KTM 150 SX 2017 Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 150 SX 2017
  6. Owner's manual

KTM 150 SX 2017 Owner's Manual

Hide thumbs Also See for 150 SX 2017:
Table of Contents

Advertisement

Quick Links

OWNER'S MANUAL
2017
125 SX
150 SX
250 SX
250 XC
300 XC
Art. no. 3213471en

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 150 SX 2017 and is the answer not in the manual?

Questions and answers

Related Manuals for KTM 150 SX 2017

Summary of Contents for KTM 150 SX 2017

  • Page 1 OWNER'S MANUAL 2017 125 SX 150 SX 250 SX 250 XC 300 XC Art. no. 3213471en...
  • Page 3 KTM accepts no liability for delivery options, devi- ations from illustrations and descriptions, misprints, and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Starting............24 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Starting off............. 25 Symbols used ........... 5 Shifting, riding ..........25 Formats used............ 5 Braking ............25 SAFETY ADVICE............6 Stopping, parking..........26 Use definition - intended use ......6 Transport ............
  • Page 5 TABLE OF CONTENTS 11.20 Removing the seat .......... 52 15.3 Installing the radiator cover (All 125/150 models)............84 11.21 Mounting the seat ........... 53 15.4 Removing the radiator cover (All 125/150 11.22 Removing the air filter box cover ...... 53 models)............

  • Page 6: Table Of Contents

    TABLE OF CONTENTS 21.4 Capacities ............ 121 21.4.1 Gear oil............ 121 21.4.2 Coolant ............ 121 21.4.3 Fuel ............121 21.5 Chassis ............121 21.6 Electrical system........... 122 21.7 Tires ............122 21.8 Fork............. 122 21.8.1 All 125/150 models........122 21.8.2 All 250 SX models ........

  • 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

    – 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 10: 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 11: 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 12: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) H01327-10 Hand brake lever ( p. 13) Kill switch ( p. 13) Clutch lever ( p. 13) Air filter box cover Plug-in stand Shift lever ( p. 16) Choke ( p. 16) Fuel tap...

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) H01329-10 Seat Filler cap Throttle grip ( p. 13) Kick starter ( p. 16) Foot brake lever ( p. 17) Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment...

  • Page 14: 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 15: 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.

  • Page 16: Opening The Filler Cap

    CONTROLS 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 17: Fuel Tap (All Sx Models)

    CONTROLS (All XC models) –  Mount filler cap and turn it clockwise until the release button engages. Info  Run the fuel tank breather hose without kinks. K00508-11 Fuel tap (All SX models) Fuel tap  is on the left of the fuel tank. ...

  • Page 18: 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 19: 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 20: 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 21: 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 22: 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. 129) –...

  • Page 23: 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. 129) –...

  • Page 24: 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. 101) –...

  • Page 25: 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 26: 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. 98) –...

  • Page 27: Starting Off

    Warning 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.)

  • Page 28: Stopping, Parking

    RIDING INSTRUCTIONS Warning Danger of accidents Moisture and dirt impair the brake system. – Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs. – On sandy, wet or slippery surfaces, use the rear brake. –...

  • Page 29: Refueling

    RIDING INSTRUCTIONS – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against acci- dents or falling over. 401475-01 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...

  • Page 30: Service Schedule

    ○ ● ● 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. ○ One-time interval ● Periodic interval...

  • Page 31: Recommended Work

    SERVICE SCHEDULE 9.1.3 Recommended work Annually Every 40 operating hours Once after 20 operating hours / Every 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 32: Recommended Work

    ● ● 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. ○ One-time interval ● Periodic interval 9.2.3...

  • Page 33: 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 34: 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 35: 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.) – ...

  • Page 36: Measuring The Rear Wheel Dimension Unloaded

    TUNING THE CHASSIS Guideline Rebound damping (All 125/150 models) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (250 SX EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (250 SX US) Comfort 17 clicks Standard 15 clicks Sport...

  • Page 37: Checking The Static 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 preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 38: Adjusting The Riding Sag

    TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – 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 39: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS Guideline Spring rate (All 125/150 models) Weight of rider: 65… 75 kg (143… 36 N/mm (206 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165… 39 N/mm (223 lb/in) 187 lb.) Weight of rider: 85… 95 kg (187… 42 N/mm (240 lb/in) 209 lb.) Spring rate (250 SX EU)

  • Page 40: 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 (All 125/150 models) 8.2 bar (119 psi)

  • Page 41: 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 42: Handlebar Position

    TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. –  Mount protection cap 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.
  • Page 43 TUNING THE CHASSIS –  Tighten screws evenly. Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Finishing work – Mount the handlebar cushion.

