KTM 125 SX Owner's Manual
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- Owner's manual (135 pages) ,
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- Owner's manual (48 pages)
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Related Manuals for KTM 125 SX
Summary of Contents for KTM 125 SX
- Page 1 OWNER'S MANUAL 2016 125 SX 150 SX 250 SX 250 XC 300 XC Art. no. 3213330en...
- Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.
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Page 4: Table Of Contents
TABLE OF CONTENTS Starting off............. 24 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Shifting, riding ..........24 Symbols used ........... 5 Braking ............25 Formats used............ 5 Stopping, parking..........25 SAFETY ADVICE............6 Transport ............26 Use definition - intended use ......6 Refueling ............ - Page 5 TABLE OF CONTENTS 11.23 Installing the air filter box cover ....... 58 15.4 Removing the radiator cover (All 125/150 models)............93 11.24 Removing the air filter ......... 59 15.5 Checking the antifreeze and coolant level ..93 11.25 Cleaning the air filter and air filter box ..
- Page 6 TABLE OF CONTENTS 21.4 Capacities ............ 126 21.4.1 Gear oil............ 126 21.4.2 Coolant ............ 126 21.4.3 Fuel ............126 21.5 Chassis ............126 21.6 Electrical system........... 127 21.7 Tires ............127 21.8 Fork............. 128 21.8.1 125/150 SX EU........128 21.8.2 125/150 SX US........
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Page 7: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required. -
Page 8: Safety Advice
Use definition - intended use (All SX models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. -
Page 9: Safe Operation
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer. -
Page 10: Important Notes
Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) H00044-10 Hand brake lever ( p. 12) Kill switch ( p. 12) Clutch lever ( p. 12) Air filter box cover Plug-in stand Shift lever ( p. 15) Choke ( p. 15) Fuel tap... -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) H00043-10 Seat Filler cap Throttle grip ( p. 12) Kick starter ( p. 15) Foot brake lever ( p. 16) Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment... -
Page 13: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. -
Page 14: Controls
CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically. L01224-11 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. -
Page 15: Opening The Filler Cap
CONTROLS Opening the filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 16: Fuel Tap (All Sx Models)
CONTROLS Fuel tap (All SX models) (All 125/150 models) Fuel tap is on the left of the fuel tank. M01127-10 (250 SX) Fuel tap is on the left of the fuel tank. Possible states (All 125/150 models) Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. •... -
Page 17: Choke
CONTROLS 6.10 Choke Choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start. -
Page 18: Foot Brake Lever
CONTROLS 6.13 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 401956-10 6.14 Plug-in stand (All SX models) The holder for plug-in stand ... -
Page 19: Preparing For Use
When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover. -
Page 20: Running In The Engine
PREPARING FOR USE – Do not exceed the maximum permissible weight and the maximum permissible axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) –... - Page 21 Sand cover for air filter (59006022000) Info See the KTM PowerParts fitting instructions. M01102-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Clean the chain. Chain cleaner ( p. 136) –...
