXC SIX DAYS EU

300 XC‑W USA

Art. no. 3211812en

INTRODUCTION 1

INTRODUCTION

The work described in these setup instructions must be performed before the vehicle is delivered to the customer.

Read the setup instructions in their entirety before beginning work.

Print out the current PDI form found on the KTM DEALER.NET.

These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-

est of technical advancement without at the same time updating this manual.

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.

It is assumed that the work will be performed by a fully trained mechanic.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-

tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt

these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery

options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-

cial equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright

owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead

to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

MEANS OF REPRESENTATION 2

Symbols used

The meaning of specific symbols is described below.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

SETUP 3

2.1Unpacking and setting up the vehicle

B00887-01

Packaging 2

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup, leave the protective

film on the vehicle until you have finished.

–Remove the separate enclosure and unpack it. Check that the scope of delivery

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Carefully loosen and remove the footrest mount.

Info

An assistant prevents the motorcycle from falling over.

–Together with an assistant, take the vehicle off the palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

600811-10

Package 12

–Remove the box and the plastic packaging.

Info

An assistant prevents the motorcycle from falling over.

To avoid damaging the motorcycle during the setup, leave the protective

film on the vehicle until you have finished.

–Remove the separate enclosure and unpack it. Check that the scope of delivery

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Together with an assistant, take the vehicle off the palette.

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

B00902-01

–Install the shock absorber. ( p. 8)

600814-01

–Route the clutch line with the clutch master cylinder toward the front between

the upper and lower triple clamps.

–Position the fork legs and tighten the screws of the triple clamp.

Guideline

Screw, top triple clamp

(EXC EU/AUS, XC‑W)

M8 20 Nm

(14.8 lbf ft)

Screw, bottom triple clamp

(EXC EU/AUS, XC‑W)

M8 15 Nm

(11.1 lbf ft)

Screw, top triple clamp

(EXC SIX DAYS)

M8 17 Nm

(12.5 lbf ft)

Screw, bottom triple clamp

(EXC SIX DAYS)

M8 12 Nm

(8.9 lbf ft)

SETUP 4

Info

The topmost milled groove in the fork leg must be flush with the top

edge of the upper triple clamp.

Position the bleeder screws toward the front.

400223-10

–Remove screws 1. Take off the handlebar clamps.

–Remove screws 2. Remove the handlebar supports.

–Place the handlebar supports in the required position. Mount and tighten

screws 2.

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

600824-10

–Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

–Position the handlebar clamps. Mount and tighten the screws.

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

The markings on the handlebar should be at the center of the handlebar

clamps.

Keep the gap widths equal when tightening.

B00903-10

(All EXC models)

–Insert the indicator lamp with the blue and brown cable colors into socket 3.

–Insert the indicator lamp with the blue and violet cable colors into socket 4.

B00904-10

(XC-W)

–Connect pull switch 5with the yellow and white cables.

SETUP 5

401408-01

(All EXC models)

–Attach the retaining bracket for the connector, the turn signal bracket with the

turn signal, and the speedometer to the upper triple clamp.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

401409-01

(XC-W)

–Attach the speedometer to the upper triple clamp.

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

B00096-10

–Position the controls on the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

600817-10

–Position the controls on the left half of the handlebar.

Info

The figure shows how to route the clutch line and wiring harness.

B00906-10

(All EXC models)

–Mount and tighten nuts 6of the turn signals on both sides.

–Connect connector 7of the right turn signal with connector 8, which is

marked green.

–Connect connector 9of the left turn signal with connector bk, which is marked

red.

SETUP 6

401382-01

(All EXC models)

–Mount the turn signal switch.

B00087-11

(200 EXC AUS)

–Mount switch bl.

B00905-10

(250/300 EXC AUS)

–Mount switch bm.

–Install the front fender. ( p. 11)

–Correctly mount the fuel tank breather.

(All EXC models)

–Refit the headlight mask with the headlight. ( p. 11)

(XC-W)

–Install the start number plate. ( p. 11)

B00907-01

–Mount the handlebar cushion.

800042-10

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Pliers for footrest spring (58429083000)

SETUP 7

B00908-01

(All EXC models)

–Mount the license plate holder with the license plate lamp, turn signals, and

reflector.

–Connect the electrical components.

–Connect the connector of the left turn signal with connector that is marked red.

–Connect the connector of the right turn signal with the connector that is marked

green.

800035-10

(All 250/300 models)

Warning

Risk of injury Battery acid and battery gases cause serious chemical

burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep the battery away from sparks or open flames. Charge only in

well-ventilated areas.

–In the event of skin contact, rinse with large amounts of water. If

battery acid gets in the eyes, rinse with water for at least 15 minutes

and contact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 9)

–Install the battery. ( p. 10)

B00097-01

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts installation instructions.

–Apply the label included in the delivery (optional).

101037-01

(All EXC models)

–Mount the mirror clamps on both sides.

B00909-01

–Mount and tighten the rear mirror on both sides.

–Mount the reflector.

–Position all controls in their exact positions on the handlebar. Tighten all screws.

–Refuel. ( p. 12)

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

WORK 8

3.1Removing the seat

B00817-10

–Remove screw 1. Lift up the seat at the rear, pull it back and then remove from

above.

3.2Mounting the seat

B00818-01

–Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear

and simultaneously push forward.

–Make sure that the seat is correctly locked in.

B00817-10

–Mount and tighten screw 1of the seat fixation.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

3.3Installing the shock absorber

B00815-11

(All 125/200 models)

–Push splash protector 1to the side and position the shock absorber. Mount

and tighten screw 2.

Guideline

Screw, top shock

absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

–Mount and tighten screw 3.

Guideline

Screw, bottom shock

absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

Info

The heim joint for the shock absorber at the swing arm is Teflon

coated. It must not be lubricated with grease or with other lubricants.

Lubricants dissolve the Teflon coating, thereby drastically reducing the

service life.

B00816-11

(All 250/300 models)

–Push splash protector 1to the side and position the shock absorber. Mount

and tighten screw 2.

Guideline

Screw, top shock

absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

–Mount and tighten screw 3.

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