KTM 125 SX EU Owner's Manual
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KTM 125 SX EU Owner's Manual

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OWNER'S MANUAL
2013
125 SX EU
125 SX USA
150 SX EU
150 SX USA
250 SX EU
250 SX USA
150 XC USA
250 XC EU/USA
300 XC EU/USA
Art. no. 3211857en

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Summary of Contents for KTM 125 SX EU

  • Page 1 OWNER'S MANUAL 2013 125 SX EU 125 SX USA 150 SX EU 150 SX USA 250 SX EU 250 SX USA 150 XC USA 250 XC EU/USA 300 XC EU/USA Art. no. 3211857en...
  • 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 Starting off............. 24 TABLE OF CONTENTS MEANS OF REPRESENTATION ........5 Shifting, riding ..........24 Symbols used ........... 5 Braking ............24 Formats used............ 5 Stopping, parking..........25 SAFETY ADVICE............6 Transport ............25 Use definition - intended use ......6 Refueling ............
  • Page 5 ......73 21.3.2 Carburetor - basic setting for sandy 13.2 Installing the front wheel ......73 surfaces (125 SX EU, 125 SX USA) ... 105 13.3 Removing the rear wheel ......74 21.3.3 Carburetor tuning (125 SX EU, 125 SX USA) ........... 106 13.4...
  • Page 6 Electrical system........... 116 21.7 Tires ............116 21.8 Fork............. 117 21.8.1 125 SX EU, 150 SX EU ......117 21.8.2 125 SX USA, 150 SX USA ......117 21.8.3 250 SX EU ..........117 21.8.4 250 SX USA ..........118 21.8.5...

  • Page 7: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 8: Safety Advice

    Use definition - intended use (All SX models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations.

  • Page 9: Safe Operation

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 10: Important Notes

    Guarantee, 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 11: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) 101649-10 Hand brake lever ( p. 12) Kill switch ( p. 12) Clutch lever ( p. 12) Air filter box lid Fork rebound setting Fuel tap Choke ( p. 15) Shift lever ( p.

  • Page 12: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) 101650-10 Seat Filler cap Handlebar cushion Throttle grip ( p. 12) Fork compression adjustment Shock absorber rebound adjustment Level viewer for brake fluid, rear Shock absorber compression adjustment Foot brake lever ( p.

  • Page 13: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. 101652-10 Type label The type label is fixed to the front of the steering head. 101653-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 14: 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. 101655-10 (All 250/300 models) The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

  • Page 15: 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 101660-10 Opening the filler cap Danger...

  • Page 16: Closing The Filler Cap

    CONTROLS Closing the filler cap (All SX models) – Mount filler cap and turn it clockwise until the fuel tank is tightly closed. Info Run the fuel tank breather hose without kinks. 101662-10 (All XC models) – Mount filler cap and turn it clockwise until the release button engages.

  • Page 17: 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 18: Kick Starter

    CONTROLS (250 SX EU, 250 SX USA) The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 101667-10 6.12 Kick starter The kick starter is fitted on the right side of the engine. The top part can be swiveled.
  • Page 19 CONTROLS The side stand is used to park the motorcycle. Info When you are riding, side stand must be folded up and secured with rubber band 800212-10...

  • Page 20: Preparing For Use

    When using your motorcycle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

  • Page 21: Running In The Engine

    PREPARING FOR USE – Do not exceed the overall maximum permitted weight and the axle loads. 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.) –...

  • Page 22: Preparations For Riding On Wet Sand

    Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info B00436-01 Your authorized KTM workshop can recommend the right carburetor tuning. – Clean the chain. Chain cleaner ( p. 127) – Mount the steel sprocket.

  • Page 23: 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 Your authorized KTM workshop can recommend the right carburetor tuning. – Mount the steel sprocket. – Clean the motorcycle. ( p. 95) –...

  • Page 24: Preparing For Riding 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 Your authorized KTM workshop can recommend the right carburetor tuning.

  • Page 25: 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. 91) –...

  • Page 26: 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 27: 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. – Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but do not overrev the engine.

  • Page 28: Refueling

    RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 29: Service Schedule

    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 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal) S30A: Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal)

  • Page 30: Service Work (As Additional Order)

    SERVICE SCHEDULE 9.1.2 Service work (as additional order) S20N S40A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 63) • Grease the steering head bearing. p. 47) • • • Check/set the carburetor components.

  • Page 31: Service Work (As Additional Order)

    • • Make the service entry in KTM DEALER.NET and in the service record. S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal) S40A: Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) / after every race 9.2.2...

