KTM 250 SX 2010 Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Motorcycle
  5. 250 SX 2010
  6. Owner's manual

KTM 250 SX 2010 Owner's Manual

Hide thumbs Also See for 250 SX 2010:
Table of Contents

Advertisement

Quick Links

Download this manual
OWNER'S MANUAL
2010
125 SX
150 SX
250 SX
Art. no. 3211480en

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 250 SX 2010 and is the answer not in the manual?

Questions and answers

Related Manuals for KTM 250 SX 2010

Summary of Contents for KTM 250 SX 2010

  • Page 1 OWNER'S MANUAL 2010 125 SX 150 SX 250 SX Art. no. 3211480en...
  • 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

    Important maintenance work to be carried out by an Checking the free play of the foot brake lever ....46 authorized KTM workshop (as additional order)....24 Important checks and maintenance work to be carried Adjusting the basic position of the foot brake lever ..
  • Page 5 TABLE OF CONTENTS Ignition curve plug connection ........54 Carburetor - basic setting for sandy surfaces (150 SX) ..82 Changing the ignition curve ..........55 Carburetor configuration (150 SX)........83 Engine characteristic - auxiliary spring (250 SX)....55 250 SX................. 84 Carburetor - basic setting for sandy surfaces (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 in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. 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) B00010-10 Hand brake lever Short circuit button Clutch lever Air filter box lid Fuel tap Choke button Shift lever Chain guide...

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

    VIEW OF VEHICLE View of the vehicle from the right rear (example) B00014-10 Shock absorber rebound adjustment Level viewer for brake fluid, rear Fork rebound adjustment Foot brake lever Kickstarter Shock absorber compression adjustment Throttle grip Fork compression adjustment Filler cap...

  • Page 11: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head.  B00015-10 Type label The type label is fixed to the front of the steering head.  400284-10 Engine number The engine number is stamped on the left side of the engine under the engine ...

  • Page 12: Controls

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

  • Page 13: Fuel Tap

    CONTROLS Fuel tap The fuel tap is on the left side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the car-  buretor. Possible states Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. •...

  • Page 14: Shift Lever

    CONTROLS Shift lever Shift lever is mounted on the left side of the engine.  B00005-10 (125 SX, 150 SX) 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 15: Plug-In Stand

    CONTROLS Plug-in stand 5.12 Note Danger of damage The parked vehicle can roll away or fall over. – Always place the vehicle on a firm and even surface. To park the motorcycle, insert plug-in stand into the left side of the wheel spindle. ...

  • Page 16: General Tips And Hints On Putting Into Operation

    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 17: Running In The Engine

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 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.

  • Page 18: Preparations For Riding On Wet Sand

    Sand cover for air filter (59006022000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info 600871-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 96) –...

  • Page 19: 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 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop. – Clean the chain. Chain cleaner ( p. 96) –...

  • Page 20: Preparations For Riding At High Temperatures And Riding Slowly

    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 600870-01 The recommended carburetor tuning is available from your authorized KTM workshop.

  • Page 21: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. In the interests of riding safety, make a habit of making a general check before you ride. – Check the gear oil level. ( p.

  • Page 22: Starting Up

    Do not change into a low gear at high engine speed. The engine overspeeds and the rear wheel can block. 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 23: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Risk of misappropriation Usage by unauthorized persons. – Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. Warning Danger of burns Some vehicle components get very hot when the vehicle is in use. –...
  • Page 24 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 35 mm (1.38 in)  Total fuel tank 8 l (2.1 US gal) Super unleaded gasoline, mixed with capacity, approx. 2-stroke engine oil (1:40) ( p.

  • Page 25: Service Schedule

    SERVICE SCHEDULE Important maintenance work that must be done in an authorized KTM workshop S10N S20A S40A Engine Check the gear oil level. ( p. 68) • • • • Change the gear oil. p. 69) Check spark plug and replace if required.

