KTM 125SX Owner's Handbook Manual
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KTM 125SX Owner's Handbook Manual

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Summary of Contents for KTM 125SX

  • Page 3: Chassis Number

    (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS...
  • Page 4 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this opportunity to thank you for putting your trust in us; we will not let you down. You are now owner of a sporty and modern motorcycle which you are bound to have a great time with provided you care for it properly.

  • Page 5: Table Of Contents

    All models out of USA ......39 General informations about KTM disc brakes ..18 Head Word Index .

  • Page 6: Serial Number Locations

    SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1. Engine number, engine type (125/200) The engine number and the engine type are stamped into the left side of the engine below the engine sprocket.

  • Page 7: Digital Speedometer, Indicator Lamp (Exc)

    Digital speedometer, indicator lamp (EXC) The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp 2 lights up when the high beam is on. Speedometer – digital Some models are equipped with a digital speedometer KMH = Speed, max.

  • Page 8: Combination Switch (Exc)

    Combination switch (EXC) The light switch has 2, respetively 3 switch positions. = Light off (this function is not available in all models) = Low beam on = High beam on You may use button to actuate the horn. The red short circuit button serves to switch off the engine.

  • Page 9: Refueling, Fuel

    125-380: Unleaded premium gasoline RON 95 mixed with high grade two stroke oil. Mixture ratio 1:40 - 1:60 Fuel and engine oil should only be mixed immediately before use. 35 mm KTM recommends SHELL ADVANCE RACING X. WARNING ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS XTREME CAUTION SHOULD BE USED...

  • Page 10: Shift Lever

    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 bet- ween first and second gear. 2,3,4,5 (6) Kickstarter The kickstarter is mounted on the left side of the engine.

  • Page 11: Compression Damping Of Shock Absorber

    Compression damping of shock absorber The damping force of the compression damping can be adjusted with knob The higher the number the higher the damping force. STANDARD ADJUSTMENT: Type White Power 1218V728 ....5 clicks Type White Power 1218V729 ....5 clicks Type White Power 1218V730 ....5 clicks Type White Power 1218V731 ....5 clicks WARNING...

  • Page 12: Driving Instructions

    – Do not make any alterations to the motorcycle, and always Check for damaged tyres. Tires showing cuts or dents must use ORIGINAL KTM SPARE PARTS. Spare parts from other be replaced. The tread depth must comply with the legal manufacturers can impair the safety of the motorcycle.

  • Page 13: Starting Off

    – D – R O NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED EPLACE THE HELMET VISOR OR GOGGLE GLASSES EARLY ENOUGH AREA XHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF HEN LIGHT SHINES DIRECTLY ON A SCRATCHED VISOR OR GOGGLES CONSCIOUSNESS AND DEATH LWAYS PROVIDE ADEQUATE VENTILA YOU WILL BE PRACTICALLY BLIND...

  • Page 14: Periodic Maintenance Schedule

    125/200 SX/MXC/EXC PERIODIC MAINTENANCE SCHEDULE 250/300/380 SX/MXC/EXC 1. service after after after 10 hours 20 hours 4000 kilometer A washed motorcycle can be checked more quickly which saves money! 1000 kilometer 2000 kilometer once a year Check gear box oil level Change gear box oil Check spark plugs, adjust distance between electrodes Renew spark plugs...
  • Page 15 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Check gear box oil level Check break fluid level Check break pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regulary Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box...

  • Page 16: 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.

  • Page 17: Breather Plug Front Fork

    Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground.

  • Page 18: Changing The Spring Preloading Of The Shock Absorber

    Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring . For this purpose, you should dismount the shock absorber and clean it thoroughly. NOTE: – Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring.

  • Page 19: Correct Chain Tension

    Correct chain tension Loosen collar nut , loosen lock nuts , and turn right and left adjusting screws equally far. Tighten lock nuts. Before tightening the collar nut, verify that the chain adjusters are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel.

  • Page 20: General Informations About Ktm Disc Brakes

    DOT 5.1. Never use brake fluid DOT 5. The color of this silicon oil-based product is purple red. The gaskets and brake hoses of KTM motorcycles are not desi- gned for DOT 5 brake fluid! Adjusting of free travel at the hand brake lever...

  • Page 21: Checking Of Brake Fluid Level - Front Brake

    Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the hand- lebar and the reservoir is provided with an inspection glass. With the reservoir in a horizontal position, the brake fluid level should not drop below the middle of the glass.

