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KTM 125 SX User Manual [Page 5]: Table Of Contents

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IMPORTANT WARRANTY AND GUARANTEE INFORMATION .3

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .5

Clutch lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Electronic speedometer, indicator lamp (EXC) . . . . . . . . .6

Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . .6

Tripmaster switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Activating/deactivating the display modes . . . . . . . . . . . .9

Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Short circuit button (SX) . . . . . . . . . . . . . . . . . . . . . . . .11

Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . .11

Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . . . . .11

Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Emergency OFF switch (Australia) . . . . . . . . . . . . . . . . .11

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Choke knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Compression damping of fork . . . . . . . . . . . . . . . . . . . .14

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .14

Damping action during compression of shock absorber (SX) .14

Compression damping of shock absorber (MXC, EXC) . .15

Rebound damping of shock absorber (SX, MXC, EXC) . .15

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Instructions for your first ride . . . . . . . . . . . . . . . . . . . . .16

Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .17

What you should check before each start . . . . . . . . . . .17

Starting when the engine is cold . . . . . . . . . . . . . . . . . .18

Starting when the engine is warm . . . . . . . . . . . . . . . . .18

What to do when the engine is "flooded" . . . . . . . . . . .18

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . .19

Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . .20

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .24

Checking and adjusting the steering head bearing . . . . .24

How to change the handlebar position . . . . . . . . . . . . .25

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .25

Cleaning the dust sleeves of the telescopic fork . . . . . . .25

Basic suspension setup for the weight of the driver . . . .26

Checking the shock absorber and spring . . . . . . . . . . . .26

Determining the static sag of the shock absorber . . . . . .26

Determining the riding sag of the shock absorber . . . . .26

Page

Checking the basic setup of the telescopic fork . . . . . . .27

Changing the spring preload on the telescopic fork (SX models) .27

Changing the spring preload on the telescopic fork

(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . . . . .27

Adjusting the spring preload on the fork (SX) . . . . . . . .28

Changing the spring preloading of the shock absorber .28

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Check chain tension

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

General information about KTM disc brakes . . . . . . . . .31

Adjusting the free travel at the hand brake lever . . . . . .32

Checking the brake fluid level - front brake . . . . . . . . . .32

Refilling the front brake fluid reservoir . . . . . . . . . . . . . .32

Checking the front brake pads . . . . . . . . . . . . . . . . . . . .32

Replacing the front brake pads . . . . . . . . . . . . . . . . . . .33

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .34

Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . .34

Dismounting and mounting the front wheel . . . . . . . . .34

Dismounting and mounting the rear wheel . . . . . . . . . .35

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .36

Replacing the battery of the digital speedometer . . . . . .36

Check/set distance of the magnetic sensor . . . . . . . . . .37

Replacing the headlight lamp/parking light lamp . . . . . .37

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Radiator cover for the cold season . . . . . . . . . . . . . . . . .38

Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . .38

Refilling/Bleeding the cooling system

Changing the original position of the clutch lever . . . . .40

Checking the oil level of the hydraulic clutch

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . . .40

Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Carburetor adjustment

Cleaning the spark arrestor (EXC USA) . . . . . . . . . . . . .41

Draining the float chamber of the carburetor . . . . . . . . .42

Checking the float level . . . . . . . . . . . . . . . . . . . . . . . . .42

Engine characteristic 250/300 SX/MXC/EXC . . . . . . . . .43

Check transmission oil level (125/200) . . . . . . . . . . . . .44

Changing the transmission oil (125/200) . . . . . . . . . . . .44

Check transmission oil level (250/300) . . . . . . . . . . . . .44

Changing the transmission oil (250/300) . . . . . . . . . . . .44

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .45

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

USE AFTER A PERIOD OF STORAGE

TECHNICAL SPECIFICATIONS – CHASSIS 125 / 200 . . . . .46

TECHNICAL DATA – ENGINE 125 / 200 . . . . . . . . . . . . . .48

TECHNICAL SPECIFICATIONS – CHASSIS 250/300 . . . . . .50

TECHNICAL DATA – ENGINE 250/300 2004 . . . . . . . . . .52

WIRING DIAGRAM, CARBURETOR SETTING . . . .APPENDIX

. . . . . . . . . . . . . . . . . . . . . . . . . . .29

. . . . . . . . . . . . . .39

. . . . . . . .40

. . . . . . . . . . . . . . . . . . . . . . . . .41

. . . . . . . . . . . . . .45

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KTM 125 SX User Manual [Page 5]: Table Of Contents

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