  • Page 26: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As Additional Order)

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop (as additional order) S10A S20N S20A S30A S40A S80A • Check/set the carburetor components. Check the intake diaphragm. • • • Check the clutch lining discs.
  • Page 27 SERVICE SCHEDULE NB1A Check the coolant level. ( p. 59) • Empty the carburetor float chamber. p. 68) • Check all controls for smooth operation. • Check braking. • Check all screws, nuts and hose clamps regularly for tightness. • NB1A: Depending on conditions of use according to requirements.

  • Page 28: Maintenance Work On Chassis And Engine

    Danger 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 29: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    Danger 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 30: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound damping of the shock absorber Danger 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 up to the last perceptible click.

  • Page 31: Checking The Static Sag Of The Shock Absorber

    Danger 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 32: Adjusting The Riding Sag

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Unscrew screw  – Turn adjusting ring until the spring is no longer under tension.  Combination wrench (50329080000) Hook wrench (T106S) – Measure the overall spring length when not under tension. – Tighten the spring by turning adjusting ring to measurement ...

  • Page 33: Installing The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the shock absorber 9.14 – Push splash protector to the side and position the shock absorber. Mount and  tighten screw  Guideline Screw, top shock absorber 80 Nm Loctite ® 243™ (59 lbf ft) –...

  • Page 34: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE Info Turn clockwise to increase damping, turn counterclockwise to reduce damp- ing. Adjusting the rebound damping of the fork 9.17 Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection covers ...

  • Page 35: Loosening The Fork Protection

    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 for a lengthy period with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 36: Adjusting The Play Of The Steering Head Bearing

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

  • Page 37: Installing The Fork Legs

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the fork legs 9.25 – Position the fork legs. Info The topmost milled groove in the fork leg must be flush to the upper edge of the upper triple clamp. Position bleeder screws toward the front.

  • Page 38: Removing The Lower Triple Clamp

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the lower triple clamp 9.28 – Remove the fork legs. p. 34) – Remove the start number plate. ( p. 37) – Remove the front fender. ( p. 37) – Remove screws and hang the CDI control unit to the side. ...

  • Page 39: Greasing The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screw  Guideline Screw, top steering stem 17 Nm Loctite ® 243™ (12.5 lbf ft) – Check that the wiring harness, throttle cables and brake and clutch lines can move freely and are routed correctly.

  • Page 40: Installing The Start Number Plate

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the start number plate 9.34 – Position the start number plate. Mount and tighten screw  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Ensure that the holding lugs engage in the fender. –...

  • Page 41: Checking The Play In The Throttle Cable

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the play in the throttle cable 9.37 – Move the handlebar to the straight-ahead position. – Push back bellows  – Pull back the throttle cable casing until you sense a resistance. – Now check throttle cable play ...

  • Page 42: Checking The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 96) Off-road chain spray ( p. 96) 400725-01 Checking the chain tension 9.41 Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 43: Adjusting The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Shift gear to neutral. – Pull on the upper part of the chain with the specified weight  Guideline 0 0 A Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section.

  • Page 44: Adjusting The Chain Guide

    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 45: Checking The Free Travel Of The Hand Brake Lever

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes 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 46: Adding Front Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 47: Removing The Front Brake Linings

    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 48: Changing 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 brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 49: Adjusting The Basic Position Of The Foot Brake Lever

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

  • Page 50: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 51: Removing The Rear Brake Linings

    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 52: Changing 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 brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 53: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Do not pull the hand brake lever when the front wheel is removed. Always lay the wheel down in such a way that the brake disc is not dam- aged.

  • Page 54: Removing The Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the rear wheel 9.65 – Jack up the motorcycle. ( p. 26) – 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.

  • Page 55: Checking The Tire Condition

    DOT marking. The first two digits indi- cate the week of manufacture and the last two digits the year of manufac- ture. KTM recommends that the tires are changed at the latest after 5 years, regardless of the actual state of wear. »...

  • Page 56: 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 57: Changing The Ignition Curve

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the ignition curve 9.71 Change the ignition curve from Performance to Soft. – Disconnect plug connection . (Figure B00029-10 p. 54)  Soft – better rideability Change the ignition curve from Soft to Performance. –...

