KTM 150 SX Owner's Manual
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KTM 150 SX Owner's Manual

2012
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OWNER'S MANUAL
2012
125 SX
150 SX
250 SX
150 XC USA
250 XC EU/USA
300 XC EU/USA
Art. no. 3211714en

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Table of Contents
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Summary of Contents for KTM 150 SX

  • Page 1 OWNER'S MANUAL 2012 125 SX 150 SX 250 SX 150 XC USA 250 XC EU/USA 300 XC EU/USA Art. no. 3211714en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Checking the riding sag of the shock absorber ....31 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........4 Adjusting the spring preload of the shock absorber ..32 IMPORTANT INFORMATION ..........5 VIEW OF VEHICLE............... 7 Adjusting the riding sag ..........
  • Page 5 Checking the tire condition..........70 150 SX............... 100 Checking the tire air pressure ......... 71 Carburetor - basic setting for sandy surfaces (150 SX) ..100 Checking the spoke tension ..........71 Carburetor configuration (150 SX)......... 101 ELECTRICAL SYSTEM ............72 250 SX...............

  • Page 6: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important Information

    Warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
  • Page 8 IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob- lems and conflicts do not have to occur.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 800192-10 Hand brake lever ( p. 10) Kill switch ( p. 10) Clutch lever ( p. 10) Air filter box lid Fuel tap Choke ( p. 12) Shift lever ( p.

  • Page 10: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 800193-10 Seat Filler cap Handlebar cushion Throttle grip ( p. 10) Shock absorber, rebound adjustment Level viewer, rear brake fluid Shock absorber, compression adjustment Foot brake lever ( p.

  • Page 11: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head.  601177-10 Type label The type label is fixed to the front of the steering head.  601177-11 Engine number The engine number is stamped on the left side of the engine under the engine ...

  • Page 12: Controls

    CONTROLS Clutch lever (All 125/150 models) The clutch lever is fitted on the left side of the handlebar.  The clutch is hydraulically operated and self-adjusting. B00001-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. ...

  • Page 13: Electric Starter Button (250/300 Xc)

    CONTROLS Electric starter button (250/300 XC) 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 electric starter is actuated. • Electric starter button B00080-10 Opening the filler cap...

  • Page 14: Fuel Tap (All Xc Models)

    CONTROLS Fuel tap (All XC models) The fuel tap is on the left side of the fuel tank. Tap handle on the fuel tap is used to open or close the supply of fuel to the carbure-  tor. Possible states Fuel supply closed OFF –...

  • Page 15: Shift Lever

    CONTROLS Shift lever 5.11 Shift lever is mounted on the left side of the engine.  B00005-10 (All 125/150 models, All XC models) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. B00005-12 (250 SX) The gear positions can be seen in the photograph.

  • Page 16: Side Stand (All Xc Models)

    CONTROLS Side stand (All XC models) 5.14 The side stand is on the left side of the vehicle.  800211-10 The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber ...

  • Page 17: 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 record at vehicle handover.

  • Page 18: Running In The Engine

    PREPARING FOR USE Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) – Check the spoke tension. ( p. 71) Info The spoke tension must be checked after half an hour of operation. –...

  • Page 19: Preparations For Riding On Wet Sand

    – Mount the dust cover for the air filter. Dust cover for air filter (59006019000) Info Read the KTM PowerParts installation instructions. B00435-01 – Mount the dust cover for the air filter for sand. Sand cover for air filter (59006022000) Info Read the KTM PowerParts installation instructions.

  • Page 20: Preparations For Riding On Wet And Muddy Surfaces

    Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info B00437-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Mount the steel sprocket. – Clean the motorcycle. ( p. 87) –...

  • Page 21: Preparing For Rides At Low Temperatures Or In Snow

    Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info B00437-01 The recommended carburetor tuning is available from your authorized KTM workshop.

  • Page 22: 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. 84) –...

  • Page 23: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 24: Stopping, Parking

    RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.
  • Page 25 Total fuel tank 7.5 l Super unleaded gasoline, mixed with capacity, approx. (1.98 US gal) 2-stroke engine oil (1:40) ( p. 118) (125/150 SX) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 118) 400382-10 (250 SX) Total fuel tank 11.5 l...

