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DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art DEAR KTM CUSTOMER sports motorcycle that will give you enormous pleasure if you service and maintain it properly. We hope you enjoy your new vehicle! Enter the serial numbers of your vehicle below.
TABLE OF CONTENTS 6.15 Shift lever ........20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 6 6.16 Kick starter ........20 Symbols used ........6 6.17 Foot brake lever ....... 21 Formats used........6 6.18 Side stand........21 SAFETY ADVICE..........7 6.19 Steering lock (125 XC‑W EU) ....
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TABLE OF CONTENTS Preparing for rides on dry sand ..38 12 SERVICE WORK ON THE CHASSIS....58 Preparing for rides on wet sand ..39 12.1 Raising the motorcycle with a lift Preparations for riding on wet and stand ..........58 muddy surfaces .......
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TABLE OF CONTENTS 12.42 Checking/correcting the fluid level of 16 COOLING SYSTEM ........113 the hydraulic clutch ......83 16.1 Cooling system ......113 12.43 Changing the hydraulic clutch 16.2 Checking the antifreeze and fluid ..........84 coolant level ........113 13 BRAKE SYSTEM .........
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! Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.
2 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 currently valid regulations and categories of the top international motorsport organizations. Info This vehicle is not approved for use on public roads.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.
– 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.
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.
3 IMPORTANT NOTES Customer service Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM. A list of authorized KTM dealers can be found on the KTM website. International KTM Website: http://www.ktm.com...
4 VIEW OF VEHICLE View of vehicle, front left (example) E00766-10 Hand brake lever ( p. 16) Light switch ( p. 17) (125 XC‑W EU) Kill switch ( p. 16) (125 XC‑W EU) p. 17) (125 XC‑W EU) Horn button ( Clutch lever ( p.
4 VIEW OF VEHICLE View of vehicle, rear right (example) E00767-10 Filler cap Throttle grip ( p. 16) Chassis number ( p. 14) Kick starter ( p. 20) Foot brake lever ( p. 21) Level viewer for brake fluid, rear...
5 SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steer- ing head. 401945-10 Type label Type label is fixed to the front of the steering head. 401946-10 Key number (125 XC‑W EU) The key number for the steering lock is stamped onto the key connector.
5 SERIAL NUMBERS Fork part number The fork part number is stamped on the inside of the axle clamp. 401947-10 Shock absorber article number Shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 0 0 1 401948-10...
6 CONTROLS Clutch lever Clutch lever is fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automati- cally. V00322-10 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.
6 CONTROLS Kill switch (150 XC‑W US) The kill switch is fitted on the left side of the handlebar. Possible states in basic position – In this position, the ignition • Kill switch circuit is closed and the engine can be started. pressed –...
6 CONTROLS Electric starter button (150 XC‑W US) The electric starter button is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position pressed – In this position, the elec- • Electric starter button tric starter is actuated.
6 CONTROLS – Press release button , turn the filler cap counterclockwise and lift it free. V00325-10 6.12 Closing the filler cap – Replace the filler cap and turn clockwise until the release but- locks in place. Info Run the fuel tank breather hose without kinks.
6 CONTROLS 6.14 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. Info If the engine is warm, the choke function must be deacti- vated.
6 CONTROLS 6.17 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 6.18 Side stand Side stand is located on the left side of the vehicle. 401943-10 The side stand is used for parking the motorcycle.
6 CONTROLS 6.20 Locking the steering (125 XC‑W EU) Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Park the vehicle. – Turn the handlebar as far as possible to the right. –...
7 COMBINATION INSTRUMENT Combination instrument overview – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. V00799-01 Activation and test Activating combination instrument The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.
7 COMBINATION INSTRUMENT Setting the Mph – Press the button – Wait 3 - 5 seconds. The settings are stored. Info If no button is pressed for 10 -12 seconds, or if an impulse comes from the wheel speed sensor, the settings are automatically saved and the setup menu is closed.
7 COMBINATION INSTRUMENT Setting the clock Condition The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2–3 seconds. The hour display flashes. – Set the hour display with the button and/or button –...