  • Page 44: 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 45: 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. 42) Main work –  Release bleeder screws Any excess pressure escapes from the interior of the fork. –...

  • Page 46: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS –  Unscrew screws . Take out the left fork leg. –  Unscrew screws . Take out the right fork leg. F00011-10 11.6 Installing the fork legs Main work – Position the fork legs. ...

  • Page 47: Installing The Fork Protector

    SERVICE WORK ON THE CHASSIS 11.8 Installing the fork protector –  Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –  Position the brake line and clamp. Mount and tighten screws –...

  • Page 48: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 129) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 49: 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 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 50: Adjusting The Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: –...

  • Page 51: Removing The Start Number Plate

    SERVICE WORK ON THE CHASSIS 11.14 Removing the start number plate –  Remove screw – Disconnect the brake line at the start number plate. Take off the start number plate. F00012-10 11.15 Installing the start number plate – Connect the brake line at the start number plate. –...

  • Page 52: Removing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work –   Remove screws with the washers and remove screws – Remove the cable ties and remove the frame protectors on the left and right. K00512-10 –...

  • Page 53: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS –  Remove nut and pull out the swingarm pivot. – Push the swingarm back and secure it against falling over. F00027-10 –  Hold the shock absorber and remove screw F00029-10 – Remove the shock absorber carefully at the bottom. F00030-01 11.19 Installing the shock absorber...

  • Page 54: Removing The Seat

    SERVICE WORK ON THE CHASSIS – Mount the chain. – Connect the chain with the connecting link. Guideline The closed side of the chain joint lock must face in the direction of travel. M01149-01 – Position the foot brake cylinder. ...

  • Page 55: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 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. – Make sure that the seat is correctly locked in. F00016-10 –...

  • Page 56: Removing The Air Filter

    SERVICE WORK ON THE CHASSIS Condition The air filter box cover is secured. – Mount and tighten screw  Guideline Screw, air filter box cover EJOT PT ® 3 Nm EJOT PT screw K60x20-Z (2.2 lbf ft) (0017060204) F00018-10 11.24 Removing the air filter Note Engine damage Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 57: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS – Clean the air filter box. – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 55) – Install the air filter box cover. ( p.

  • Page 58: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.29 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down before performing any work on the vehicle. – ...

  • Page 59: 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 60: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. –  Remove screws F00021-10 (All SX models) –  Remove screw with the rubber bushing. – Pull the fuel tank breather hose off the tank lid.

  • Page 61: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS Main work – Check the throttle cable routing. ( p. 63) – 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 damaged. F00033-02 (All SX models) –...

  • Page 62: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11.35 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces the road grip. – Remove the lubricant from the tires using a suitable cleaning agent. Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. –...

  • Page 63: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS » If the chain tension does not meet the specification: – Adjust the chain tension. ( p. 61) Finishing work – Remove the motorcycle from the lift stand. ( p. 42) 11.37 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents.
  • Page 64 SERVICE WORK ON THE CHASSIS –  Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) –  Measure distance of 18 chain rollers in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 65: 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 66: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS (All XC models) –  Turn handle of the fuel tap to the OFF position. (Figure K00488-10 p. 15) – Remove the fuel tank. p. 57) Main work – Check the throttle cable routing. The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor.

  • Page 67: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 11.44 Checking/correcting the fluid level of the hydraulic clutch Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. – Wear suitable protective clothing and safety glasses. – Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
  • Page 68 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –  Remove screws –   Remove cover with membrane H01330-10 –  Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 69: 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 70: 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 71: Checking The Front Brake Linings

    69) 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 72 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.

  • Page 73: 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 74: 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 75: 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 76: 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 77 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.

  • Page 78: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 79: 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 80: 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 81: 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 82 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.

  • Page 83: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery (All XC models) Warning Risk of injury Batteries contain harmful substances. – Keep batteries out of the reach of children. – Keep sparks and open flames away from the batteries. – Only charge batteries in well-ventilated rooms. –...

  • Page 84: 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 85: Changing The Main Fuse (All Xc Models)

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the quiescent current, the start ability of the battery, and the alternator. With this device, you cannot overcharge the battery.