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Page 22: Preparing For Rides On Wet Sand
Rain cover for air filter (59006021000) Info See the KTM PowerParts fitting instructions. M01103-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Clean the chain. Chain cleaner ( p. 136) –... -
Page 23: Preparing For Rides On Wet And Muddy Surfaces
Rain cover for air filter (59006021000) Info See the KTM PowerParts fitting instructions. M01103-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01 – Fit the steel sprocket. – Clean the motorcycle. ( p. 107) –... -
Page 24: Preparing For Rides At Low Temperature Or In Snow
Fit a waterproofing device on the air filter. Rain cover for air filter (59006021000) Info See the KTM PowerParts fitting instructions. M01103-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01... -
Page 25: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 103) –... -
Page 26: Starting Off
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines. -
Page 27: Braking
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system. -
Page 28: Transport
RIDING INSTRUCTIONS Transport Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. -
Page 29: Service Schedule
Check the screws and nuts for tightness. ● ● Check idle. ● ● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ● Periodic interval... -
Page 30: Service Work (As Additional Order)
SERVICE SCHEDULE 9.1.2 Service work (as additional order) Annually Every 40 operating hours Every 30 operating hours Once after 20 operating hours Every 10 operating hours/after every race Once after 10 operating hours ● Change the front brake fluid. ● Change the rear brake fluid. -
Page 31: Service Work (As Additional Order)
● Final check: Check the vehicle for safe operation and take a test ride. ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ● Periodic interval 9.2.2 Service work (as additional order) -
Page 32: Tuning The Chassis
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight. – As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing). Guideline Standard rider weight 75…... -
Page 33: Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber. -
Page 34: Adjusting The High-Speed Compression Damping Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed setting can be seen in fast compression of the shock absorber. -
Page 35: Adjusting The Rebound Damping Of The Shock Absorber
Adjusting the rebound damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – ... -
Page 36: Measuring The Rear Wheel Sag Unloaded
TUNING THE CHASSIS Guideline Rebound damping (125/150 SX EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (125/150 SX US) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (250 SX EU) Comfort 17 clicks Standard 15 clicks Sport... -
Page 37: Checking The Static Sag Of The Shock Absorber
TUNING THE CHASSIS (All 250/300 models) – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the rear fairing. – Note down the value as dimension 400988-10 Finishing work –... -
Page 38: Checking The Riding Sag Of The Shock Absorber
Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 39: Adjusting The Riding Sag
TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work (All 125/150 models) – Loosen screw – Turn adjusting ring until the spring is no longer under tension. Hook wrench (T106S) – Measure the overall spring length while the spring is not under tension. –... - Page 40 TUNING THE CHASSIS Main work – Choose and mount a suitable spring. Guideline Spring rate (125/150 SX EU) Weight of rider: 65… 75 kg (143… 39 N/mm (223 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165… 42 N/mm (240 lb/in) 187 lb.) Weight of rider: 85…...
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Page 41: Checking The Basic Setting Of The Fork
S00861-10 Info This is due to the volume of the hose and not due to a defect in the fork pump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 8.2 bar (119 psi) -
Page 42: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS – Mount the protection cap. Finishing work – Remove the motorcycle from the lift stand. ( p. 44) 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. (125/150 SX EU) –... -
Page 43: Adjusting The Rebound Damping Of The Fork
TUNING THE CHASSIS Guideline Compression damping (125/150 SX US) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping (250 SX US) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping (All XC models) Comfort 17 clicks Standard 15 clicks Sport... -
Page 44: Handlebar Position
TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. – Mount protection caps (125/150 SX US, All XC models, 250 SX US) – Turn the red adjusting screw all the way clockwise. Info The adjusting screw ... - Page 45 TUNING THE CHASSIS Main work – Remove screws . Take off the handlebar clamps. Remove the handlebar and lay it to one side. Info Cover the components to protect them against damage. Do not kink the cables and lines. –...
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Page 46: Service Work On The Chassis
SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. –... -
Page 47: Bleeding The Fork Legs
SERVICE WORK ON THE CHASSIS 11.3 Bleeding the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work (125/150 SX EU) – Release bleeder screws Any excess pressure escapes from the interior of the fork. –... -
Page 48: Removing The Fork Legs
SERVICE WORK ON THE CHASSIS 11.5 Removing the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) – Remove the front wheel. p. 84) Main work – Remove screws and take off the clamp. –... -
Page 49: Removing The Fork Protector
SERVICE WORK ON THE CHASSIS – Tighten screws Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) – Tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) M01135-11 – Position the brake caliper. Mount and tighten screws Guideline Loctite ®... -
Page 50: Installing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Pull off the upper triple clamp with the handlebar and hang to the side. Info Protect the components against damage by covering them. Do not kink the cables and lines. M01136-10 –... - Page 51 SERVICE WORK ON THE CHASSIS (250 SX EU) – Position the fork legs. Bleeder screws are positioned toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp.
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Page 52: Checking The Play Of The Steering Head Bearing
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam- aged over time. -
Page 53: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Main work – Loosen screws . Remove screw – Loosen and retighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. –... -
Page 54: Installing The Start Number Plate
SERVICE WORK ON THE CHASSIS 11.15 Installing the start number plate (All 125/150 models) – Connect the brake line at the start number plate. – Position the start number plate. The holding lugs engage in the fender. – Mount and tighten screw Guideline Remaining screws, chassis 10 Nm... - Page 55 SERVICE WORK ON THE CHASSIS Main work (All 125/150 models) – Remove screws with the washers. – Remove the cable ties and remove the frame protectors on the left and right. M01145-10 – Remove screw – Remove fitting Info Raise the wheel slightly to be able to remove the screws more easily.