7 COMBINATION INSTRUMENT Display mode SPEED (speed) – Repeatedly press the button briefly until SPEED appears on the left side of the display. The current speed is displayed in the SPEED display mode. The current speed can be displayed in Km/h or Mph. Info Make the setting according to the country.
7 COMBINATION INSTRUMENT Info Repeatedly press the button briefly until the desired function is reached. If no button is pressed for 20 seconds, the settings are automatically saved. Briefly press Activates the flashing display and changes to the button the next display Press the but- No function for 2–3...
7 COMBINATION INSTRUMENT 7.11 Display mode SPEED/CLK (time) – Repeatedly press the button briefly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the but- The display changes to the Setup menu of the for 2–3 clock.
7 COMBINATION INSTRUMENT Press the but- The stop watch and the lap time are reset. for 2–3 seconds. Briefly press Next display mode the button Press the but- Stops the clock. for 2–3 seconds. Briefly press Starts the stop watch or stop the current lap the button time measurement, stores it and the stop watch starts the next lap.
7 COMBINATION INSTRUMENT 7.16 Display mode SPEED/TR1 (trip master 1) – Repeatedly press the button briefly until TR1 appears at the top right of the display. TR1 (trip master 1) runs constantly and counts up to 999.9. You can use it to measure trips or the distance between refueling stops.
7 COMBINATION INSTRUMENT Info The TR2 value can also be corrected manually during the journey with the button and the button If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the but- Increases value of TR2. for 2–3 seconds.
7 COMBINATION INSTRUMENT Briefly press Next display mode the button Press the but- No function for 2–3 seconds. Press the but- No function for 2–3 seconds. Briefly press No function the button 7.21 Display mode SPEED/S1 (stop watch 1) – Repeatedly press the button briefly until S1 appears at the top right of the display.
7 COMBINATION INSTRUMENT 7.23 Table of functions Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode The display Next display No function...
7 COMBINATION INSTRUMENT Display Press the but- Briefly press Press the but- Briefly press Wait 3 - 5 Wait 10 - 12 for 2–3 the button for 2–3 the button seconds. seconds. seconds. seconds. Display mode Displays of Next display No function No function SPEED/TR1 (trip...
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.
8 PREPARING FOR USE (125 XC‑W EU) – Adjust the free travel of the hand brake lever. ( p. 86) (150 XC‑W US) – Adjust the basic position of the hand brake lever. ( p. 87) – Adjust the basic position of the foot brake lever. p.
8 PREPARING FOR USE Starting power of lithium-ion batteries at low temperatures (150 XC‑W US) Lithium-ion batteries are far lighter than lead batteries, have a low self-discharge rate, and have more starting power at temperatures over 15 °C (60 °F). At low temperatures, however, the starting power of lithium-ion batteries drops to below that of lead batter- ies.
Fit a sand cover on the air filter. Sand cover for air filter (79006922000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info M01105-01 Your authorized KTM workshop can recommend the right carburetor tuning.
Fit a waterproofing device on the air filter. Waterproofing device for air filter (79006921000) Info See the KTM PowerParts fitting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning.
Waterproofing device for air filter (79006921000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Mount the steel sprocket. – Clean the motorcycle. ( p. 132) –...
Mount the rain cover for the air filter. Waterproofing device for air filter (79006921000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info M01106-01 Your authorized KTM workshop can recommend the right carburetor tuning.
9 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. –...
9 RIDING INSTRUCTIONS Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable ele- ments of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Condition The motorcycle was stationary for more than 1 week.
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.
9 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. –...
9 RIDING INSTRUCTIONS – Switch off the engine. – Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away. 401475-01 Refueling Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. –...
10 SERVICE SCHEDULE 10.1 Additional information Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately. Different service intervals may apply in your country, depending on the local operating conditions. 10.2 Required work Every 10 operating hours when used for motorsports...
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 ● Periodic interval 10.3...
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.
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 high-speed setting can be seen in fast compression 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.
11 TUNING THE CHASSIS 11.7 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 51) – Hold the motorcycle upright with the aid of an assistant. – Again measure the distance between the rear axle and mark- ing SAG on the rear fender using the sag gauge.
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.
11 TUNING THE CHASSIS 11.10 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 58) – Remove the shock absorber. p. 67) – After removing the shock absorber, clean it thoroughly. Main work –...