  • Page 32: 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 33: 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 34: Adjusting The Rebound Damping Of The Shock Absorber

    Adjusting the rebound 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.) – Turn adjusting screw clockwise up to the last perceptible click.

  • Page 35: Measuring The Sag Of The Unloaded Rear Wheel

    TUNING THE CHASSIS Guideline Rebound damping (125 SX EU, 150 SX EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (125 SX USA, 150 SX USA) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping (250 SX EU)

  • Page 36: Checking The Static Sag 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 37: Adjusting The Riding Sag

    Measure the overall spring length while the spring is not under tension. – Tighten the spring by turning adjusting ring to measurement Guideline Spring preload (125 SX EU, 9 mm (0.35 in) 150 SX EU) Spring preload (125 SX USA, 12 mm (0.47 in)
  • Page 38 TUNING THE CHASSIS Guideline Spring rate (125 SX EU, 150 SX EU) 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 39: Checking The Basic Setting 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 SX EU, 150 SX EU) 101275-10 Comfort 14 clicks Standard...

  • Page 40: Adjusting The Rebound 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 B00295-10 Rebound damping (125 SX EU, 150 SX EU) Comfort 14 clicks Standard 12 clicks Sport...

  • Page 41: Adjusting The Handlebar Position

    TUNING THE CHASSIS 10.15 Adjusting the handlebar position Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it to one side.

  • Page 42: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with the lift stand (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 43: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS Main work – Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. – Mount and tighten bleeder screws. 101672-10 Finishing work – Remove the motorcycle from the lift stand. ( p.

  • Page 44: Positioning The Fork Protection

    SERVICE WORK ON THE CHASSIS 11.6 Positioning the fork protection – Position the fork protection on the left fork leg. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Position the brake line. Position the clamp and mount and tighten screws –...

  • Page 45: Removing The Fork Protector

    SERVICE WORK ON THE CHASSIS – Position the brake caliper and mount and tighten screws Guideline Screw, front brake caliper 25 Nm Loctite ® 243™ (18.4 lbf ft) – Position the brake line. Put the clamp on and mount and tighten screws 800191-11 Finishing work –...

  • Page 46: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS Main work – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and set it aside. Info Protect the motorcycle and its attachments against damage by covering them. Do not bend the cables and lines. 101673-10 –...

  • Page 47: Position The Brake Caliper And Mount And Tighten Screws 4 . Guideline

    SERVICE WORK ON THE CHASSIS – Fully tighten screws Guideline Screw, bottom triple clamp 12 Nm (8.9 lbf ft) 101733-10 – Tighten screw Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 101676-10 – Mount and tighten screw Guideline Screw, top steering stem 17 Nm...

  • Page 48: 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 49: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS 11.15 Greasing the steering head bearing – Remove the lower triple clamp. p. 43) – Install the lower triple clamp. p. 44) 800010-10 11.16 Removing the start number plate – Remove screw and take off the clamp. –...

  • Page 50: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 11.19 Installing the front fender Main work – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 101724-10 Finishing work – Install the start number plate. ( p.

  • Page 51: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11.21 Installing the shock absorber Main work – 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) 101729-11 –...

  • Page 52: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 11.24 Removing the air filter box lid Condition The air filter box lid is secured. – Remove screws 101684-10 – Pull off the air filter box lid in area sideways and remove it toward the front. 101685-10 11.25 Installing the air filter box lid...

  • Page 53: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS Main work – Detach air filter holder at the bottom and swing it to one side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. 601196-10 11.27 Installing the air filter...

  • Page 54: Securing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 51) – Install the air filter box lid. ( p. 50) 11.29 Securing the air filter box lid Preparatory work –...

  • Page 55: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.32 Installing the main silencer – Mount the main silencer with rubber sleeve – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 800199-11 11.33 Changing the glass fiber yarn filling of the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

  • Page 56: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 57: Checking The Chain For Dirt

    SERVICE WORK ON THE CHASSIS Main work – Position the fuel tank and fit the two spoilers to the sides of the radiator bracket. – Make sure that no cables are trapped or damaged. 101689-01 – Mount the fuel tank vent hose. –...

  • Page 58: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 127) Off-road chain spray ( p. 127) 400725-01 11.38 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 59: Checking The Chain, Rear Sprocket, Engine Sprocket And Chain Guide

    SERVICE WORK ON THE CHASSIS Main work – Loosen nut – Loosen nuts – Adjust the chain tension by turning the 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 the reference marks .

