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Related Manuals for KTM 125 SX 2018
Summary of Contents for KTM 125 SX 2018
- Page 1 OWNER'S MANUAL 2018 125 SX 150 SX Art. no. 3213636en...
- 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 Shifting, riding ..........23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 Applying the brakes......... 23 Symbols used ........... 4 Stopping, parking..........24 Formats used............ 4 Transport ............24 SAFETY ADVICE............5 Use definition – intended use......5 Refueling ............ - Page 5 TABLE OF CONTENTS 11.27 Securing the air filter box cover ....50 15.6 Plug-in connector of ignition timing map adjustment............. 84 11.28 Sealing the air filter box ....... 51 15.7 Changing the ignition timing map ..... 84 11.29 Removing the main silencer ......51 15.8 Checking the basic position of the shift lever ..
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Page 6: 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 7: Safety Advice
SAFETY ADVICE Use definition – intended use This vehicle is designed and built to withstand the normal stresses and strains of competitive use. This vehicle complies with the cur- rently valid regulations and categories of the top international motorsport organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic. -
Page 8: Safe Operation
– Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing. Work rules Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. -
Page 9: Owner's Manual
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
Manufacturer and implied warranty The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in KTM Dealer.net, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty. -
Page 11: View Of Vehicle
VIEW OF VEHICLE View of vehicle, front left (example) A00030-10 Hand brake lever ( p. 12) Kill switch ( p. 12) Clutch lever ( p. 12) Air filter box cover Plug-in stand Shift lever ( p. 14) Choke ( p. 14) Fuel tap... -
Page 12: View Of Vehicle, Rear Right (Example)
VIEW OF VEHICLE View of vehicle, rear right (example) A00029-10 Seat Filler cap Throttle grip ( p. 12) Kick starter ( p. 14) Foot brake lever ( p. 14) 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. F00009-10 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. F00001-10 Throttle grip Throttle grip... -
Page 15: Closing The Filler Cap
CONTROLS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid skin, eye and clothing contact with fuel. – Immediately consult a doctor if you swallow fuel. – Do not inhale fuel vapors. – In case of skin contact, rinse the affected area with plenty of water. –... -
Page 16: Choke
CONTROLS 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 17: Plug-In Stand
CONTROLS 6.12 Plug-in stand The holder for plug-in stand is on the left side of the wheel spindle. The plug-in stand is used to park the motorcycle. Info Remove the plug-in stand before riding. 0 0 1 402001-10 6.13 Service hour counter The service hour counter is fitted in front of the handlebar. -
Page 18: 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 19: Running In The Engine
PREPARING FOR USE – Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle. – Do not make any off-road trips that exceed your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. –... -
Page 20: Preparing For Rides On Dry Sand
Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. M01105-01 – 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. 105) –... -
Page 21: Preparing For Rides On Wet Sand
Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – 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. 105) –... -
Page 22: Preparing For Rides On Wet And Muddy Surfaces
Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – 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. 88) –... -
Page 23: Preparing For Rides At Low Temperature Or In Snow
Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. M01106-01 – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. M01107-01... -
Page 24: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –... -
Page 25: Starting Off
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system. -
Page 26: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation People who act without authorization endanger themselves and others. – Do not leave the vehicle unattended if the engine is running. – Protect the vehicle against access by unauthorized persons. Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. –... -
Page 27: Refueling
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. – Switch off the engine for refueling. –... -
Page 28: Service Schedule
● ● ● ● Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. ○ One-time interval... -
Page 29: Recommended Work
SERVICE SCHEDULE ● Periodic interval Recommended work after every race Annually Every 40 operating hours Once after 20 operating hours / Every 20 operating hours Once after 10 operating hours / Every 10 operating hours ● Change the front brake fluid. ●... -
Page 30: 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 31: Adjusting The Low-Speed Compression Damping Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow 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 32: Adjusting The Rebound Damping Of The Shock Absorber
Risk of injury Parts of the shock absorber will fly off if the shock absorber is disassembled incorrectly. The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise up to the last perceptible click. -
Page 33: Checking The Static Sag Of The Shock Absorber
TUNING THE CHASSIS Main work – Position the sag gauge in the rear axle and measure the distance to marking SAG on the rear fender. Sag gauge (00029090000) Pin for sag gauge (00029990010) – Note down the value as dimension 402415-10 Finishing work –... -
Page 34: Checking The Riding Sag Of The Shock Absorber
The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Before changing the spring pretension, make a note of the present setting, e.g., by measuring the length of the spring. -
Page 35: Adjusting The Riding Sag
TUNING THE CHASSIS 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) – Remove the shock absorber. p. 45) – After removing the shock absorber, clean it thoroughly. Main work – Choose and mount a suitable spring. -
Page 36: Adjusting The Fork Air Pressure
A little air escapes from the fork leg when connecting. 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 (125/150 SX EU) 8.5 bar (123 psi) -
Page 37: Adjusting The Compression Damping Of The Fork
TUNING THE CHASSIS 10.14 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screw clockwise all the way. Info Adjusting screw is located at the upper end of the right fork leg. –... -
Page 38: Handlebar Position
TUNING THE CHASSIS 10.16 Handlebar position The holes on the handlebar supports are placed at a distance of from the center. Hole distance A 3.5 mm (0.138 in) The handlebar can be mounted in 2 different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider. - Page 39 TUNING THE CHASSIS Finishing work – Mount the handlebar cushion.