11 TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn white adjusting screw clockwise as far as it will go. Info Adjusting screw is located at the upper end of the left fork leg.
11 TUNING THE CHASSIS Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. 11.14 Handlebar position On the upper triple clamp, there are 2 holes at a distance of each other. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center.
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11 TUNING THE CHASSIS – 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. – Remove screws .
12 SERVICE WORK ON THE CHASSIS 12.1 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.
12 SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 58) – Remove the fork protector. ( p. 59) Main work – Push dust boots of both fork legs downward.
12 SERVICE WORK ON THE CHASSIS 12.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line, wiring harness, and clamp. Mount and tighten screws –...
12 SERVICE WORK ON THE CHASSIS 12.8 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).
12 SERVICE WORK ON THE CHASSIS Main work – Remove screw . Loosen screw . Pull off the upper triple clamp with the handlebar and hang it to one side. Info Protect the components against damage by covering them. Do not bend the cables and lines. V00336-10 –...
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12 SERVICE WORK ON THE CHASSIS – 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 COMP (white adjusting screw). Grooves are milled into the side of the upper end of the fork legs.
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages 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.
12 SERVICE WORK ON THE CHASSIS – Check the steering head bearing and change if neces- sary. Finishing work – Remove the motorcycle from the lift stand. ( p. 58) 12.12 Adjusting the steering head bearing play Preparatory work – Raise the motorcycle with a lift stand.
12 SERVICE WORK ON THE CHASSIS 12.14 Removing front fender Preparatory work – Remove the headlight mask with the headlight. ( p. 108) Main work – Remove screws V00340-10 – Remove screws . Take off front fender. V00341-10 12.15 Installing front fender Main work –...
12 SERVICE WORK ON THE CHASSIS 12.16 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 58) Main work – Remove screw and lower the rear wheel with the swingarm as far as possible without blocking the rear wheel. Secure the rear wheel in this position.
12 SERVICE WORK ON THE CHASSIS 12.19 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 –...
12 SERVICE WORK ON THE CHASSIS 12.21 Installing the air filter box cover – Insert the air filter box cover in area and clip it into area V00346-12 Condition The air filter box cover is secured. – Mount and tighten screw Guideline Screw, air filter box EJOT PT...
12 SERVICE WORK ON THE CHASSIS 12.23 Installing the air filter Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area Long-life grease ( p. 153) 102178-10 – Insert air filter and position retaining pin in bushing The air filter is correctly positioned.
12 SERVICE WORK ON THE CHASSIS Finishing work – Install the air filter. p. 70) – Install the air filter box cover. ( p. 69) 12.25 Securing the air filter box cover Preparatory work – Remove the air filter box cover. ( p.
12 SERVICE WORK ON THE CHASSIS – Remove screws – Pull off the main silencer at the rubber sleeve and the spring ring from the manifold. E00772-10 12.28 Installing the main silencer – Mount the main silencer with the rubber sleeve and spring ring.
12 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 dam- age.
12 SERVICE WORK ON THE CHASSIS Main work – Turn handle of the fuel tap to the OFF position. (Figure V00326-10 p. 19) – Pull off the fuel hose. Info Remaining fuel may flow out of the fuel hose. – Remove screws with the collar bushings.
12 SERVICE WORK ON THE CHASSIS Main work – Check throttle cable routing. ( p. 81) – 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.
12 SERVICE WORK ON THE CHASSIS 12.33 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. –...
12 SERVICE WORK ON THE CHASSIS Main work – Pull the chain at the end of the chain sliding piece upward to measure chain tension Info The bottom chain section must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard Chain wear is not always even, so you should repeat...
12 SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning adjusting screws 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...
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12 SERVICE WORK ON THE CHASSIS – Pull at the top part of the chain with the specified weight Guideline Weight, chain wear measure- 10 … 15 kg (22 … 33 lb.) ment – Measure the distance of 18 chain links in the lower chain section.
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12 SERVICE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check that the chain sliding piece is firmly seated.