  • Page 58: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Check the O-ring in the locking cap. – Position the locking cap. – Mount and tighten the screws. Guideline Remaining screws, engine 6 Nm (4.4 lbf ft) Removing the seat 9.74 – Remove screw .

  • Page 59: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw with the collar sleeve.  – Remove the tube from the fuel tank vent line. B00033-10 – Pull both spoilers sideways off of radiator bracket and lift off the fuel tank. ...

  • Page 60: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount and tighten screws with the collar sleeve.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Connect the fuel hose. – Mount the seat. ( p. 56) B00031-11 Cooling system 9.78 (125 SX, 150 SX) Water pump...

  • Page 61: Checking The Coolant Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Correct the coolant level. Alternative 1 Coolant ( p. 94) Alternative 2 Coolant (mixed ready to use) ( p. 94) – Mount the radiator cap. Checking the coolant level 9.80 Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. –...

  • Page 62: Refilling With Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE (125 SX, 150 SX) – 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)

  • Page 63: Removing The Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the main silencer 9.83 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Remove screws ...

  • Page 64: Removing The Glass Fiber Yarn Filling Of The Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the glass fiber yarn filling of the main silencer 9.87 Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. –...

  • Page 65: Removing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the air filter 9.91 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 66: Adjusting The Basic Position Of The Clutch Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Oil the dry air filter with a high quality filter oil. Oil for foam air filter ( p. 96) – Clean the air filter box. – Check the carburetor connection boot for damage and tightness. –...

  • Page 67: Changing The Hydraulic Clutch Fluid

    MAINTENANCE WORK ON CHASSIS AND ENGINE » If the level of the fluid does not meet specifications: – Correct the fluid level of the hydraulic clutch. Brake fluid DOT 4 / DOT 5.1 ( p. 94) – Position the cover with the membrane. Mount and tighten the screws. Changing the hydraulic clutch fluid 9.96 Warning...

  • Page 68: Checking The Basic Position Of The Shift Lever

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Inject the liquid into the system until it escapes from hole of the master  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 69: Carburetor - Adjusting The Idle Speed

    MAINTENANCE WORK ON CHASSIS AND ENGINE (250 SX) Altitude above sea level 500 m (1,640 ft) Ambient temperature 20 °C (68 °F) Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 95) The idle speed is adjusted with adjustment screw ...

  • Page 70: Emptying The Carburetor Float Chamber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust to the point between these two positions with the highest idle speed. Info If there is a large engine speed rise, reduce the idle speed to a normal level and repeat the above steps. If the procedure described here does not lead to satisfactory results, the cause may be a wrongly dimensioned idling jet.

  • Page 71: Changing The Gear Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE (125 SX, 150 SX) – Remove gear oil level check screw  – Check the gear oil level. A small amount of gear oil should flow out of the hole. » If no gear oil flows out: –...

  • Page 72: Refilling With Gear Oil

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Place the motorcycle on a level surface. – Place a suitable container under the engine. (125 SX, 150 SX) – Remove the gear oil drain plug with magnet  – Remove the gear oil drain plug ...
  • Page 73 MAINTENANCE WORK ON CHASSIS AND ENGINE (125 SX, 150 SX) – Remove gear oil level check screw  B00049-10 (250 SX) – Remove gear oil level check screw  B00050-10 – Remove screw cap  – Add gear oil until it flows out of the hole of the gear oil level check screw. Engine oil (15W/50) ( p.

  • Page 74: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start Operating error Go through the steps of starting the engine. p. 19) – Motorcycle was out of use for a long Empty the carburetor float chamber. time and there is old fuel in the float p.
  • Page 75 TROUBLESHOOTING Faults Possible cause Action – Engine overheats Radiator fins very dirty Clean the radiator fins. – Foam formation in cooling system Drain the coolant. p. 59) – Refill with coolant. p. 60) – Damaged cylinder head or cylinder Check the cylinder head or cylinder head gas- head gasket ket.

  • Page 76: Cleaning

    CLEANING Cleaning the motorcycle 11.1 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 77: Storage

    Check the tire air pressure. ( p. 54) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 26) –...