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Page 40: 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 41: Cleaning The Dust Boots Of The Fork Legs
SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) – Remove the fork protector. ( p. 40) Main work – Push dust boots of both fork legs downward. -
Page 42: Installing The Fork Legs
SERVICE WORK ON THE CHASSIS 11.6 Installing the fork legs Main work – Position the fork legs. Bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. -
Page 43: Removing The Lower Triple Clamp
SERVICE WORK ON THE CHASSIS 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) – Remove the front wheel. p. 71) – Remove the fork legs. p. 39) – Remove the start number plate. ( p. - Page 44 SERVICE WORK ON THE CHASSIS – Position the fork legs. Bleeder screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info The air suspension AER valve is located in the left fork leg. Grooves are milled into the side of the upper end of the fork legs.
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Page 45: Checking The Play Of The Steering Head Bearing
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time. -
Page 46: Greasing The Steering Head Bearing
SERVICE WORK ON THE CHASSIS Guideline Screw, top steering stem 20 Nm Loctite ® 243™ (14.8 lbf ft) Finishing work – Check the play of the steering head bearing. ( p. 43) – Remove the motorcycle from the lift stand. ( p. -
Page 47: Installing The Front Fender
SERVICE WORK ON THE CHASSIS 11.17 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) M01144-10 Finishing work – Install the start number plate. ( p. -
Page 48: Installing The Shock Absorber
SERVICE WORK ON THE CHASSIS – Remove the connecting link of the chain. – Take off the chain. M01149-01 – Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. A00004-10 –... - Page 49 SERVICE WORK ON THE CHASSIS – Position the swingarm and mount the swingarm pivot. Info Pay attention to flat area – Mount and tighten nut Guideline Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) K00862-10 – Mount the chain. –...
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Page 50: Removing The Seat
SERVICE WORK ON THE CHASSIS 11.20 Removing the seat – Remove screws – Raise the rear of the seat, pull the seat back, and lift it off. F00017-10 11.21 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward. -
Page 51: Installing The Air Filter Box Cover
SERVICE WORK ON THE CHASSIS 11.23 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area A00009-12 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box cover EJOT PT... -
Page 52: Installing The Air Filter
SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 105) Info Only squeeze the air filter to dry it; never wring it out. –... -
Page 53: Sealing The Air Filter Box
SERVICE WORK ON THE CHASSIS 11.28 Sealing the air filter box Preparatory work – Remove the air filter box cover. ( p. 48) Main work – Seal the air filter box in marked area S00847-10 Finishing work – Install the air filter box cover. ( p. -
Page 54: 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. – Fit the new glass fiber yarn filling into the inner tube. -
Page 55: Installing The Fuel Tank
SERVICE WORK ON THE CHASSIS – Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the tank lid. F00032-10 – Pull both spoilers off the sides of the radiator bracket and lift off the fuel tank. F00033-01 11.33 Installing the fuel tank... -
Page 56: Checking The Chain For Dirt
SERVICE WORK ON THE CHASSIS – Mount the fuel tank breather hose. – Mount and tighten screw with the rubber bushing. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) F00032-11 – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –... -
Page 57: Checking The Chain Tension
SERVICE WORK ON THE CHASSIS Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 105) – After drying, apply chain spray. Off-road chain spray ( p. -
Page 58: 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 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks . - Page 59 SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated. »...
