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

Ktm owner's manual motorcycle 125 sx, 250 sx
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OWNER'S MANUAL
2007
125 SX
250 SX
ART. NR. 3.211.174 EN

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Summary of Contents for KTM 125 SX

  • Page 1 OWNER’S MANUAL 2007 125 SX 250 SX ART. NR. 3.211.174 EN...
  • Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
  • Page 3 » INTRODUCTION 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.
  • Page 4 SPARE PARTS, ACCESSORIES For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. TRANSPORT When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position.

  • Page 5: Table Of Contents

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE .......9 Instructions for your first ride ....9 Running in .

  • Page 6: Serial Number Locations

    SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » 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.

  • Page 7: Short Circuit Button

    OPERATION INSTRUMENTS » Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without kinks.

  • Page 8: Shift Lever

    » OPERATION INSTRUMENTS 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 between first and second gear. 2,3,4,5, (6) Kickstarter The kickstarter is mounted on the left side of the engine.

  • Page 9: Rebound Damping Of Fork

    (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps.

  • Page 10: Shock Absorber Rebound Damping

    Severe injuries could be the result. Never unscrew the black screw [5] connection (15mm). – Wear suitable clothing when driving a motorcycle. smart KTM drivers always wear a helmet, boots, gloves, and a jacket, regardless of whether driving all day or just go for a short ride.

  • Page 11: Driving Instructions

    Arrange for the braking system to be checked by an author- ized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings.

  • Page 12: Starting When The Engine Is Warm

    Always pro- vide adequate ventilation while the engine is running. Do not ride your motorcycle with full load and do not rev up the engine when cold. Since the piston warms up and expands faster than the water cooled cylinder, this might cause engine damage.

  • Page 13: Shifting/Riding

    – In the event that, while riding on your motorcycle, you notice any unusual operation-related noise, stop immediately, turn the engine off, and contact an authorized KTM dealer. Braking Turn off the gas and apply the hand and foot brakes at the same time.

  • Page 14: Periodic Maintenance Schedule

    Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver! »...
  • Page 15 » PERIODIC MAINTENANCE SCHEDULE 125/250 SX 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear...

  • Page 16: Maintenance Work On Chassis And Engine

    OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out.

  • Page 17: Basic Suspension Setup For The Weight Of The Driver

    EXAMPLE: Motorcycle jacked up (dimension A) ..... .600 mm Motorcycle on ground, unloaded (dimension B) ... .– 565 mm Static sag .

  • Page 18: Checking The Basic Setup Of The Telescopic Fork

    The type number of the telescopic fork is embossed on the inside of the fork leg axle passage. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged.

  • Page 19: Changing The Fork Offset (Caster) (Xc)

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course.

  • Page 20: Checking And Adjusting The Steering Head Bearing

    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. Tighten 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.

  • Page 21: Check Chain Tension

    The screws [4] must be secured with loctite 243. Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The dis- tance between the chain and the swing arm should be approx.

  • Page 22: Correct Chain Tension

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 23: General Information About Ktm Disc Brakes

    Have the brake disk replaced as soon as it reaches the service limit. – Have any repairs on the brake system be performed by a KTM dealer. BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces- sary to top up the brake fluid.

  • Page 24: Adjusting The Free Travel At The Hand Brake Lever

    If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4].

  • Page 25: Replacing The Front Brake Pads

    If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].

  • Page 26: Checking The Rear Brake Pads

    Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground.

  • Page 27: Dismounting And Mounting The Rear Wheel

    – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.

  • Page 28: Tires, Air Pressure

    – Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle behaves.

  • Page 29: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE 10 mm when engine ist cold Cooling system The water pump [1] in the engine circulates the cooling liquid. The cooling liquid is cooled by the air stream. This means that the cooling effect decreases with the traveling speed.

  • Page 30: Cleaning The Air Filter

    [2] and filter support [3] from the filter box. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter maintenance (Bio Dirt Remover and Liquid Bio Power).

  • Page 31: Changing The Original Position Of The Clutch Lever

    If necessary, add SAE 10 biodegradable hydraulic oil (Motorex clutch fluid 75), available from your authorized KTM shop. KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic clutch in 125/200 models. Do not mix this oil with any other hydraulic oil. Always use original KTM hydraulic oil (available from your authorized KTM workshop) to make sure your clutch operates smoothly.

