Contents

1 MEANS OF REPRESENTATION
- 1.1 Symbols used
- 1.2 Formats used
2 SAFETY ADVICE
- 2.1 Use definition - intended use
- 2.2 Safety advice
- 2.3 Degrees of risk and symbols
- 2.4 Tampering warning
- 2.5 Safe operation
- 2.6 Protective clothing
- 2.7 Work rules
- 2.8 Environment
- 2.9 Owner's Manual
3 IMPORTANT NOTES
- 3.1 Manufacturer and implied warranty
- 3.2 Operating and auxiliary substances
- 3.3 Spare parts, accessories
- 3.4 Service
- 3.5 Figures
- 3.6 Customer service
4 VIEW OF VEHICLE
- 4.1 View of vehicle, front left (example)
- 4.2 View of vehicle, rear right (example)
5 SERIAL NUMBERS
- 5.1 Chassis number
- 5.2 Type label
- 5.3 Key number (All EXC models)
- 5.4 Engine number
- 5.5 Fork part number
- 5.6 Shock absorber article number
6 CONTROLS
- 6.1 Clutch lever
- 6.2 Hand brake lever
- 6.3 Throttle grip
- 6.4 Kill switch (All EXC models)
- 6.5 Kill switch (All XC-W models)
- 6.6 Horn button (All EXC models)
- 6.7 Light switch (All EXC models)
- 6.8 Light switch (All XC-W models)
- 6.9 Turn signal switch (All EXC models)
- 6.10 Emergency OFF switch (EXC AU)
- 6.11 Electric starter button (All 200/250/300 EU/US models, 300 EXC BR)
- 6.12 Electric starter button (EXC AU)
- 6.13 Overview of indicator lamps (All EXC models)
- 6.14 Overview of indicator lamps (All XC-W models)
- 6.15 Opening the filler cap
- 6.16 Closing the filler cap
- 6.17 Fuel tap
- 6.18 Choke
- 6.19 Shift lever
- 6.20 Kick starter
- 6.21 Foot brake lever
- 6.22 Side stand
- 6.23 Steering lock (All EXC models)
- 6.24 Locking the steering (All EXC models)
- 6.25 Unlocking the steering (All EXC models)
7 SPEEDOMETER
- 7.1 Speedometer overview
- 7.2 Activation and test
- 7.3 Setting kilometers or miles
- 7.4 Setting the speedometer functions
- 7.5 Setting the clock
- 7.6 Viewing the lap time
- 7.7 Display mode SPEED (speed)
- 7.8 Display mode SPEED/H (service hours)
- 7.9 Setup menu
- 7.10 Setting the unit of measurement
- 7.11 Display mode SPEED/CLK (time)
- 7.12 Setting the clock
- 7.13 Display mode SPEED/LAP (lap time)
- 7.14 Viewing the lap time
- 7.15 Display mode SPEED/ODO (odometer)
- 7.16 Display mode SPEED/TR1 (trip master 1)
- 7.17 Display mode SPEED/TR2 (trip master 2)
- 7.18 Setting TR2 (trip master 2)
- 7.19 Display mode SPEED/A1 (average speed 1)
- 7.20 Display mode SPEED/A2 (average speed 2)
- 7.21 Display mode SPEED/S1 (stop watch 1)
- 7.22 Display mode SPEED/S2 (stop watch 2)
- 7.23 Table of functions
- 7.24 Table of conditions and menu activation
8 PREPARING FOR USE
- 8.1 Advice on first use
- 8.2 Running in the engine
- 8.3 Preparing the vehicle for difficult riding conditions
- 8.4 Preparing for rides on dry sand
- 8.5 Preparing for rides on wet sand
- 8.6 Preparations for riding on wet and muddy surfaces
- 8.7 Preparations for riding at high temperatures and low speeds
- 8.8 Preparing for riding at low temperatures or in snow
9 RIDING INSTRUCTIONS
- 9.1 Checks and maintenance work when preparing for use
- 9.2 Starting
- 9.3 Start off
- 9.4 Shifting, riding
- 9.5 Braking
- 9.6 Stopping, parking
- 9.7 Transport
- 9.8 Refueling
10 SERVICE SCHEDULE
- 10.1 Service schedule
- 10.2 Service work (as additional order)
11 TUNING THE CHASSIS
- 11.1 Checking the basic chassis setting with the rider's weight
- 11.2 Compression damping of the shock absorber
- 11.3 Adjusting the low-speed compression damping of the shock absorber