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Page 60: Checking The Frame
If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info Always replace a frame that has been damaged due to a mechanical impact. Repair of the frame is not authorized by KTM. K00519-01 11.40 Checking the swingarm –... -
Page 61: Checking The Rubber Grip
SERVICE WORK ON THE CHASSIS 11.42 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness. Info The rubber grips are vulcanized onto a sleeve on the left and onto the han- dle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar. -
Page 62: Changing The Hydraulic Clutch Fluid
SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Check the fluid level. Fluid level below container rim 4 mm (0.16 in) »... - Page 63 SERVICE WORK ON THE CHASSIS – Now inject the liquid into the system until it emerges from the drill hole of the master cylinder without bubbles. – Now and then, extract fluid from the master cylinder reservoir to prevent overflow. –...
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Page 64: Brake System
Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at multiple points on each... -
Page 65: Checking The Front Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 66: Checking The Front Brake Linings
64) H01333-10 12.7 Changing the front brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) - Page 67 Danger of accidents Brake linings which have not been approved alter the braking efficiency. Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
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Page 68: Checking The Free Travel Of Foot Brake Lever
BRAKE SYSTEM – Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly. 100397-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs. –... -
Page 69: Checking The Rear Brake Fluid Level
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Old brake fluid reduces the braking effect. -
Page 70: Adding Rear Brake Fluid
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake lin- ings are worn down. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. -
Page 71: Changing The Rear Brake Linings
Changing the rear brake linings Warning Danger of accidents Incorrect maintenance will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation. –... - Page 72 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 73: Wheels, Tires
WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 38) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. -
Page 74: Removing The Rear Wheel
WHEELS, TIRES – Clean and grease the wheel spindle. Long-life grease ( p. 105) – 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... -
Page 75: Installing The Rear Wheel
WHEELS, TIRES 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –... -
Page 76: Checking The Tire Condition
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) - Page 77 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diame- ter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions. You should hear a high note.
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Page 78: Cooling System
COOLING SYSTEM 14.1 Cooling system 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 79: Removing The Radiator Cover
COOLING SYSTEM – Position radiator shield – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) K00460-10 14.4 Removing the radiator cover –... -
Page 80: Checking The Coolant Level
COOLING SYSTEM » If the coolant level does not match the specified value: – Correct the coolant level. Coolant ( p. 103) – Mount the radiator cap. 14.6 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –... -
Page 81: Refilling With Coolant
COOLING SYSTEM Condition The engine is cold. – Position the motorcycle upright. – Place a suitable container under the water pump cover. – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring. -
Page 82: Tuning The Engine
TUNING THE ENGINE 15.1 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 83: Carburetor Setting
TUNING THE ENGINE 15.3 Carburetor setting Effects of the carburetor setting H01400-01 The different carburetor components must be tuned both to one another and for the use intended. Main jet MJ The main jet MJ has the greatest influence with the throttle slide open (full throttle). If the insulator of a new spark plug is very light or white after a brief ride at full throttle, or if the engine knocks, a larger main jet needs to be used. - Page 84 TUNING THE ENGINE K00496-01 When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindri- cal part of the needle is less. When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling jet is only minimal.
