KTM 125 XC-W 2018 Setup Instructions
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KTM 125 XC-W 2018 Setup Instructions

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SETUP INSTRUCTIONS
2018
125 XC‑W
150 XC‑W
Art. no. 3213704en

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Summary of Contents for KTM 125 XC-W 2018

  • Page 1 SETUP INSTRUCTIONS 2018 125 XC‑W 150 XC‑W Art. no. 3213704en...
  • Page 3 KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Means Of Representation

    1 MEANS OF REPRESENTATION Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips.
  • Page 5 2 SETUP Unpacking and setting up the vehicle Condition Packaging V2 – Remove the box and the plastic packaging. Info An assistant prevents the motorcycle from falling over. To avoid damaging the motorcycle during the setup, leave the protective film on the vehicle until you E00851-10 have finished.

  • Page 6: Mount And Tighten Screws

    2 SETUP – Together with an assistant, take the vehicle off the pallet. – Position the vehicle on a lift stand. – Check the vehicle and attachments for transport damage. – Install the shock absorber. ( p. 15) 402051-01 (125 XC‑W EU) –...
  • Page 7 2 SETUP Warning Danger of accidents A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the mate- rial becomes fatigued. The handlebar may break as a result. – Change the handlebar if the handlebar is damaged E00483-01 or bent.
  • Page 8 2 SETUP (125 XC‑W EU) – Position the controls on the left half of the handlebar. S01453-01 (150 XC‑W US) – Position the controls on the left half of the handlebar. S01454-01 Condition Packaging V12 (125 XC‑W EU) – Connect all plug-in connectors to the plug-in holder. –...
  • Page 9 2 SETUP – Preassemble the hand guards on the left and right. E00852-01 – Mount the left hand guard. – Mount the right hand guard. E00853-01 – Secure the handlebar cushion with two cable ties. – Install front fender. ( p.
  • Page 10 2 SETUP – Position the right footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted. R01229-10 – Position spring as shown. Spring engages in area E00794-10 – Press the spring with special tool Pliers for footrest spring (79029083000) The special tool is applied to area on the footrest.
  • Page 11 2 SETUP – Position the left footrest and pin. Info Only insert the pin to the extent that the spring can still be mounted. S01398-10 – Position spring as shown. Spring engages in area E00798-10 – Press the spring with special tool Pliers for footrest spring (79029083000) The special tool is applied to area on the footrest.
  • Page 12 Screw, frame protector 3 Nm (2.2 lbf ft) – E00801-10 Mount the cable tie(s). – Unpack and mount the KTM PowerParts included in the deliv- ery (optional). Info Read the accompanying KTM PowerParts fitting instruc- tions. – Set kilometers or miles. ( p.

  • Page 13: Remove Screws

    3 WORK Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.
  • Page 14 3 WORK Mounting the seat – Hook in the front of the seat on the collar bushing of the fuel tank, lower it at the rear and push it forward. – Make sure that the seat is correctly locked in. V00343-10 –...
  • Page 15 3 WORK Main work – Turn handle of the fuel tap to the OFF position. (Figure V00326-10 p. 25) – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws with the collar bushings. E00774-10 –...
  • Page 16 3 WORK Main work – Check throttle cable routing. ( p. 14) – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables or throttle cables are trapped or dam- aged.
  • Page 17 3 WORK Main work – Check throttle cable routing. The throttle cable must be routed behind the handle- bar, on the right of the frame, and to the carburetor. The throttle cable must be secured behind the fuel tank con- tact area rubber band.
  • Page 18 3 WORK Installing the fork legs Main work – Position the fork legs. Bleeder screws are positioned toward the front. Info The rebound damping is located in right fork leg REB (red adjusting screw). The compression damping is located in left fork leg COM (white adjusting screw). Grooves are milled into the side of the upper end of the H01595-10 fork legs.

  • Page 19: Tighten Screws 3 . Guideline

    3 WORK – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change front wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.
  • Page 20 3 WORK Main work Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batter- ies. – Only charge batteries in well-ventilated rooms. – F00138-10 Maintain a minimum clearance from inflammable materials when charging batteries.
  • Page 21 3 WORK Info Even when there is no load on the battery, it discharges steadily. The charging level and the method of charging are very important for the service life of the battery. Rapid recharging with a high charging current shortens the service life of the battery. If the charging current, charging voltage, or charging time are exceeded, the battery will be destroyed.
  • Page 22 3 WORK 3.13 Installing the battery (150 XC‑W US) Main work – Insert the battery into the battery compartment with the termi- nals facing forward and secure with holding bracket Battery (HJTZ5S-FP) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis –...
  • Page 23 3 WORK Finishing work – Install the headlight mask with the headlight. ( p. 21) – Check the headlight setting. ( p. 22) 3.15 Removing the headlight mask with the headlight (125 XC‑W EU) – Press and hold the kill switch while the engine is idling until the engine stops.

  • Page 24: Tighten Screw

    3 WORK 3.17 Checking the headlight setting – Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight. – Make another mark at a distance under the first mark.
  • Page 25 3 WORK 3.19 Opening the filler cap 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 26 3 WORK 3.21 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 27 3 WORK 3.22 Fuel tap The fuel tap is on the left side of the fuel tank. Open or close the supply of fuel to the carburetor using tap han- on the fuel tap. Possible states Fuel supply closed OFF – Fuel cannot flow from the fuel tank •...
  • Page 28 3 WORK 3.24 Adjusting the combination instrument function Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. – Repeatedly press the button briefly until H appears at the bottom right of the display. –...
  • Page 29 3 WORK Info The seconds can only be set to zero. If no button is pressed for 15 - 20 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.

  • Page 30: Technical Data

    4 TECHNICAL DATA Chassis tightening torques EJOT PT Remaining screws, chassis ® K60x25‑Z 2 Nm (1.5 lbf ft) EJOT EJOFORM PT Screw, seat fixing ® K60x23/18 2.5 Nm (1.84 lbf ft) Screw, fixed grip 5 Nm (3.7 lbf ft) Loctite ®...
  • Page 31 4 TECHNICAL DATA Screw, side stand attachment 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, subframe 35 Nm (25.8 lbf ft) Loctite ® 2701™ Screw, top steering stem 20 Nm (14.8 lbf ft) Screw, top triple clamp 20 Nm (14.8 lbf ft) Engine bracket screw 60 Nm (44.3 lbf ft) Remaining nuts, chassis...
  • Page 32 5 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 32) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification –...

  • Page 33: Auxiliary Substances

    6 AUXILIARY SUBSTANCES Long-life grease Recommended supplier Motorex ® – Bike Grease 2000...
  • Page 34 7 STANDARDS JASO FD JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
  • Page 35 *3213704en* 3213704en 04/2017 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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