- 11.4 Adjusting the high-speed compression damping of the shock absorber
- 11.5 Adjusting the rebound damping of the shock absorber
- 11.6 Measuring the sag of the unloaded rear wheel
- 11.7 Checking the static sag of the shock absorber
- 11.8 Checking the riding sag of the shock absorber
- 11.9 Adjusting the spring preload of the shock absorber
- 11.10 Adjusting the riding sag
- 11.11 Checking the basic setting of the fork
- 11.12 Adjusting the compression damping of the fork
- 11.13 Adjusting the rebound damping of the fork
- 11.14 Adjusting the spring preload of the fork (EXC, XCW)
- 11.15 Handlebar position
- 11.16 Adjusting the handlebar position
12 SERVICE WORK ON THE CHASSIS
- 12.1 Raising the motorcycle with a lift stand
- 12.2 Removing the motorcycle from the lift stand
- 12.3 Bleeding the fork legs
- 12.4 Cleaning the dust boots of the fork legs
- 12.5 Removing the fork protector
- 12.6 Installing the fork protector
- 12.7 Removing the fork legs
- 12.8 Installing the fork legs
- 12.9 Removing the lower triple clamp (200 XCW US, 250 XCW US, 300 EXC BR, 300 XCW US)
- 12.10 Removing the lower triple clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days)
- 12.11 Installing the lower triple clamp (200 XCW US, 250 XCW US, 300 EXC BR, 300 XCW US)
- 12.12 Installing the lower triple clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days)
- 12.13 Checking the play of the steering head bearing
- 12.14 Adjusting the play of the steering head bearing
- 12.15 Greasing the steering head bearing
- 12.16 Removing the front fender
- 12.17 Installing the front fender
- 12.18 Removing the shock absorber
- 12.19 Installing the shock absorber
- 12.20 Removing the seat
- 12.21 Mounting the seat
- 12.22 Removing the air filter box lid
- 12.23 Installing the air filter box lid
- 12.24 Removing the air filter
- 12.25 Installing the air filter
- 12.26 Cleaning the air filter and air filter box
- 12.27 Sealing the air filter box
- 12.28 Removing the main silencer
- 12.29 Installing the main silencer
- 12.30 Changing the glass fiber yarn filling of the main silencer
- 12.31 Removing the fuel tank
- 12.32 Installing the fuel tank
- 12.33 Checking the chain for dirt
- 12.34 Cleaning the chain
- 12.35 Checking the chain tension
- 12.36 Adjusting the chain tension
- 12.37 Checking the chain, rear sprocket, motor sprocket, and chain guide
- 12.38 Checking the frame
- 12.39 Checking the swingarm
- 12.40 Checking the routing of the throttle cable
- 12.41 Checking the rubber grip
- 12.42 Additionally securing the rubber grip
- 12.43 Adjusting the basic position of the clutch lever
- 12.44 Checking/correcting the fluid level of the hydraulic clutch
- 12.45 Changing the hydraulic clutch fluid
- 12.46 Removing the engine guard
- 12.47 Installing the engine guard
13 BRAKE SYSTEM
- 13.1 Checking the free travel of the hand brake lever
- 13.2 Adjusting free travel of hand brake lever (All EXC models)
- 13.3 Adjusting the basic position of the hand brake lever (All XC-W models)
- 13.4 Checking the brake discs
- 13.5 Checking the front brake fluid level
- 13.6 Adding front brake fluid
- 13.7 Checking the front brake linings
- 13.8 Changing the front brake linings
- 13.9 Checking the free travel of foot brake lever
- 13.10 Adjusting the basic position of the foot brake lever
- 13.11 Checking the rear brake fluid level
- 13.12 Adding brake fluid for the rear brake
- 13.13 Checking the rear brake linings