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Page 56: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Hold the shock absorber and remove screw M01151-10 – Carefully take the shock absorber out of the vehicle toward the bottom. M01152-01 (All 250/300 models) – Remove screw – Remove fitting B02098-10 –... - Page 57 SERVICE WORK ON THE CHASSIS – Mount and tighten screw Guideline Screw, top shock 60 Nm Loctite ® 2701™ absorber (44.3 lbf ft) M01151-11 – Position the swingarm and mount the swingarm pivot. Info Pay attention to the flat area –...
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Page 58: Removing The Seat
SERVICE WORK ON THE CHASSIS (All 250/300 models) – Raise the swingarm slightly, and carefully position the shock absorber in the vehicle from the top. – Mount and tighten screw Guideline Screw, top shock 60 Nm Loctite ® 2701™ absorber (44.3 lbf ft) B02100-11... -
Page 59: Removing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) M01156-10 (All 250/300 models) – Mount the front seat on to the collar bushing of the fuel tank, lower it at the rear, and simultaneously push it forward. -
Page 60: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS – Pull off the air filter box cover in area sideways and remove it toward the front. B02101-11 11.23 Installing the air filter box cover (All 125/150 models) – Insert the air filter box cover in area and clip it into area M01158-12 Condition... -
Page 61: Removing The Air Filter
SERVICE WORK ON THE CHASSIS 11.24 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 62: Installing The Air Filter
SERVICE WORK ON THE CHASSIS 11.26 Installing the air filter Main work (All 125/150 models) – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 136) 102178-10 –... -
Page 63: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS (All 250/300 models) – Drill a hole at markings Guideline Diameter 6 mm (0.24 in) C00229-10 Finishing work – Install the air filter box cover. ( p. 58) 11.28 Sealing the air filter box Preparatory work –... -
Page 64: Installing The Main Silencer
SERVICE WORK ON THE CHASSIS (All 250/300 models) – Remove screws with the washers. – Pull off the main silencer from the manifold at rubber sleeve L00924-10 11.30 Installing the main silencer (All 125/150 models) – Position the main silencer with rubber sleeve –... -
Page 65: Removing The Fuel Tank
SERVICE WORK ON THE CHASSIS Main work – Remove screws . Pull out inner tube – Remove the glass fiber yarn filling from the inner tube. – Clean the parts that need to be reinstalled and check for damage. –... -
Page 66: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. – Pull the hose off the fuel tank breather on the tank lid. M01164-10 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. - Page 67 SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water.
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Page 68: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS – Mount and tighten screws with the collar bushings. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the fuel hose. M01185-11 Finishing work – Mount the seat. ( p. 56) 11.34 Checking the chain for dirt –... -
Page 69: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS 11.36 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. -
Page 70: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws to the left and right. Guideline Chain tension 55… 58 mm (2.17… 2.28 in) Turn adjusting screws ... - Page 71 SERVICE WORK ON THE CHASSIS (All 125/150 models) – Check the chain sliding guard for wear. » If the lower edge of the chain pin is at the level of or below the chain slid- ing guard: – Change the chain sliding guard. –...
- Page 72 SERVICE WORK ON THE CHASSIS (All 250/300 models) – Check the chain sliding guard for wear. » If the lower edge of the chain pin is at the level of or below the chain slid- ing guard: – Change the chain sliding guard. –...
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Page 73: Checking The Frame
If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must be replaced. Repair of the frame is not authorized by KTM. M01118-01 11.40 Checking the swingarm –... -
Page 74: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS Main work (All 125/150 models) – Check the routing of the throttle cable. The throttle cable must be routed along the back of the handlebar, to the right of the frame, below the fuel tank bracket, and to the carburetor. The throttle cable must be fixed on the fuel tank bracket with a rubber band. -
Page 75: Additionally Securing The Rubber Grip
SERVICE WORK ON THE CHASSIS 11.43 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 72) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip. - Page 76 SERVICE WORK ON THE CHASSIS (All 125/150 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Remove screws – Remove cover with membrane L01222-10 – Fill bleeding syringe with the appropriate hydraulic fluid.
