Table of Contents
Advertisement
Quick Links
REPAIRMANUAL2004-2010
BEDIENUNGSANLEITUNGEN
OWNER'S MANUAL
MANUALE O'USO
MANUEL D'UTILISATION
MANUAL DE INSTRUCCIONES
REPARATURANLEITUNG
REPAIR MANUAL
MANUALE DI REPARAZIONE
MANUEL DE REPARATION
MANUAL DE REPARACION
FEDERBEIN
SHOCK ABSORBER
AMMORTIZZATORE
AMMORTISSEUR
AMORTIGUADOR
GABEL
FORK
FORCELLA
FOURCHE
HORQUILLA
Advertisement
Chapters
Table of Contents
Troubleshooting
Related Manuals for KTM 150 SX 2010
Summarization of Contents
Means of Representation
Symbols used
The symbols used in the manual are explained, indicating expected or unexpected reactions.
Formats used
The typographical and other formats used in the manual are explained.
Important Information
Use definition
Defines the intended use of KTM sport motorcycles and compliance with motorsport organizations.
Maintenance
Prerequisite for perfect operation and prevention of wear through proper maintenance.
Warranty
Details warranty claims and conditions, emphasizing authorized workshop service.
Spare parts, accessories
Guidance on using approved spare parts and accessories for safety and liability.
Work rules
Information on special tools, non-reusable parts, and thread lockers for repairs.
Transport
Notes on safe transport, including danger of damage and fire hazards.
View of Vehicle
View of the vehicle from the left front (example)
Illustrates the left front view of the vehicle with numbered parts.
View of the vehicle from the right rear (example)
Illustrates the right rear view of the vehicle with numbered parts.
Location of Serial Numbers
Chassis number
Details the location of the chassis number stamped on the steering head.
Type label
Indicates the location of the type label fixed to the front of the steering head.
Engine number
Specifies the location of the engine number stamped on the engine.
Fork part number
Shows the location of the fork part number stamped on the fork stub.
Shock absorber part number
Indicates the location of the shock absorber part number on the shock absorber.
Controls
Clutch lever
Description of the clutch lever operation and adjustment.
Hand brake lever
Location and function of the hand brake lever for the front brake.
Short circuit button
Explains the function and states of the short circuit button.
Throttle grip
Location of the throttle grip on the handlebar.
Fuel tap
Details the fuel tap operation and possible states for fuel supply.
Choke
Describes the choke lever activation for a richer fuel-air mixture on cold starts.
Shift lever
Information on the shift lever mounting and gear positions.
Kickstarter
Description of the kickstarter fitting and its swiveling top part.
Foot brake lever
Location and function of the foot brake lever for the rear brake.
Plug-in stand
Instructions for parking the motorcycle using the plug-in stand.
General Tips and Hints on Putting into Operation
Advice on first use
Safety advice for first use, including rider judgment, protective clothing, and vehicle handling.
Running in the engine
Guidelines for engine performance and throttle usage during the running-in phase.
Preparing the vehicle for difficult operating conditions
Recommendations for vehicle preparation for various difficult conditions.
Preparations for riding on dry sand
Specific preparations for riding on dry sand, including radiator cap and air filter box.
Preparations for riding on wet sand
Preparations for riding on wet sand, including radiator cap and air filter box.
Preparations for riding on wet and muddy surfaces
Steps for preparing the motorcycle for wet and muddy surface riding conditions.
Preparations for riding at high temperatures and riding slowly
Guidance for riding in high temperatures and slow conditions.
Preparations for riding at low temperatures and in snow
Specific preparations for riding in low temperatures and snowy conditions.
Riding Instructions
Checks before putting into operation
Essential checks to ensure the motorcycle is in perfect technical condition before use.
Starting
Safety warnings and procedures for starting the engine, including exhaust gas hazards.
Braking
Information on braking techniques, adapting to conditions, and potential issues.
Stopping, parking
Safety instructions for stopping and parking the motorcycle.
Refueling
Safety warnings regarding fuel flammability, poisoning, and environmental hazards.
Service Schedule
Important maintenance work that must be done in an authorized KTM workshop
Schedule of maintenance tasks to be performed by an authorized KTM workshop.
Important maintenance work to be carried out by an authorized KTM workshop (as additional order)
Additional maintenance work recommended for authorized KTM workshops.
Important checks and maintenance work to be carried out by the rider
List of checks and maintenance tasks to be performed by the rider.
Maintenance Work on Chassis and Engine
Jacking up the motorcycle
Instructions on how to safely jack up the motorcycle for maintenance.
Checking the basic chassis setting with the rider's weight
Guidance on adjusting basic chassis settings to match rider weight for optimal characteristics.
Compression damping of shock absorber
Explanation of separate regulation for low- and high-speed compression damping.