- 13.14 Changing the brake linings of the rear brake
14 WHEELS, TIRES
- 14.1 Removing the front wheel
- 14.2 Installing the front wheel
- 14.3 Removing the rear wheel
- 14.4 Installing the rear wheel
- 14.5 Checking the tire condition
- 14.6 Checking the tire air pressure
- 14.7 Checking the spoke tension
15 ELECTRICAL SYSTEM
- 15.1 Removing the battery (All 200/250/300 models)
- 15.2 Installing the battery (All 200/250/300 models)
- 15.3 Recharging the battery (All 200/250/300 models)
- 15.4 Changing the main fuse (All 200/250/300 models)
- 15.5 Removing the headlight mask with the headlight
- 15.6 Refitting the headlight mask with the headlight
- 15.7 Changing the headlight bulb
- 15.8 Changing the turn signal bulb (All EXC models)
- 15.9 Checking the headlight setting
- 15.10 Adjusting the headlight range
- 15.11 Changing the speedometer battery
16 COOLING SYSTEM
- 16.1 Cooling system
- 16.2 Checking the antifreeze and coolant level
- 16.3 Checking the coolant level
- 16.4 Draining the coolant
- 16.5 Refilling with coolant
17 TUNING THE ENGINE
- 17.1 Checking the play in the throttle cable
- 17.2 Adjusting the play in the throttle cable
- 17.3 Carburetor - idle
- 17.4 Carburetor - adjusting the idle speed
- 17.5 Emptying the carburetor float chamber
- 17.6 Checking the basic position of the shift lever
- 17.7 Adjusting the basic position of the shift lever
- 17.8 Engine characteristic - auxiliary spring (All 250/300 models)
- 17.9 Engine characteristic - setting the auxiliary spring (All 250/300 models)
18 SERVICE WORK ON THE ENGINE
- 18.1 Checking the gear oil level
- 18.2 Changing the gear oil
- 18.3 Draining the gear oil
- 18.4 Refilling with gear oil
- 18.5 Adding gear oil
19 CLEANING, CARE
- 19.1 Cleaning the motorcycle
- 19.2 Checks and maintenance steps for winter operation
20 STORAGE
- 20.1 Storage
- 20.2 Preparing for use after storage
21 TROUBLESHOOTING
22 TECHNICAL DATA
- 22.1 Engine
  - 22.1.1 All 125 models
  - 22.1.2 All 200 models
  - 22.1.3 All 250 models
  - 22.1.4 All 300 models
- 22.2 Engine tightening torques
  - 22.2.1 All 125/200 models
  - 22.2.2 All 250/300 models
- 22.3 Capacities
  - 22.3.1 Gear oil
  - 22.3.2 Coolant
  - 22.3.3 Fuel
- 22.4 Chassis
- 22.5 Electrical system
- 22.6 Tires
- 22.7 Fork
  - 22.7.1 125 EXC EU, all 200 models
  - 22.7.2 250/300 EXC EU/AU, XC-W US, 300 EXC BR
  - 22.7.3 125 EXC Six Days EU
  - 22.7.4 250/300 Six Days
- 22.8 Shock absorber
  - 22.8.1 All 125/200 models
  - 22.8.2 All 250/300 models
- 22.9 Chassis tightening torques
- 22.10 Carburetor
  - 22.10.1 All 125 models
  - 22.10.2 200 EXC EU
  - 22.10.3 200 EXC AU
  - 22.10.4 200 XCW US
  - 22.10.5 250 EXC EU, 250 EXC Six Days EU
  - 22.10.6 250 EXC AU
  - 22.10.7 250 XCW US
  - 22.10.8 300 EXC EU, 300 EXC Six Days EU
  - 22.10.9 300 EXC AU
  - 22.10.10 300 EXC BR
  - 22.10.11 300 XCW US, 300 XCW Six Days US
23 CARBURETOR TUNING
- 23.1 Carburetor tuning (All 125 models)
- 23.2 Carburetor tuning (All 200 models)
- 23.3 Carburetor tuning (All 250 models)
- 23.4 Carburetor tuning (All 300 EXC EU/AU/Six Days, 300 XC-W US/Six Days)
- 23.5 Carburetor tuning (300 EXC BR)
- 23.6 General carburetor tuning
24 SUBSTANCES
25 AUXILIARY SUBSTANCES
26 STANDARDS
27 LIST OF ABBREVIATIONS
28 LIST OF SYMBOLS
- 28.1 Yellow and orange symbols
- 28.2 Green and blue symbols
INDEX
- A
- B
- C
- D
- E
- F
- G
- H
- I
- K
- L
- M
- O
- P
- R
- S
- T
- U
- V
- W