  • Page 22: Changing The Basic Position Of The Foot Brake Pedal

    Mount the right brake pad and fix it with the bolt. Mount the left brake pad and insert the bolt until it stops. Mount the clips. When mounting the brake pads, be sure to check for correct fit of the sli- ding metal-sheet in the caliper support and of the leaf spring WARNING...

  • Page 23: Checking The Rear Brake Pads

    Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings 1 mm may not be less than 1 mm (0.04 in). WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN ’...

  • Page 24: Dismounting And Mounting The Rear Wheel

    The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer. Mount collar nut , turn speedometer drive in a way that the flexible spee- dometer shaft will curve upwards in a slight bow (see pict.) and tighten collar nut to 40 Nm (30 ft.lb).

  • Page 25: Tires-Air Pressure

    (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING...
  • Page 26 1. use the right button to 2. push the left button until TOTAL MILEAGE „DST“ select the position to be the right figure is showed changed in the display AFTER CHANGING BATTERY 1 sec 5. push the button on the back with a sharp object approx.

  • Page 27: Adjustin Digital Speedometer

    WHEEL CIRCUMFERENCE „WS“ 1. make sure that the indication 2. use the right button to select the position 5 sec "TRP" is active and push the but- to be changed ton on the back approx. 5 seconds ("WS" appears) 1 sec 5.

  • Page 28: Replacing Headlight Lamp (H4)

    Replacing headlight lamp (H4) Loosen both rubber bands and tilt headlight mask to the front. Remove bulb plug and remove rubber cap . Turn the supporting ring counter- clockwise and remove it from the reflector together with the bulb. Insert a new bulb such that the noses fit into the recess .

  • Page 29: Radiator Cover For The Cold Season

    Remount the radiator protection. NOTE: The radiator shutter can be obtained from your KTM dealer Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (cf.

  • Page 30: Cleaning The Air Filter

    . Use adhesive tape to attach the new glass-fiber yarn packing to the inner tube, and slide on outer tube. Mount silencer cap. Glass-fiber yarn packings are available at your authorized KTM dealer. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING...

  • Page 31: Carburetor Adjustment

    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 tempe- rature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ). Mixing ratio (2-stroke motor oil : super fuel) 1:40 –...

  • Page 32: Checking The Float Level

    SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore of the master cylinder in a bubble-free state. Make sure that the oil does not over- flow. The bleeder syringe can be purchased at your KTM dealer. CAUTION AVING COMPLETED THE BLEEDING PROCEDURE...

  • Page 33: Check Transmission Oil Level (125/200)

    Check transmission oil level (125/200) In order to check the transmission oil level the control screw on the clutch cover is to be removed. Oil should just barely escape from the inspection opening when the motorcycle is in an upright position. If necessary, remove the plug and top up with engine oil 20W-40 (i.

  • Page 34: Cleaning

    CLEANING 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. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 35: Technical Specifications - Chassis (125/200)

    TECHNICAL SPECIFICATIONS CHASSIS 125 SX / EXC, 200 MXC / EXC 2001 125 SX 125 EXC 200 MXC 200 EXC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm (11,3/12,6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake...
  • Page 37 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head 18 Nm (13 ft.lb) Nuts-cylinder base 30 Nm (22 ft.lb) Flywheel collar nut M 12x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 16x1.5 180 Nm (133 ft.lb) Nut for inner clutch hub M 18x1.5 120 Nm (88 ft.lb)

  • Page 38: Technical Specifications - Chassis (250/300/380)

    TECHNICAL SPECIFICATIONS CHASSIS 250/300/380 SX, MXC, EXC 2001 250/380 SX 250/300/380 MXC 250/300/380 EXC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm (11,3/12,6 in) Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disc brake with carbon-steel brake disc Ø...
  • Page 40 TIGHTENING TORQUES - ENGINE Flange bolts - cylinder-head 35 Nm (25 ft.lb) Nuts-cylinder base M 10 35 Nm (25 ft.lb) Flywheel collar nut M 12x1 60 Nm (44 ft.lb) Nut for primary sprocket (LH thread) M 18x1.5 Loctite 243 150 Nm (110 ft.lb) Nut for inner clutch hub M 18x1.5 Loctite 243 100 Nm (74 ft.lb)

  • Page 43: Head Word Index

    FUEL TAP ........7 CHANGING THE BASIC POSITION OF THE FOOT BRAKE PEDAL . . .20 GENERAL INFORMATIONS ABOUT KTM DISC BRAKES .18 CHANGING THE ORIGINAL POSITION OF THE CLUTCH LEVER 14 HAND BRAKE LEVER .
  • Page 45 320590...

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