  • Page 26: Service Schedule (Sx)

    Final check: Check the vehicle for safe operation and take a test ride. • • • Make the service entry in KTM DEALER.NET and in the service record. • • • S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal) S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)

  • Page 27: Maintenance Work (As An Additional Order)

    SERVICE SCHEDULE (SX) Maintenance work (as an additional order) S20N S40A • Change the front brake fluid. Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 57) • Grease the steering head bearing. p. 43) • Check/set the carburetor components. •...

  • Page 28: Service Schedule (Xc)

    Final check: Check the vehicle for safe operation and take a test ride. • • Make the service entry in KTM DEALER.NET and in the service record. • • S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)

  • Page 29: Service Work (As Additional Order)

    SERVICE SCHEDULE (XC) Service work (as additional order) S40A S80A • Change the front brake fluid. Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 57) • Grease the steering head bearing. p. 43) • Check/set the carburetor components. •...

  • Page 30: Tuning The Chassis

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 31: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 32: Adjusting The Rebound Damping Of The Shock Absorber

    10.5 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) – Turn adjusting screw clockwise with a screwdriver to the last click.

  • Page 33: Measuring The Sag Of The Unloaded Rear Wheel

    The static sag is the difference between measurements   – Check the static sag. Static sag (125/150 SX) 30 mm (1.18 in) Static sag (250 SX) 30 mm (1.18 in) Static sag (150 XC USA) 34 mm (1.34 in)

  • Page 34: Adjusting The Spring Preload Of The Shock Absorber

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to 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 35: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS Guideline Spring rate (125/150 SX) Weight of rider: 65… 75 kg (143… 45 N/mm (257 lb/in) 165 lb.) Weight of rider: 75… 85 kg (165… 48 N/mm (274 lb/in) 187 lb.) Weight of rider: 85… 95 kg (187…...

  • Page 36: Adjusting The Compression Damping Of The Fork

     Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping (125/150 SX) 101275-10 Comfort 14 clicks Standard 12 clicks...

  • Page 37: Handlebar Position

    TUNING THE CHASSIS Guideline Rebound damping (125/150 SX) Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping (250 SX) Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping (150 XC USA) Comfort 14 clicks Standard 12 clicks...
  • Page 38 TUNING THE CHASSIS – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position the handlebar clamp. Mount and tighten screws  Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft)

  • Page 39: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS Raising the motorcycle with the lift stand 11.1 (All 125/150 models) Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine.

  • Page 40: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS – Remove bleeder screws briefly.  Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. – Remove the motorcycle from the lift stand. ( p. 37) 101276-10 Cleaning the dust boots of the fork legs 11.4 –...

  • Page 41: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS Removing the fork legs 11.7 – Remove the front wheel. p. 68) – Remove screws and take off the clamp.  – Remove screws and take off the brake caliper.  – Allow the brake caliper and brake line to hang tension-free to the side. 800191-10 –...

  • Page 42: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS Removing the fork protector 11.9 – Remove the fork legs. p. 39) – Remove screws on the left fork leg. Lift off the fork protector.  – Remove the screws on the right fork leg. Lift off the fork protector. B00306-10 Installing the fork protector 11.10...

  • Page 43: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Installing the lower triple clamp 11.12 – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 119) 0 0 3 – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 44: Checking The Play Of The Steering Head Bearing

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (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 45: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Adjusting the play of the steering head bearing 11.14 – Raise the motorcycle with the lift stand. ( p. 37) – Loosen screws . Remove screw   – Loosen and retighten screw  Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

  • Page 46: Removing The Front Fender

    SERVICE WORK ON THE CHASSIS Removing the front fender 11.18 – Remove screws . Remove the front fender.  – Make sure the spacers remain in place. B00307-10 Installing the front fender 11.19 – Ensure that the spacers are mounted in the fender. –...

  • Page 47: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS Installing the shock absorber 11.21 – Insert the shock absorber from above. – Position the shock absorber. – Mount and tighten screw  Guideline Screw, top shock absorber 60 Nm Loctite ® 2701 (44.3 lbf ft) 800207-11 –...

  • Page 48: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS Removing the air filter box lid 11.24 – Pull off the air filter box lid in area sideways and remove it toward the front.  800200-10 Installing the air filter box lid 11.25 – Insert the air filter box lid into the rear area and clip it into the front area ...

  • Page 49: Cleaning The Air Filter And Air Filter Box

    SERVICE WORK ON THE CHASSIS – Put in both parts together, position them, and fix them with air filter holder  Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. –...