KTM EXC 125 2016 Owner's Manual

KTM EXC 125 2016 Motorcycle manual cover

Pages 153

Year 2016

Language(s)

of 153

KTM EXC 125 2016 Motorcycle Specification

The KTM EXC 125 2016 is a high-performance off-road motorcycle designed for competitive enduro racing and demanding terrain. It features a lightweight and robust chassis with a Chromium-Molybdenum steel central-tube frame, optimizing rigidity and handling precision. The engine is a single-cylinder, two-stroke, 124.8cc powerhouse that delivers exceptional power-to-weight ratio, with a Keihin PWK 36S AG carburetor ensuring optimal fuel-air mixture for peak performance. The bike's cooling system incorporates a centrifugal water pump and a large radiator to maintain optimal engine temperatures during intense rides.

Suspension components include a WP XPlor 48 upside-down front fork with 300mm of travel and a WP XPlor PDS rear shock absorber offering 310mm of travel, both fully adjustable for compression and rebound damping. This setup provides excellent shock absorption and stability over rough terrain. The braking system is robust, featuring Brembo hydraulic disc brakes with a 260mm front disc and a 220mm rear disc, providing reliable stopping power under varied conditions.

The KTM EXC 125 2016 is equipped with a 6-speed transmission, offering smooth and precise gear shifts, and a wet multi-disc clutch for enhanced durability and easier maintenance. Its exhaust system includes a high-performance expansion chamber and silencer, designed to maximize engine output while complying with noise regulations. The bike's ergonomics are tailored for rider comfort and control, with a slim profile, grippy seat, and adjustable handlebars. The fuel tank capacity is 9.5 liters, providing a good balance between range and weight distribution.

Overall, the KTM EXC 125 2016 combines advanced engineering, high-quality components, and rider-focused design to deliver a top-tier off-road motorcycle that excels in both performance and reliability.

KTM EXC 125 2016 Motorcycle F.A.Q.

What type of engine oil is recommended for the KTM EXC 125 2016?

The recommended engine oil for the KTM EXC 125 2016 is a high-quality synthetic 2-stroke oil.

How often should the air filter be cleaned on the KTM EXC 125 2016?

The air filter should be cleaned after every 5-10 hours of riding, or more frequently in dusty conditions.

What is the correct spark plug type for a KTM EXC 125 2016?

The correct spark plug for the KTM EXC 125 2016 is an NGK BR8ECM.

How can I troubleshoot starting issues with my KTM EXC 125 2016?

Check the fuel supply, inspect the spark plug for wear or fouling, and ensure the battery is charged.

What is the recommended tire pressure for the KTM EXC 125 2016?

The recommended tire pressure is 1.0 to 1.2 bar (14.5 to 17.4 psi) for off-road riding.

How should I maintain the chain on my KTM EXC 125 2016?

Clean and lubricate the chain every 300-500 km, and adjust the tension as needed to ensure it is within specifications.

What are common signs that the carburetor needs to be adjusted on a KTM EXC 125 2016?

Common signs include rough idling, poor throttle response, or excessive smoke.

How do I properly store my KTM EXC 125 2016 for the winter?

Drain the fuel, remove the battery, clean the motorcycle thoroughly, and store it in a dry, covered area.

What should I do if my KTM EXC 125 2016 is overheating?

Check the coolant level, ensure the radiator is not blocked, and inspect the water pump for proper operation.

How can I improve the suspension performance on my KTM EXC 125 2016?

Adjust the suspension settings to match your weight and riding conditions, and consider upgrading to higher-performance components if necessary.