  • Page 86: 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 87: Removing The Radiator Cover (All 125/150 Models)

    COOLING SYSTEM – Position the matching radiator cover ( p. 84). The larger catch is located at the top left. Info Do not use both radiator covers at the same time. H01341-10 –  Position radiator shield –  Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)

  • Page 88: 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 89: Draining The Coolant

    COOLING SYSTEM 15.7 Draining the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
  • Page 90 COOLING SYSTEM (All 125/150 models) –  Make sure that screw is tightened. – Position the motorcycle upright. – Completely fill the radiator with coolant. Coolant ( p. 127) K00528-10 –  Loosen screw until coolant escapes without bubbles. – ...
  • Page 91 COOLING SYSTEM – Allow the engine to warm up and cool down again. – Check the coolant level. ( p. 86)

  • Page 92: 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 93: Carburetor Setting

    TUNING THE ENGINE Finishing work – Check the throttle grip for smooth operation. – Install the fuel tank. p. 58) – Mount the seat. ( p. 53) – Check the play in the throttle cable. ( p. 90) 16.3 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.
  • Page 94 TUNING THE ENGINE Influence of throttle slide adjustment K00495-01 The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence. When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influ- ence.

  • Page 95: Carburetor - Idle

    TUNING THE ENGINE Info The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1 corresponds to the leanest. The optimal carburetor tuning is shown under the respective model. Clip position 1...

  • Page 96: Plug-In Connector Of Ignition Timing Map Adjustment

    TUNING THE ENGINE –  Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall. – Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall. –...

  • Page 97: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 16.8 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 98: Engine Characteristic - Setting The Auxiliary Spring (All 250/300 Models)

    TUNING THE ENGINE Engine characteristic – setting the auxiliary spring 16.11 (All 250/300 models) Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

  • Page 99: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 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 100: Checking The Gear Oil Level

    SERVICE WORK ON THE ENGINE 17.2 Checking the gear oil level Info The gear oil level must be checked when the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (All 125/150 models) –...
  • Page 101 SERVICE WORK ON THE ENGINE Main work (All 125/150 models) –  Remove the gear oil drain plug with magnet –  Remove gear oil drain plug – Let the gear oil drain fully. – Clean the gear oil drain plug thoroughly. –...

  • Page 102: Adding Gear Oil

    SERVICE WORK ON THE ENGINE – Start the engine and check that it is oil-tight. Finishing work – Check the gear oil level. ( p. 98) 17.4 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.

  • Page 103: Cleaning, Care

    CLEANING, CARE 18.1 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 104: 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. 42) –...

  • Page 105: Preparing For Use After Storage

    STORAGE 19.2 Preparing for use after storage (All XC models) – Install the battery. p. 81) – Remove the motorcycle from the lift stand. ( p. 42) – Perform checks and maintenance work when preparing the vehicle for use. p. 24) –...

  • Page 106: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Carry out the start procedure. ( p. 24) tric starter) – Battery discharged Recharge the battery. p. 82) (All XC models) – Check the charging voltage. –...
  • Page 107 TROUBLESHOOTING Faults Possible cause Action (All SX models) Engine stalls or is popping into the Lack of fuel – carburetor  Turn handle of the fuel tap to the ON position. (Figure K00510-10 p. 15) (All XC models) –  Turn handle of the fuel tap to the ON position.

  • Page 108: 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 109: All 250 Sx Models

    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 All 250 SX models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control...

  • Page 110: Xc Us

    TECHNICAL DATA Transmission ratio First gear 15:31 Second gear 16:25 Third gear 20:25 Fourth gear 22:23 Fifth gear 25:22 Sixth gear 26:20 Ignition system Contactless controlled, fully electronic ignition with digital igni- tion adjustment, type Kokusan Spark plug NGK BR 7 ES Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid...

  • Page 111: All 250 Sx Models

    TECHNICAL DATA – Screw, retaining bracket, rotary valve 6 Nm (4.4 lbf ft) Screw, stator 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, water pump wheel 6 Nm (4.4 lbf ft) Loctite ® 243™ – Bleeder screw, cylinder head 8 Nm (5.9 lbf ft) –...

  • Page 112: All Xc Models

    TECHNICAL DATA – Bleeder screw, cylinder head 10 Nm (7.4 lbf ft) – Outer clutch cover 8 Nm (5.9 lbf ft) – Screw, alternator cover 8 Nm (5.9 lbf ft) – Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Screw, control flap, exhaust control 10 Nm (7.4 lbf ft) Loctite...
  • Page 113 TECHNICAL DATA Loctite ® 243™ Screw, shift drum locating 10 Nm (7.4 lbf ft) Screw, shift lever 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, starter motor 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, stator 10 Nm (7.4 lbf ft) Loctite ®...

  • Page 114: Carburetor

    TECHNICAL DATA 21.3 Carburetor 21.3.1 All 125 models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 82 Needle position 3rd position from top Jet needle 6BFY43-74 (6BFY44-74, 6BFY44-73, 6BFY43-73) Main jet 480 (490, 500, 520, 540) Idling jet 45 (42.5/47.5) Starting jet Needle jet...