  • Page 50: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS Installing the main silencer 11.30 – Mount the main silencer with rubber sleeve  – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 800199-11 Changing the glass fiber yarn filling of the main silencer 11.31 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

  • Page 51: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS – Close the fuel tap. – Pull off the fuel hose. Info Remaining fuel may run out of the fuel hose. – Remove screws with the collar sleeve.  B00315-12 – Remove screw with the collar sleeve. ...

  • Page 52: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS – Mount the fuel tank vent hose. – Mount and tighten screw with the collar bushing.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) B00316-11 – Mount and tighten screws with the collar sleeve. ...

  • Page 53: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Checking the chain tension 11.36 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load.

  • Page 54: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Checking the chain, rear sprocket, engine sprocket and chain guide 11.38 – Raise the motorcycle with the lift stand. ( p. 37) – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...

  • Page 55: Adjusting The Chain Guide

    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 the chain sliding piece for tightness. »...

  • Page 56: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 800206-10 Checking the swingarm 11.41 –...
  • Page 57 SERVICE WORK ON THE CHASSIS (150 XC USA) – Check the throttle cable routing. The throttle cable must be routed to the carburetor on the left side of the upper frame tube behind the handlebars. » If the throttle cable is not routed as specified: –...

  • Page 58: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS Checking the rubber grip 11.43 – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip.

  • Page 59: Checking The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Checking the fluid level of the hydraulic clutch 11.46 Info The fluid level rises with increasing wear of the clutch lining discs. (All 125/150 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion.
  • Page 60 SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from bore hole of the mas-  ter cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –...
  • Page 61 SERVICE WORK ON THE CHASSIS – Inject the liquid into the system until it escapes from bore hole of the mas-  ter cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. –...

  • Page 62: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 63: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to 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.

  • Page 64: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 65 Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 66: Checking The Free Travel Of Foot Brake Lever

    BRAKES – Correct the brake fluid quantity to level  Guideline Dimension (brake fluid level below 5 mm (0.2 in)  top edge of container) Brake fluid DOT 4 / DOT 5.1 ( p. 117) – Position the cover with the membrane. Mount and tighten the screws. Info 100399-10 Clean up overflowed or spilt brake fluid immediately with water.

  • Page 67: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 68: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 69 BRAKES – Clean the brake caliper and brake caliper support. – Check that leaf spring in the brake caliper and sliding plate in the brake   caliper support are seated correctly. Info The arrow on the leaf spring points in the rotation direction of the brake disc.

  • Page 70: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 13.1 – Raise the motorcycle with the lift stand. ( p. 37) – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 71: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw  Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly against on the brake disc.

  • Page 72: Checking The Tire Condition

    13.5 Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle.

  • Page 73: Checking The Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.

  • Page 74: Electrical System

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 75: Removing The Main Fuse (250/300 Xc)

    ELECTRICAL SYSTEM Info Even when there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid recharging with a high charging current shortens the battery's service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves.

  • Page 76: Installing The Main Fuse (250/300 Xc)

    ELECTRICAL SYSTEM Installing the main fuse (250/300 XC) 14.5 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Insert the main fuse. Fuse (58011109110) Info A reserve fuse...

  • Page 77: Cooling System

    COOLING SYSTEM Cooling system 15.1 (All 125/150 models) 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 operating the vehicle at the specified ...

  • Page 78: Installing The Radiator Cover (All Sx Models)

    COOLING SYSTEM – Attach the radiator shield at holding lugs . Attach mounting points at the radi-   ator. – Install the fuel tank. p. 49) 601224-10 Installing the radiator cover (All SX models) 15.4 – Remove the fuel tank. p.

  • Page 79: Checking The Coolant Level

    COOLING SYSTEM » If the level of the coolant does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 117) Alternative 2 Coolant (mixed ready to use) ( p. 117) – Mount the radiator cap. Checking the coolant level 15.6 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.

  • Page 80: Refilling With Coolant

    COOLING SYSTEM (All 125/150 models) – Remove screw . Remove radiator cap   – Completely drain the coolant. – Mount screw with a new seal ring and tighten it.  Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 601186-11 (All 250/300 models)

  • Page 81: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 16.1 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 2…...

  • Page 82: Carburetor - Adjusting The Idle Speed

     position. Guideline Idle air adjusting screw (125 SX) Open 1.5 turns Idle air adjusting screw (150 SX) Open 2 turns Idle air adjusting screw (150 XC USA) B00048-11 Open 1.5 turns...