Adjusting the high-speed compression damping of the shock absorber
Detailed steps for adjusting the high-speed compression damping.
Adjusting the low-speed compression damping of the shock absorber
Instructions for adjusting the low-speed compression damping.
Adjusting the rebound damping of the shock absorber
Procedure for adjusting the rebound damping on the shock absorber.
Checking the static sag of the shock absorber
Steps to check the static sag of the rear wheel shock absorber.
Checking the riding sag of the shock absorber
Procedure for checking the riding sag of the shock absorber with rider and assistance.
Adjusting the spring preload of the shock absorber x
Detailed instructions for adjusting the spring preload of the shock absorber.
Checking the basic setting of the fork
Notes on determining fork settings and considerations for bottoming out.
Adjusting the compression damping of the fork
Instructions on how hydraulic compression damping affects fork suspension behavior.
Adjusting the rebound damping of the fork
Details on how hydraulic rebound damping influences fork suspension behavior.
Loosening the fork protection
Steps for loosening the fork protection before removal or adjustment.
Checking the play of the steering head bearing
Guidance on checking steering head bearing play for vehicle handling.
Adjusting the play of the steering head bearing x
Instructions for adjusting steering head bearing play.
Removing the fork legs x
Step-by-step procedure for removing the fork legs.
Installing the fork legs x
Detailed instructions for installing the fork legs.
Removing the front fender
Procedure for removing the front fender.
Installing the front fender
Instructions for installing the front fender.
Removing the start number plate
Steps to remove the start number plate.
Installing the start number plate
Instructions for installing the start number plate.
Handlebar position
Information on handlebar mounting positions and distances.
Adjusting the handlebar position x
Steps for adjusting the handlebar position for rider comfort.
Checking the play in the throttle cable
Procedure to check the play in the throttle cable.
Adjusting the play in the throttle cable x
Instructions for adjusting the throttle cable play.
Cleaning the chain
Guidance on cleaning the chain and the importance of maintenance.
Checking the chain tension
Procedure to check chain tension and correct it if necessary.
Checking the rear sprocket/engine sprocket for wear
Instructions for checking wear on rear and engine sprockets.
Adjusting the chain tension
Details on adjusting chain tension and ensuring correct rear wheel alignment.
Checking the brake discs
Procedure to check brake disc thickness for wear.
Checking the free travel of the hand brake lever
Instructions to check free travel of the hand brake lever.
Checking the front brake fluid level
Procedure to check the front brake fluid level in the reservoir.
Adding front brake fluid x
Instructions for adding front brake fluid, including safety precautions.
Checking the front brake linings
Procedure to check the minimum thickness and condition of front brake linings.
Changing the front brake linings x
Steps for changing the front brake linings.
Checking the free play of the foot brake lever
Procedure to check the free play of the foot brake lever.
Checking the rear brake fluid level
Instructions to check the rear brake fluid level in the viewer.
Adding rear brake fluid x
Steps for adding rear brake fluid, including safety precautions.
Checking the rear brake linings
Procedure to check the minimum thickness and condition of rear brake linings.
Removing the rear brake linings x
Instructions for removing the rear brake linings.
Removing the front wheel x
Steps for safely removing the front wheel.
Installing the front wheel x
Instructions for correctly installing the front wheel.
Checking the tire condition
Guidance on checking tire condition, tread depth, and age.
Checking the spoke tension
Procedure for checking spoke tension and its importance for wheel balance.
Changing the ignition curve
Instructions for changing the ignition curve between Performance and Soft modes.
Engine characteristic - auxiliary spring (250 SX)
Explanation of auxiliary spring function and its influence on engine characteristics.
Removing the seat
Steps for removing the motorcycle seat.
Removing the fuel tank x
Procedure for safely removing the fuel tank, including fuel hazards.
Installing the fuel tank x
Instructions for correctly installing the fuel tank.
Cooling system
Description of the coolant circulation system and factors affecting cooling.
Checking the antifreeze and coolant level
Procedure for checking coolant antifreeze and level, with safety warnings.
Draining the coolant x
Instructions for safely draining the coolant.
Refilling with coolant x
Steps for refilling the cooling system with coolant.
Removing the main silencer
Procedure for removing the main silencer, with burn hazard warning.
Changing the glass fiber yarn filling of the main silencer x
Instructions for changing the glass fiber yarn filling in the main silencer.
Removing the air filter box lid
Steps for removing the air filter box lid.
Installing the air filter x
Instructions for correctly installing the air filter, with damage warning.
Cleaning the air filter x
Procedure for cleaning the air filter, with environmental hazard warning.
Adjusting the basic position of the clutch lever
Instructions for adjusting clutch lever position for hand size.
Changing the hydraulic clutch fluid x
Steps for changing the hydraulic clutch fluid, with environmental hazard warning.