– Change the swingarm. Info Always change a damaged swingarm. Repair of the swingarm is not authorized by KTM. S01317-10 12.39 Checking throttle cable routing Warning Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
12 SERVICE WORK ON THE CHASSIS 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.
12 SERVICE WORK ON THE CHASSIS 12.41 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle- bar.
12 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 4 mm (0.16 in) »...
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12 SERVICE WORK ON THE CHASSIS – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane E00780-10 – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p.
13 BRAKE SYSTEM 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. –...
Warning 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 front and rear brake disc thickness at multiple...
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
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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13 BRAKE SYSTEM – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, if necessary extract excess.
13 BRAKE SYSTEM Info Clean up overflowed or spilled brake fluid immediately with water. 13.9 Checking the free travel of foot brake lever Warning Danger of accidents The brake system fails in the event of overheating. If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.
Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
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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13 BRAKE SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
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13 BRAKE SYSTEM – Add brake fluid to level Brake fluid DOT 4 / DOT 5.1 ( p. 151) – Mount screw cap with membrane and O-ring. Info Clean up overflowed or spilled brake fluid immediately with water. E00348-10...
14 WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 58) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure that you do not press the brake caliper against the spokes when pushing back the brake...
14 WHEELS, TIRES 14.2 Installing the front 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. –...
14 WHEELS, TIRES Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes. –...
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14 WHEELS, TIRES Main work – Check the wheel bearing for damage and wear. » If the wheel bearing is damaged or worn: – Change the rear wheel bearing. – Clean and grease shaft seal rings and contact surface of the spacers. Long-life grease ( p.
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of H01144-01 wear.
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.) –...
15 ELECTRICAL SYSTEM 15.1 Removing the battery (150 XC‑W US) Warning Environmental hazard Batteries contain environmentally-hazardous materials. – Do not dispose of batteries as household waste. – Dispose of batteries at a collection point for used batteries. Warning Environmental hazard Hazardous substances cause environmental damage. –...
15 ELECTRICAL SYSTEM 15.2 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) ( p. 147) – Mount and tighten screw Guideline Remaining screws, 10 Nm (7.4 lbf ft)
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15 ELECTRICAL SYSTEM 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. – S00863-10 Maintain a minimum clearance from inflammable materials when charging batteries.
15 ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the bat- tery charger. Battery charger (58429074000) The charging time may be longer at low temperatures. This battery charger is not suitable for the trickle charging of lithium-ion batteries.
15 ELECTRICAL SYSTEM – Take off protection caps – Remove faulty main fuse Info You can recognize a faulty fuse by a burned-out fuse wire A spare fuse is located in the starter relay. – Install a new main fuse. Fuse (58011109110) ( p.
15 ELECTRICAL SYSTEM 15.6 Installing the headlight mask with the headlight Main work – Connect plug-in connector E00357-11 – Position the headlight mask and fix it with rubber bands The holding lugs engage in the fender. – Position the brake line and wiring harness in the brake line guide.
15 ELECTRICAL SYSTEM – Pull out headlight bulb – Insert the new headlight bulb. Headlight (HS1/socket BX43t) ( p. 147) – Insert the protection cap with the bulb socket into the reflector and turn it clockwise all the way. Info Ensure that O-ring is seated properly.
15 ELECTRICAL SYSTEM Main work – Loosen screw – Adjust the headlight range by pivoting the headlight. Guideline The boundary between light and dark must be exactly on the lower marking for a motorcycle with rider (instructions on how to apply the marking: Checking the headlight setting). Info V00369-10 If you have a payload, you may have to correct the...
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15 ELECTRICAL SYSTEM – Set the clock. ( p. 25)
16 COOLING SYSTEM 16.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
16 COOLING SYSTEM 16.3 Checking the coolant level 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.
16 COOLING SYSTEM Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...
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16 COOLING SYSTEM – Loosen screw and wait until coolant escapes without bub- bles. – Mount and tighten screw Guideline Bleeder screw, cylin- 8 Nm (5.9 lbf ft) der head (125 XC‑W Bleeder screw, cylin- 8 Nm (5.9 lbf ft) der head (150 XC‑W V00377-10 –...
17 TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Turn the handlebar as far as possible to the right. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable.
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17 TUNING THE ENGINE Main work – Turn the handlebar as far as possible to the right. – Push back sleeve – Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster – Loosen nut – Turn barrel adjuster so that there is play in the throttle...