  • Page 83: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE – Adjust the idle speed with adjusting screw  Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 12) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw slowly in a clockwise direction until the idle speed ...

  • Page 84: Ignition Curve Plug Connection

    TUNING THE ENGINE Ignition curve plug connection 16.6 Plug connection is located in front of the fuel tank on the left side of the frame.  Possible states Soft – The plug connection is disconnected to achieve better rideability. • Performance –...

  • Page 85: Engine Characteristic - Auxiliary Spring (All 250/300 Models)

    TUNING THE ENGINE Engine characteristic - auxiliary spring (All 250/300 models) 16.10 The auxiliary spring is located on the right side of the engine below the water pump cover. Possible states Auxiliary spring with yellow marking – Auxiliary spring mounted at the factory with •...

  • Page 86: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the gear oil level 17.1 Info The gear oil level must be checked when the engine is cold. – Stand the motorcycle upright on a horizontal surface. (All 125/150 models) – Remove gear oil level check screw ...

  • Page 87: Draining The Gear Oil

    SERVICE WORK ON THE ENGINE Draining the gear oil 17.3 Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 88: Adding Gear Oil

    SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 89: Cleaning, Care

    CLEANING, CARE Cleaning the motorcycle 18.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 90: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. 401058-01 Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 37) – Cover the vehicle with a tarp or cover that is permeable to air.

  • Page 91: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 20) (250/300 XC) – Battery discharged Recharge the battery. p. 72) – Check the charging voltage. –...
  • Page 92 TROUBLESHOOTING Faults Possible cause Action Engine stalls or is popping into the Lack of fuel (All SX models) – carburetor of the fuel tap to the ON Turn handle  position. (Figure 601185-10 p. 12) (All XC models) – of the fuel tap to the ON Turn handle ...

  • Page 93: Technical Data - Engine

    1.4 mm (0.055 in) Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 150 SX 21.2 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 143.6 cm³ (8.763 cu in) Stroke 58.4 mm (2.299 in)

  • Page 94: 150 Xc Usa

    TECHNICAL DATA - ENGINE 6th gear 22:24 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.4 mm (0.055 in) Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 150 XC USA...

  • Page 95: 250 Xc Eu/Usa

    TECHNICAL DATA - ENGINE X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48 mm (1.89 in) Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydraulically activated Gearbox 5-gear, claw shifted Transmission ratio 1st gear...

  • Page 96: Xc Eu/Usa

    TECHNICAL DATA - ENGINE 300 XC EU/USA 21.6 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 293 cm³ (17.88 cu in) Stroke 72 mm (2.83 in) Bore 72 mm (2.83 in) Exhaust valve - Beginning of adjustment 5,600 rpm Exhaust valve - end of adjustment with red auxiliary spring 7,200 rpm...

  • Page 97: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES All 125/150 models 22.1 ® Screw, membrane 2 Nm (1.5 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, alternator cover 5 Nm (3.7 lbf ft) –...

  • Page 98: 250/300 Xc

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, clutch cover 10 Nm (7.4 lbf ft) ® Screw, clutch slave cylinder 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, clutch spring 10 Nm (7.4 lbf ft) ® Screw, control flap, exhaust control 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 99 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, stator 8 Nm (5.9 lbf ft) Loctite 243™ – Screw, water pump cover 10 Nm (7.4 lbf ft) – Screw, cylinder head 27 Nm (19.9 lbf ft) ® Screw, kick starter 25 Nm (18.4 lbf ft) Loctite 2701 –...

  • Page 100: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR 125 SX 23.1 Carburetor type KEIHIN PWK 38S AG Carburetor identification number AQ7_0 Needle position 3rd position from top Jet needle NOZI (NOZH, NOZJ) Main jet 182 (180, 185) Idling jet 42 (40, 45) Starting jet Idle air adjusting screw Open 1.5 turns...

  • Page 101: Carburetor Configuration (125 Sx)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (125 SX) 23.3 400709-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...

  • Page 102: Carburetor - Basic Setting For Sandy Surfaces (150 Sx)

    Idling jet 40 (42) Starting jet Idle air adjusting screw Open 2 turns Throttle slide 6.5 with cut-out Carburetor - basic setting for sandy surfaces (150 SX) 23.5 Idle air adjusting screw Open 1.5 turns Idling jet Jet needle NOZH...