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Page 77: Brake System
Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc ... -
Page 78: Checking The Front Brake Fluid Level
KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –... -
Page 79: Checking The Front Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. - Page 80 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.
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Page 81: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Correct the brake fluid quantity to level Guideline 5 mm (0.2 in) Dimension (brake fluid level below top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 134) – Position the cover with the membrane. Mount and tighten the screws. Info L00956-11 Wash off overflowed or spilled brake fluid immediately with water. -
Page 82: Checking The Rear Brake Fluid Level
KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –... -
Page 83: Adding Rear Brake Fluid
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 84: Checking The Rear Brake Linings
Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage. - Page 85 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.
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Page 86: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 44) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 87: Removing The Rear Wheel
WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) –... -
Page 88: Installing The Rear Wheel
Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle. -
Page 89: Checking The Tire Air Pressure
Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes. - Page 90 WHEELS, TIRES » If the spoke tension varies: – Correct the spoke tension. – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Torque wrench with various accessories in set (58429094000)
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Page 91: Electrical System
ELECTRICAL SYSTEM 14.1 Removing the battery (All XC 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. –... -
Page 92: Recharging The Battery (All Xc Models)
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. -
Page 93: Change The Main Fuse (All Xc Models)
ELECTRICAL SYSTEM 14.4 Change the main fuse (All XC models) Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the air filter box cover. -
Page 94: Cooling System
COOLING SYSTEM 15.1 Cooling system (All 125/150 models) Water pump in the engine ensures forced circulation of the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. -
Page 95: Removing The Radiator Cover (All 125/150 Models)
COOLING SYSTEM – Position the matching radiator cover ( p. 92). The larger catch is located at the top left. Info Do not use both radiator covers at the same time. M01125-01 – Position radiator shield – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 96: Checking The Coolant Level
COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the antifreeze in the coolant does not match the specified value: –... -
Page 97: Refilling With Coolant
COOLING SYSTEM – Position the motorcycle upright. – Place a suitable container under the water pump cover. (All 125/150 models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. - Page 98 COOLING SYSTEM (All 250/300 models) – Make sure that screw is tightened. B02126-10 – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant 1.2 l (1.3 qt.) Coolant ( p. 134) – Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
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Page 99: Tuning The Engine
TUNING THE ENGINE 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to determine the play in throttle cable Play in throttle cable 2…... -
Page 100: Carburetor - Idle
TUNING THE ENGINE – Check the play in the throttle cable. ( p. 97) Carburetor – idle 16.3 The idle setting of the carburetor has a big influence on the starting behavior, stable idling, and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. -
Page 101: Ignition Curve Plug-In Connector
TUNING THE ENGINE Guideline Idle air adjusting screw (All 125 models) Open 2 turns Idle air adjusting screw (All 150 models) Open 1 turn Idle air adjusting screw (250 SX) Open 2 turns Idle air adjusting screw (250 XC) Open 2 turns Idle air adjusting screw (300 XC) Open... -
Page 102: Changing The Ignition Timing Map
TUNING THE ENGINE (All 250/300 models) The plug-in connector is located on the frame under the fuel tank. Possible states (All 125/150 models) Soft – The plug-in connection of the ignition timing map is disconnected to • achieve better rideability. Performance –... -
Page 103: Adjusting The Basic Position Of The Shift Lever
TUNING THE ENGINE 16.8 Adjusting the basic position of the shift lever – Remove screw and take off shift lever 401950-12 – Clean gear teeth of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. - Page 104 TUNING THE ENGINE – Remove cap , adjusting spring , auxiliary spring , and spring insert from the clutch cover. – Pull both springs off of the spring insert. B00056-11 – Mount the required auxiliary spring and adjusting spring and position them together in the clutch cover.