  • Page 32: Carburetor Adjustment

    After you finish bleeding, remove the bleeder syringe, mount the bleeder screw, correct the level in the reservoir and mount the cover (see above). 1:40 (125 SX), 1:60 (250 SX) > choose leaner carburetor adjustment > choose richer carburetor adjustment...

  • Page 33: Draining The Float Chamber Of The Carburetor

    MAINTENANCE WORK ON CHASSIS AND ENGINE JET NEEDLE RANGE OF ACTION TYPE RICHER R1468D R1469D R1470D R1471D JET NEEDLE RANGE OF ACTION TYPE RICHER N1EF N1EG N1EH N1EI N1EJ 60° Part-throttle range C main jet Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position).

  • Page 34: Adjusting The Engine Characteristic Via The Ignition Curve

    Auxiliary spring for aggressive engine characteristic (included in scope of sup- ply). Spare part number 548.37.072.000, RED color mark To mount, tilt the motorcycle approx. 45° to the left, remove both screws [2], lift off the closing cover [3] and remove the springs including the spring insert [4] from the clutch cover.

  • Page 35: Check Transmission Oil Level (125)

    4T 15W50). Changing the transmission oil (125 SX) To change the gear oil warm up the engine and park the motorcycle on a hor- izontal surface. Remove oil drain plugs [3] and [4] and drain the used oil into an appropriate container. Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets.

  • Page 36: Cleaning

    – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.

  • Page 37: Technical Specifications - Chassis 125 / 250

    Chain Steering head angle Wheel base Seat height, unloaded Ground clearance, unloaded Weight (without fuel) STANDARD ADJUSTMENT – FORK 125 SX WP 4860 MXMA CC WP 4860 MXMA CC 14.18.7C.01 Compression adjuster 18 Rebound adjuster Spring 432.455.00.042W 432.455.00.044W Fork oil...
  • Page 38 TECHNICAL SPECIFICATIONS – CHASSIS 125/250 SX 2007 TIGHTENING TORQUES – CHASSIS Collar screw, front wheel spindle Brake caliper, front Brake disks Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, upper steering stem Blind srcew (top) Collar screw (bottom) Clamping screws, fork stubs Collar nut, rear wheel spindle Hexagon nut, swing arm bolt...

  • Page 39: Technical Specifications - Engine 125 / 250

    TECHNICAL SPECIFICATIONS – ENGINE 125/250 SX 2007 ENGINE 125 SX Design Liquid-cooled, single-cylinder, two-stroke engine with intake and exhaust control Piston displacement 124,8 cm Bore / stroke 54 / 54,5 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91), mixed with high grade two stroke oil...
  • Page 40 Nuts-cylinder base (250 SX) Flywheel collar nut Nut for primary sprocket (125 SX) Nut for primary sprocket (250 SX) Nut for inner clutch hub (125 SX) Nut for inner clutch hub (250 SX) Bundschraube Kupplungsfeder Oil drain plug (125/250 SX)

  • Page 41: Index

    Changing the transmission oil (125) ... . .34 Changing the original position of the clutch lever ..30 Changing the oil level of hydraulic clutch 125 SX ..30 Changing the oil level of hydraulic clutch 250 SX ..30 Changing the spring preload on the telescopic fork .
  • Page 42 » SCHALTPLAN WIRING DIAGRAMM red-white red-black green...
  • Page 43 » SCHALTPLAN WIRING DIAGRAMM ENGLISH CABLE COLOURS bl: black ye: yellow bu: blue gr: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple ENGLISH CABLE COLOURS bl: black ye: yellow bu: blue gr: green re: red wh: white br: brown...
  • Page 44 LSO = Luftregulierschraube offen = Leerlaufdüse POS = Nadel Clip Position von oben = Hauptdüse NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 95 CARBURETOR TABLE 125 SX 2007 - 6°C bis 5°C 6°C bis 15°C 19°F to 41°F 42°F to 60°F 1,75 R1470D...
  • Page 45 VERGASERTABELLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK-S 36 AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C ALTITUDE TEMPERATURE 3000 m 10000 ft NADEL NEEDLE 2301 m 7501 ft 2300 m 7500 ft NADEL NEEDLE 1501 m 5001 ft 1500 m 5000 ft NADEL NEEDLE 751 m 2501 ft...
  • Page 46 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

125 sx 2007250 sx 2007

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