  • Page 103: Carburetor Configuration (150 Sx)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (150 SX) 23.6 401037-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions.

  • Page 104: Carburetor - Basic Setting For Sandy Surfaces (250 Sx)

    TECHNICAL DATA - CARBURETOR 250 SX 23.7 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0181 Needle position 3rd position from top Jet needle N1EI (N1EH, N1EJ) Main jet 158 (155, 160) Idling jet 42 (40) Starting jet Idle air adjusting screw Open 2 turns Throttle slide...

  • Page 105: Carburetor Configuration (250 Sx)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (250 SX) 23.9 401038-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...

  • Page 106: 150 Xc Usa

    TECHNICAL DATA - CARBURETOR 150 XC USA 23.10 Carburetor type KEIHIN PWK 36S AG Carburetor identification number BC1_0 Needle position 3rd position from top Jet needle NOZI (NOZH, NOZJ) Main jet 170 (168, 172) Idling jet 42 (40, 45) Starting jet Idle air adjusting screw Open 1.5 turns...

  • Page 107: 250 Xc Eu/Usa

    TECHNICAL DATA - CARBURETOR Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info 0 0 3 Not for sandy surfaces 0 0 4 0 0 5 B00075-10...

  • Page 108: Carburetor Configuration (250 Xc Eu/Usa)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (250 XC EU/USA) 23.13 401040-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw is open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...

  • Page 109: 300 Xc Eu/Usa

    TECHNICAL DATA - CARBURETOR 300 XC EU/USA 23.14 Carburetor type KEIHIN PWK 36S AG Carburetor identification number BC5_0 Needle position 4th position from top Jet needle N2ZK (N2ZJ, N2ZL) Main jet 165 (162) Idling jet Starting jet Idle air adjusting screw Open 2 turns Throttle slide...
  • Page 110 TECHNICAL DATA - CARBURETOR Needle position from above Main jet 1... 5 Needle position from above The carburetor configuration depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info 0 0 3 Not for sandy surfaces 0 0 4 0 0 5 B00075-10...

  • Page 111: Technical Data - Chassis

    Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Secondary ratio (125 SX, 150 XC USA) 13:50 Secondary ratio (250/300 XC, 150 SX) 14:50 Secondary ratio (250 SX) 13:48 Chain 5/8 x 1/4" Rear sprockets available...

  • Page 112: Tires

    Total fuel tank capacity, 7.5 l (1.98 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) approx. p. 118) (125/150 SX) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) p. 118) (250 SX) Total fuel tank capacity, 11.5 l (3.04 US gal)

  • Page 113: Technical Data - Fork

    TECHNICAL DATA - FORK 125/150 SX 25.1 Fork part number 14.18.7L.01 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport...

  • Page 114: 150 Xc Usa

    TECHNICAL DATA - FORK 150 XC USA 25.3 Fork part number 14.18.7L.71 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s)

  • Page 115: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER 125/150 SX 26.1 Shock absorber part number 18.18.7L.01 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns Standard 2 turns Sport 1.5 turns...

  • Page 116: 150 Xc Usa

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber oil ( p. 118) SAE 2.5 150 XC USA 26.3 Shock absorber part number 18.18.7L.71 Shock absorber WP Suspension 5018 BAVP DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2.5 turns...
  • Page 117 TECHNICAL DATA - SHOCK ABSORBER Riding sag 100 mm (3.94 in) Fitted length 486 mm (19.13 in) Shock absorber oil ( p. 118) SAE 2.5...

  • Page 118: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) – Screw, shock absorber adjusting ring 5 Nm (3.7 lbf ft) –...

  • Page 119: Substances

    2-stroke engine oil According to – JASO FC ( p. 121) Guideline – ® Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex products. Fully synthetic Supplier ® Motorex – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 According to –...
  • Page 120 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)

  • Page 121: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 122 AUXILIARY SUBSTANCES Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Synthetic...

  • Page 123: Standards

    STANDARDS JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles –...

  • Page 124: Index

    INDEX Compression damping, high-speed INDEX shock absorber, adjusting ..... 29 Accessories ........5 Compression damping, low-speed Air filter shock absorber, adjusting .
  • Page 125 INDEX removing ....... . . 44 Preparing for use advice on first use ......15 Front wheel after storage .
  • Page 126 INDEX Swingarm checking ....... . . 54 Technical data carburetor ......98-108 chassis .
  • Page 127 *3211714en* 3211714en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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