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Page 85: Carburetor - Idle
TUNING THE ENGINE Carburetor – idle 15.4 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 speed is set wrongly. Info The carburetor and its components are subject to increased wear caused by engine vibration. -
Page 86: Plug-In Connector Of Ignition Timing Map Adjustment
TUNING THE ENGINE 15.6 Plug-in connector of ignition timing map adjustment Plug-in connector of the ignition timing map adjustment is located on the frame under the fuel tank. Possible states Soft – The plug-in connector of the ignition timing map adjustment is discon- •... -
Page 87: Service Work On The Engine
SERVICE WORK ON THE ENGINE 16.1 Emptying the carburetor float chamber Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not refuel the vehicle in the vicinity of open flames or lit cigarettes. –... -
Page 88: Changing The Gear Oil
SERVICE WORK ON THE ENGINE Main work – Remove gear oil level check 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 89: Adding Gear Oil
SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death. – Always make sure there is sufficient ventilation when running the engine. – Use an effective exhaust extraction system when starting or running the engine in an enclosed space. -
Page 90: Cleaning, Care
CLEANING, CARE 17.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –... -
Page 91: Storage
74) – 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. 38) – Cover the vehicle with a tarp or similar cover that is permeable to air. -
Page 92: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Carry out the start procedure. ( p. 22) – Motorcycle was out of use for a long Empty the carburetor float chamber. time and there is old fuel in the float p. - Page 93 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Bent radiator hose Change the radiator hose. – Incorrect ignition point due to loose Adjust the ignition. stator – White smoke emission (steam in Damaged cylinder head or cylinder Check the cylinder head and cylinder head gas- exhaust gas) head gasket ket.
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Page 94: Technical Data
TECHNICAL DATA 20.1 Engine 20.1.1 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 95: Engine Tightening Torques
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 20.2 Engine tightening torques – Screw, inner membrane sheets EJOT DELTA PT ®... -
Page 96: Carburetor
TECHNICAL DATA 20.3 Carburetor 20.3.1 All 125 models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 82 Needle position 3rd position from top Jet needle 6BFY42‑75 (6BFY43‑75) Main jet 480 (470, 490, 500, 520, 540) Idling jet 35 (30 / 32.5 / 37.5 / 40) Starting jet Needle jet S‑7... -
Page 97: Carburetor Tuning (All 125 Models)
TECHNICAL DATA 20.3.3 Carburetor tuning (All 125 models) 402815-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. -
Page 98: All 150 Models
TECHNICAL DATA 20.3.4 All 150 models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 83 Needle position 3rd position from top Jet needle 6BFY42‑74 (6BFY43‑74) Main jet 470 (460, 480, 490, 500, 520) Idling jet 35 (30 / 32.5 / 37.5 / 40) Starting jet Needle jet S‑4... -
Page 99: Carburetor Tuning (All 150 Models)
TECHNICAL DATA 20.3.6 Carburetor tuning (All 150 models) 402817-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from top Main jet Info Do not use on sandy terrain. -
Page 100: Capacities
TECHNICAL DATA 20.4 Capacities 20.4.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 103) 20.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 103) 20.4.3 Fuel Total fuel tank capacity, 7 l (1.8 US gal) Super unleaded (98 octane) mixed with 2-stroke engine oil approx. -
Page 101: Tires
100/90 - 19 57M TT Dunlop GEOMAX MX3S Dunlop GEOMAX MX3S The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 20.7 Fork 20.7.1 125/150 SX EU Fork article number 34.18.8R.01... -
Page 102: Shock Absorber
TECHNICAL DATA 20.8 Shock absorber 20.8.1 125/150 SX EU Shock absorber article number 18.18.7R.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 turns Standard 1.5 turns Sport... -
Page 103: Chassis Tightening Torques
TECHNICAL DATA Spring length Weight of rider: 65… 75 kg (143… 165 lb.) 255 mm (10.04 in) Weight of rider: 75… 85 kg (165… 187 lb.) 260 mm (10.24 in) Weight of rider: 85… 95 kg (187… 209 lb.) 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag... - Page 104 TECHNICAL DATA – Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) – Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite ®...
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Page 105: 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 – REACT PERFORMANCE DOT 4 Motorex ®... - Page 106 SUBSTANCES Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 107) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...
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Page 107: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier Motorex... - Page 108 AUXILIARY SUBSTANCES Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic...
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Page 109: Standards
STANDARDS JASO T903 MA Different technical development directions required a separate specification for 4-stroke motorcycles – the JASO T903 MA standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. -
Page 110: 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 111: Index
INDEX fluid, changing ......60 INDEX Clutch lever ........12 Accessories . - Page 112 INDEX Front fender Preparing for use installing ....... . . 45 advice on first use .
- Page 113 INDEX Technical data capacities ....... . 98 carburetor ....... . 94 chassis .
- Page 114 *3213636en* 3213636en 03/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...