17 TUNING THE ENGINE 17.3 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.
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17 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 influence.
17 TUNING THE ENGINE 402674-01 Column 2 corresponds to a needle in the standard position. Column 1 corresponds to a needle which is half a clip leaner. Column 3 corresponds to a needle which is half a clip richer. Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the carburation.
17 TUNING THE ENGINE Carburetor – adjusting the idle speed 17.5 – Screw idle air adjusting screw all the way in. – Turn the idle air adjusting screw to the specified basic setting. Info The basic setting of the carburetor is specified in the technical data.
17 TUNING THE ENGINE 17.6 Ignition curve plug-in connector 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 disconnected to achieve better rideability. Performance –...
17 TUNING THE ENGINE – 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. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle components during the shift procedure.
17 TUNING THE ENGINE Engine characteristic – setting the auxiliary spring 17.11 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.
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17 TUNING THE ENGINE – Mount and tighten the screws. Guideline Screw, exhaust control 5 Nm (3.7 lbf ft) cover (125 XC‑W EU) Screw, exhaust control 5 Nm (3.7 lbf ft) cover (150 XC‑W US)
18 SERVICE WORK ON THE ENGINE 18.1 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. –...
18 SERVICE WORK ON THE ENGINE 18.2 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 (125 XC‑W EU) –...
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18 SERVICE WORK ON THE ENGINE Info Drain the gear oil while the engine is at operating temperature. Preparatory work – Park the motorcycle on a level surface. – Place a suitable container under the engine. Main work – Remove gear oil drain plug with magnet.
18 SERVICE WORK ON THE ENGINE 18.4 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. Preparatory work –...
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18 SERVICE WORK ON THE ENGINE – Remove filler plug – Add gear oil until it emerges from the drill hole of the gear oil monitoring screw. Engine oil (15W/50) ( p. 151) – Mount and tighten the gear oil monitoring screw. Guideline Screw, gear oil level 8 Nm (5.9 lbf ft)
19 CLEANING, CARE 19.1 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. –...
19 CLEANING, CARE – After the motorcycle has cooled off, lubricate all moving parts and bearings. – Clean the chain. ( p. 76) – Treat bare metal parts (except for brake discs and exhaust sys- tem) with anti-corrosion materials. Preserving materials for paints, metal and rubber p.
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 58) – Cover the vehicle with a tarp or similar cover that is permeable...
20 STORAGE Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus- ing engine parts and the exhaust system to rust.
21 TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked Operating error Carry out the start procedure. (electric starter) p. 42) (150 XC‑W US) – Battery discharged Recharge the battery. p. 105) – Check the charging voltage. – Check the closed current.
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21 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power Fuel feed interrupted Check the fuel tank breather. – Clean the fuel tap. – Check/set the carburetor components. – Air filter very dirty Clean the air filter and air filter box. p.
22 TECHNICAL DATA Pistons Forged aluminum Piston rings 1 rectangular ring, 1 half keystone ring X (upper edge of piston to upper edge of cylinder) 0 … 0.10 mm (0 … 0.0039 in) Z (height of control flap) 36.5 mm (1.437 in) Primary transmission 23:73 Clutch...
22 TECHNICAL DATA 22.4 Carburetor tuning 22.4.1 Carburetor tuning (125 XC‑W EU) 402816-01 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.
22 TECHNICAL DATA 22.4.2 Carburetor tuning (150 XC‑W US) 402818-01 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.
22 TECHNICAL DATA 22.5 Capacities 22.5.1 Gear oil Gear oil 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 151) 22.5.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 151) 22.5.3 Fuel Total fuel tank capacity, approx. 9.5 l (2.51 US gal) Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60) p.
110/100 - 18 64M TT Dunlop GEOMAX AT 81 F Dunlop GEOMAX AT 81 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.9 Fork Fork article number 14.18.8R.61...
23 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 corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 Motorex ®...
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23 SUBSTANCES Engine oil, 2-stroke Standard/classification – JASO FD ( p. 155) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Fork oil (SAE 4) (48601166S1) Standard/classification –...
25 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 sepa- rate motorcycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.