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Page 105: Service Work On The Engine
SERVICE WORK ON THE ENGINE 17.1 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –... -
Page 106: Changing The Gear Oil
SERVICE WORK ON THE ENGINE Main work (All 125/150 models) – Remove the gear oil monitoring screw – Check the gear oil level. A small quantity of gear oil must run out of the drilled hole. » If no gear oil runs out: –... -
Page 107: Refilling With Gear Oil
SERVICE WORK ON THE ENGINE Preparatory work – Park the motorcycle on a level surface. – Place a suitable container under the engine. Main work (All 125/150 models) – Remove the gear oil drain plug with magnet – Remove gear oil drain plug –... -
Page 108: Adding Gear Oil
SERVICE WORK ON THE ENGINE 17.6 Adding gear oil Info Too little gear oil or poor-quality gear oil results in premature wear to the transmission. Gear oil must only be topped up when the engine is cold. Preparatory work – Park the motorcycle on a level surface. -
Page 109: Cleaning, Care
CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. -
Page 110: Storage
– Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 44) –... -
Page 111: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 23) tric starter) – Battery discharged Recharge the battery. p. 90) (All XC models) – Check the charging voltage. –... - Page 112 TROUBLESHOOTING Faults Possible cause Action (All 125/150 models) Engine stalls or is popping into the Lack of fuel – carburetor Turn handle of the fuel tap to the ON position. (Figure M01127-10 p. 14) (250 SX) – Turn handle of the fuel tap to the ON position.
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Page 113: Technical Data
TECHNICAL DATA 21.1 Engine 21.1.1 All 125 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing... - Page 114 TECHNICAL DATA Sixth gear 22:24 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 21.1.3 250 SX Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³...
- Page 115 TECHNICAL DATA Piston rings 2 half keystone rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48 mm (1.89 in) Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydraulically activated Gearbox 6-gear, claw shifted Transmission ratio...
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Page 116: Engine Tightening Torques
TECHNICAL DATA 21.2 Engine tightening torques 21.2.1 All 125/150 models – Screw, inner membrane sheets EJOT DELTA PT ® 35x25 1 Nm (0.7 lbf ft) – Screw, membrane core plate EJOT DELTA PT ® 30x12 1 Nm (0.7 lbf ft) –... -
Page 117: All Xc Models
TECHNICAL DATA Loctite ® 243™ Screw, locking lever 6 Nm (4.4 lbf ft) Screw, retaining bracket of exhaust 7 Nm (5.2 lbf ft) Loctite ® 2701™ control Loctite 222™ Screw, stator 6 Nm (4.4 lbf ft) ® Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite ®... - Page 118 TECHNICAL DATA – Screw, gear oil level check 10 Nm (7.4 lbf ft) – Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) Screw, intermediate wheel bolt 8 Nm (5.9 lbf ft) Loctite ® 648™ Screw, kick starter spring 10 Nm (7.4 lbf ft) Loctite ®...
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Page 119: Carburetor
TECHNICAL DATA 21.3 Carburetor 21.3.1 All 125 models Carburetor type KEIHIN PWK 38S AG Carburetor identification number BS5_0 Needle position 2nd position from top Jet needle N1EF (N1EE, N1EG) Main jet 182 (180, 185) Idling jet 50 (48, 52) Starting jet Idle air adjusting screw Open 2 turns... -
Page 120: Carburetor Tuning (All 125 Models)
TECHNICAL DATA 21.3.3 Carburetor tuning (All 125 models) KEIHIN PWK 38S AG -20°C ... -7°C -6°C ... 5°C 6°C ... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C M/FT ASL TEMP ... -
Page 121: All 150 Models
TECHNICAL DATA 21.3.4 All 150 models Carburetor type KEIHIN PWK 38S AG Carburetor identification number BS6_0 Needle position 1st position from top Jet needle N0ZG (N0ZE, N0ZF) Main jet 180 (182, 185) Idling jet 45 (48, 50) Starting jet Idle air adjusting screw Open 1 turn Throttle slide... -
Page 122: Carburetor Tuning (All 150 Models)
TECHNICAL DATA 21.3.6 Carburetor tuning (All 150 models) KEIHIN PWK 38S AG -20°C ... -7°C -6°C ... 5°C 6°C ... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C M/FT ASL TEMP ... -
Page 123: Carburetor - Basic Setting For Sandy Surfaces (250 Sx)
TECHNICAL DATA 21.3.7 250 SX Carburetor type KEIHIN PWK 36S AG Carburetor identification number BS8_0 Needle position 2nd position from top Jet needle N1EH (N1EF, N1EG) Main jet 158 (160, 162) Idling jet 42 (45) Starting jet Idle air adjusting screw Open 2 turns Throttle slide... -
Page 124: Carburetor Tuning (250 Sx)
TECHNICAL DATA 21.3.9 Carburetor tuning (250 SX) KEIHIN PWK 36S AG -20°C ... -7°C -6°C ... 5°C 6°C ... 15°C 16°C ... 24°C 25°C ... 36°C 37°C ... 49°C M/FT ASL TEMP ... -
Page 125: Carburetor Tuning (250 Xc)
TECHNICAL DATA 21.3.10 250 XC Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ6_A Needle position 3rd position from top Jet needle N2ZW (N2ZH, N2ZJ) Main jet 175 (172) Idling jet 38 (40) Starting jet Idle air adjusting screw Open 2 turns Throttle slide... - Page 126 TECHNICAL DATA Needle Needle position from above Main jet Info Not for sandy surfaces...