  • Page 78: Technical Data - Engine

    TECHNICAL DATA - ENGINE 125 SX 13.1 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing...

  • Page 79: Capacity - Gear Oil

    TECHNICAL DATA - ENGINE Ignition Kokusan 2K-1 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 Kickstarter 250 SX 13.3 Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 249 cm³...

  • Page 80: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES 125 SX, 150 SX 14.1 – Remaining screws, engine 6 Nm (4.4 lbf ft) – Screw, alternator cover 5 Nm (3.7 lbf ft) – Screw, exhaust control cover 5 Nm (3.7 lbf ft) ® Screw, ignition system/stator 6 Nm (4.4 lbf ft) Loctite...
  • Page 81 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Gear oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –...

  • Page 82: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR 125 SX 15.1 Carburetor type KEIHIN PWK 38S AG Carburetor identification number 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 Throttle slide...

  • Page 83: Carburetor Configuration (125 Sx)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (125 SX) 15.3 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 84: Carburetor - Basic Setting For Sandy Surfaces (150 Sx)

    TECHNICAL DATA - CARBURETOR 150 SX 15.4 Carburetor type KEIHIN PWK 38S AG Carburetor identification number Needle position 2nd 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 Throttle slide...

  • Page 85: Carburetor Configuration (150 Sx)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (150 SX) 15.6 400710-01 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 86: Carburetor - Basic Setting For Sandy Surfaces (250 Sx)

    TECHNICAL DATA - CARBURETOR 250 SX 15.7 Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK0180 Needle position 3rd position from top Jet needle N1EI (N1EH) Main jet 158 (155, 160) Idling jet 42 (40) Starting jet Idle air adjusting screw Open 1.0 turn Throttle slide...

  • Page 87: Carburetor Configuration (250 Sx)

    TECHNICAL DATA - CARBURETOR Carburetor configuration (250 SX) 15.9 400711-01 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 88: Technical Data - Chassis

    80/100 - 21 51M TT 110/90 - 19 62M TT Bridgestone M59 Bridgestone M70 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 16.2 Total fuel tank capacity, 8 l (2.1 US gal) Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) approx.

  • Page 89: Technical Data - Fork

    TECHNICAL DATA - FORK 125 SX, 150 SX 17.1 Fork part number 14.18.7J.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 10 clicks Spring length with preload spacer(s)

  • Page 90: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER 125 SX, 150 SX 18.1 Shock absorber part number 12.18.7J.01 Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, high-speed Comfort 2 turns Standard 1.5 turns Sport...
  • Page 91 TECHNICAL DATA - SHOCK ABSORBER Shock absorber oil ( p. 95) SAE 2.5...

  • Page 92: 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 5… 6 Nm (3.7… 4.4 lbf ft) – Remaining nuts, chassis 15 Nm (11.1 lbf ft) –...

  • Page 94: Wiring Diagram

    WIRING DIAGRAM Wiring diagram 20.1 re-wh re-bl B00059-10...
  • Page 95 WIRING DIAGRAM Components CDI controller Generator Pulse generator Ignition coil Plug-in connector, ignition curve Short circuit button Cable colors Green gr-bl Gray-black Gray Black ye-bl Yellow-black bu-wh Blue-white re-wh Red-white re-bl Red-black Brown...

  • Page 96: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 97 SUBSTANCES Shock absorber oil (SAE 2.5) (50180342S1) according to – SAE ( p. 98) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) according to –...

  • Page 98: 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 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –...
  • Page 99 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...

  • Page 100: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation.

  • Page 101: Index

    INDEX Compression damping INDEX fork, adjusting ......31 Accessories ........5 Compression damping, high-speed Air filter shock absorber, adjusting...
  • Page 102 INDEX removing ....... . . 50 removing ....... . . 52 Fuel tank Rebound damping installing .
  • Page 103 INDEX Use definition ....... . . 5 View of vehicle right rear .
  • Page 104 *3211480en* 3211480en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

2010 150 sx2010 125 sx

Table of Contents

Save PDF