  • Page 115: Carburetor Tuning (All 125 Models)

    TECHNICAL DATA 21.3.3 Carburetor tuning (All 125 models) 402669-01 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 116: All 150 Models

    TECHNICAL DATA 21.3.4 All 150 models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 83 Needle position 3rd position from top Jet needle 6BFY43-74 (6BFY44-74, 6BFY44-73, 6BFY43-73) Main jet 470 (460, 480, 490, 500, 520) Idling jet 45 (42.5/47.5) Starting jet Needle jet S‑1...

  • Page 117: Carburetor Tuning (All 150 Models)

    TECHNICAL DATA 21.3.6 Carburetor tuning (All 150 models) 402670-01 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 118: All 250 Sx Models

    TECHNICAL DATA 21.3.7 All 250 SX models Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 84 Needle position 3rd position from top Jet needle 6BFY43-73 (6BFY44-73) Main jet 440 (430, 450, 460) Idling jet 42.5 (45/47.5) Starting jet Needle jet S‑1 Idle air adjusting screw...

  • Page 119: Carburetor Tuning (All 250 Sx Models)

    TECHNICAL DATA 21.3.9 Carburetor tuning (All 250 SX models) 402671-01 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 120: 21.3.10 250 Xc Us

    TECHNICAL DATA 21.3.10 250 XC US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 85 Needle position 3rd position from top Jet needle 6BFY44-74 (6BFY43-74) Main jet 440 (430, 450, 460) Idling jet 37.5 (35/40) Starting jet Needle jet R‑8 Idle air adjusting screw Open...
  • Page 121 TECHNICAL DATA Needle Needle position from top Main jet Info Do not use on sandy terrain.

  • Page 122: 21.3.12 300 Xc Us

    TECHNICAL DATA 21.3.12 300 XC US Carburetor type MIKUNI TMX 38 Carburetor identification number TMX 38 81 Needle position 3rd position from top Jet needle 6BFY44-73 (6BFY43-73) Main jet 430 (420, 440, 450, 460) Idling jet 37.5 (35/40) Starting jet Needle jet R‑8 Idle air adjusting screw...

  • Page 123: Capacities

    TECHNICAL DATA Needle Needle position from top Main jet Info Do not use on sandy terrain. 21.4 Capacities 21.4.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 127) 21.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p.

  • Page 124: Electrical System

    Dunlop GEOMAX MX3S (All XC models) 90/90 - 21 54M TT 110/100 - 18 64M TT Dunlop GEOMAX AT81F Dunlop GEOMAX AT81 Additional information is available in the Service section under: http://www.ktm.com 21.8 Fork 21.8.1 All 125/150 models Fork article number 34.18.8Q.01...

  • Page 125: All 250 Sx Models

    TECHNICAL DATA 21.8.2 All 250 SX models Fork article number 34.18.8Q.03 Fork WP Performance Systems Upside down AER 48 Compression damping Comfort 15 clicks Standard 12 clicks Sport 9 clicks Rebound damping Comfort 20 clicks Standard 17 clicks Sport 14 clicks Air pressure 10.2 bar (148 psi) Fork length...

  • Page 126: Sx Eu

    TECHNICAL DATA Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 6 mm (0.24 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 36 N/mm (206 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 39 N/mm (223 lb/in) Weight of rider: 85…...

  • Page 127: All Xc Models

    TECHNICAL DATA Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 5 mm (0.2 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 39 N/mm (223 lb/in) Weight of rider: 75…...

  • Page 128: Chassis Tightening Torques

    TECHNICAL DATA 21.10 Chassis tightening torques Loctite ® 243™ Screw, fixed grip 5 Nm (3.7 lbf ft) – Screw, service hour counter 1 Nm (0.7 lbf ft) – Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) – Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) –...

  • Page 129: 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 130 SUBSTANCES Multi-purpose grease (00062010051) Recommended supplier Klüber Lubrication ® – CENTOPLEX 2 EP Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification – SAE ( p. 130) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

  • Page 131: 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 132: 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 133: 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 134: Index

    INDEX Chassis number ....... 12 INDEX Choke ........16 Accessories .
  • Page 135 INDEX Fork legs removing ....... . . 56 bleeding ....... . . 43 Motorcycle dust boots, cleaning .
  • Page 136 INDEX removing ....... . . 49 Starting ........24 Steering head bearing greasing .
  • Page 137 *3213471en* 3213471en 05/2016 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

This manual is also suitable for:

125 sx 2017250 sx 2017250 xc 2017300 xc 2017125 sx eu 2017125 sx us 2017 ... Show all

Table of Contents