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Page 127: Carburetor Tuning (300 Xc)
TECHNICAL DATA 21.3.12 300 XC Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ7_A Needle position 3rd position from top Jet needle N8RG (N8RH) Main jet 172 (170, 175) Idling jet Starting jet Idle air adjusting screw Open 2 turns Throttle slide 7 with cut-out 21.3.13 Carburetor tuning (300 XC) -
Page 128: 21.3.14 General Carburetor Tuning
TECHNICAL DATA Needle Needle position from above Main jet Info Not for sandy surfaces 21.3.14 General carburetor tuning 1... 5 Needle position from top The five possible needle positions are shown here. 0 0 1 The carburetor tuning depends on the defined ambient and operating conditions. 0 0 2 0 0 3 0 0 4... -
Page 129: Electrical System
Dunlop Geomax MX 32 F Dunlop Geomax MX 32 (All XC models) 90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop Geomax AT 81 F Dunlop Geomax AT 81 Additional information is available in the Service section under: http://www.ktm.com... -
Page 130: Fork
TECHNICAL DATA 21.8 Fork 21.8.1 125/150 SX EU Fork part number 34.18.8P.01 Fork WP Performance Systems Upside down AER 48 Compression damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks Rebound damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks Air pressure 8.2 bar (119 psi) -
Page 131: Sx Us
TECHNICAL DATA Sport 10 clicks Spring length with preload spacer(s) 488 mm (19.21 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85…... -
Page 132: Shock Absorber
TECHNICAL DATA 21.9 Shock absorber 21.9.1 125/150 SX EU Shock absorber article number 18.18.7P.01 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport... -
Page 133: Sx Eu
TECHNICAL DATA Riding sag 110 mm (4.33 in) Fitted length 477 mm (18.78 in) Shock absorber fluid ( p. 135) SAE 2.5 21.9.3 250 SX EU Shock absorber part number 18.18.7O.03 Shock absorber WP Performance Systems 5018 DCC Link Compression damping, low-speed Comfort 17 clicks Standard... -
Page 134: All Xc Models
TECHNICAL DATA Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) Fitted length 490 mm (19.29 in) Shock absorber fluid ( p. 135) SAE 2.5 21.9.5 All XC models Shock absorber part number 18.18.7O.73 Shock absorber WP Performance Systems 5018 DCC Link... - Page 135 TECHNICAL DATA – Screw, throttle grip 5 Nm (3.7 lbf ft) – Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ® 2701™ – Nut, rim lock 12 Nm (8.9 lbf ft) –...
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Page 136: Substances
SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ®... - Page 137 SUBSTANCES Multi-purpose grease (00062010051) Recommended supplier Klüber Lubrication ® – CENTOPLEX 2 EP Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 138) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
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Page 138: Auxiliary Substances
Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer Grip adhesive (00062030051) Recommended supplier KTM AG – GRIP GLUE High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex ® –... - Page 139 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 140: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 141: List Of Abbreviations
LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly... -
Page 142: Index
INDEX Clutch INDEX fluid level, checking/correcting ....73 Accessories ........8 fluid, changing . - Page 143 INDEX dust boots, cleaning ......45 Motorcycle installing ....... . . 46 cleaning .
- Page 144 INDEX Starting ........23 Steering head bearing greasing .
- Page 145 *3213330en* 3213330en 07/2015 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...