Checking the basic position of the shift lever
Procedure to check the basic position of the shift lever relative to boot.
Adjusting the basic position of the shift lever x
Instructions for adjusting the shift lever position.
Carburetor
Information on carburetor settings and potential wear issues.
Carburetor - adjusting the idle speed x
Detailed steps for adjusting carburetor idle speed.
Emptying the carburetor float chamber x
Procedure for emptying the carburetor float chamber, with fuel hazard warnings.
Checking the gear oil level
Instructions to check the gear oil level when the engine is cold.
Changing the gear oil x
Steps for changing the gear oil, with safety warnings.
Draining the gear oil x
Procedure for safely draining the gear oil.
Refilling with gear oil x
Instructions for refilling the gear oil, with warning about premature wear.
Adding gear oil x
Steps for adding gear oil when the engine is cold.
Trouble Shooting
Engine fails to start
Troubleshooting steps for engine start failures, including operating errors and fuel supply issues.
Engine fails to idle
Possible causes and remedies for engine idling problems.
Engine lacks power
Troubleshooting steps for reduced engine power.
Engine overheats
Causes and solutions for engine overheating issues.
White smoke emission (steam in exhaust gas)
Troubleshooting for white smoke emission, possibly indicating cylinder head gasket issues.
Cleaning
Cleaning the motorcycle
Instructions for cleaning the motorcycle, with material damage and environmental warnings.
Storage
Storage
Actions for putting the motorcycle into storage for a longer period.
Putting into operation after storage
Steps to take the motorcycle back into operation after storage.
Technical Data - Engine
125 SX
Technical specifications for the 125 SX engine.
150 SX
Technical specifications for the 150 SX engine.
250 SX
Technical specifications for the 250 SX engine, including TVC and gear ratios.
Capacity - gear oil
Specifications for gear oil capacity.
Capacity - coolant
Specifications for coolant capacity.
Technical Data - Engine Tightening Torques
125 SX, 150 SX
Engine tightening torques for 125 SX and 150 SX models.
250 SX
Engine tightening torques for the 250 SX model.
Technical Data - Carburetor
125 SX
Carburetor specifications for the 125 SX model.
Carburetor - basic setting for sandy surfaces (125 SX)
Basic carburetor settings for riding on sandy surfaces for 125 SX.
Carburetor configuration (125 SX)
Carburetor configuration table for 125 SX based on ambient conditions.
150 SX
Carburetor specifications for the 150 SX model.
Carburetor - basic setting for sandy surfaces (150 SX)
Basic carburetor settings for riding on sandy surfaces for 150 SX.
250 SX
Carburetor specifications for the 250 SX model.
Carburetor - basic setting for sandy surfaces (250 SX)
Basic carburetor settings for riding on sandy surfaces for 250 SX.
Technical Data - Chassis
Frame
Technical details of the frame.
Fork
Specifications for the WP Suspension fork.
Suspension travel
Front and rear suspension travel specifications.
Brake discs - wear limit
Specifies the minimum wear limit for front and rear brake discs.
Tires
Information on tire validity and specifications for front and rear tires.
Technical Data - Fork
125 SX, 150 SX
Technical specifications for the WP Suspension fork for 125 SX and 150 SX.
250 SX
Technical specifications for the WP Suspension fork for the 250 SX.
Technical Data - Shock Absorber
125 SX, 150 SX
Technical specifications for the WP Suspension PDS 5018 DCC shock absorber.
250 SX
Technical specifications for the WP Suspension PDS 5018 DCC shock absorber for 250 SX.
Wiring Diagram
Wiring diagram
Schematic representation of the motorcycle's electrical system.
Substances
Brake fluid DOT 4 / DOT 5.1
Specifications and recommendations for brake fluid.
Coolant
Guidance on suitable coolant and mixture ratios.
Engine oil (15W/50)
Specifications and recommendations for engine oil.
Fork oil (SAE 5)
Specifications and recommendations for fork oil.
Hydraulic fluid (15)
Specifications and recommendations for hydraulic fluid.
Auxiliary Substances
Air filter cleaner
Recommended air filter cleaner products.
Chain cleaner
Recommended chain cleaner products.
Cleaning and polishing materials for metal, rubber and plastic
Recommended cleaning and polishing materials for various parts.
Contact spray
Recommended contact spray products.
Long-life grease
Recommended long-life grease products.
Motorcycle cleaner
Recommended motorcycle cleaner products.
Off-road chain spray
Recommended off-road chain spray products.
Oil for foam air filter
Recommended oil for foam air filters.
Standards
JASO T903 MA
Specification for 4-stroke motorcycle engine oils.
SAE
Definition of SAE viscosity classes for oils.
JASO FC
Classification for 2-stroke engine oil for extreme racing demands.
Need help?
Do you have a question about the 150 SX 2010 and is the answer not in the manual?
Questions and answers