  • Page 60: Remaining Screws, Chassis M6

    SERVICE WORK ON THE CHASSIS – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Change the chain sliding guard. – Check the chain sliding guard for tightness. »...

  • Page 61: Adjusting The Chain Guide

    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 11.43 Checking the swingarm –...
  • Page 62 SERVICE WORK ON THE CHASSIS Main work (125/150 SX) – Check the routing of the throttle cable. The throttle cable must be routed along the back of the handlebar, to the right of the frame, below the fuel tank bracket, and to the carburetor. »...

  • Page 63: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS (250/300 XC) – Check the routing of the throttle cable. The throttle cable must be routed along the back of the handlebar, to the right of the frame, below the fuel tank bracket, and to the carburetor. »...

  • Page 64: Checking/Correcting The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar. Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.

  • Page 65: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11.49 Changing the hydraulic clutch fluid Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. (All 125/150 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion.
  • Page 66 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 67: Brake System

    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...

  • Page 68: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to 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 69: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to 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 70 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 71: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – 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. 124) – Position the cover with the membrane. Mount and tighten the screws. Info 100399-10 Wash off overflowed or spilled brake fluid immediately with water.

  • Page 72: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to 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 73: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to 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 74 BRAKE SYSTEM – 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 75: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 40) Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

  • Page 76: 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 the brake disc.

  • Page 77: Checking The Tire Condition

    Checking the tire condition 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 78: 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 79: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery (250/300 XC) Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 80: Changing The Main Fuse (250/300 Xc)

    – 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 81 ELECTRICAL SYSTEM Main work – Remove screw 101395-10 – Lift rear fairing slightly and pull starter relay out of the holder. 101396-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay.

  • Page 82: Cooling System

    COOLING SYSTEM 15.1 Cooling system (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 coolant temperature will not result in a risk of malfunctions.

  • Page 83: Installing The Radiator Cover (All Sx Models)

    COOLING SYSTEM – Attach the radiator shield at holding lugs . Attach mounting points at the radi- ator. 101750-10 Finishing work – Install the fuel tank. p. 54) – Mount the seat. ( p. 49) 15.4 Installing the radiator cover (All SX models) Preparatory work –...

  • Page 84: Checking The Coolant Level

    COOLING SYSTEM – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant antifreeze. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. –...

  • Page 85: Refilling With Coolant

    COOLING SYSTEM Condition The engine is cold. – Position the motorcycle upright. – Place a suitable container under the water pump cover. (All 125/150 models) – Remove screw . Take off radiator cap – Completely drain the coolant. – Mount and tighten screw with a new seal ring.
  • Page 86 COOLING SYSTEM – Position the motorcycle upright. – Fill the radiator completely with coolant. Coolant 1.2 l (1.3 qt.) Coolant ( p. 124) Coolant (mixed ready to use) p. 124) – Mount radiator cap – Run the engine until it is warm. –...

  • Page 87: Tuning The Engine

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

  • Page 88: Carburetor - Adjusting The Idle Speed

    Screw in idle air adjusting screw all the way and turn it to the specified basic position. Guideline Idle air adjusting screw (125 SX EU, 125 SX USA) Open 1.5 turns Idle air adjusting screw (150 SX EU, 150 SX USA)

  • Page 89: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Danger Danger of poisoning Exhaust gases are toxic 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 90: Plug-In Connection, Ignition Timing Map

    TUNING THE ENGINE Main work – Place a cloth beneath the carburetor to soak up emerging fuel. – Remove plug – Completely drain the fuel. – Mount and tighten the plug. 101714-10 16.6 Plug-in connection, ignition timing map Plug-in connection is located in front of the fuel tank on the left side of the frame.

  • Page 91: Engine Characteristic - Auxiliary Spring (All 250/300 Models)

    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 compo- nents during the shift procedure.
  • Page 92 TUNING THE ENGINE – Mount the required auxiliary spring and adjusting spring and slide them into the clutch cover together. Auxiliary spring with yellow marking (54637072300) Auxiliary spring with green marking (54837072100) Auxiliary spring with red marking (54837072000) The recess in spring insert engages in the angle lever.

  • Page 93: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. Main work (All 125/150 models) –...

  • Page 94: Draining The Gear Oil

    SERVICE WORK ON THE ENGINE 17.3 Draining the gear oil 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 95: Adding Gear Oil

    SERVICE WORK ON THE ENGINE Main work – Remove screw cap and fill up gear oil. Gear oil (All 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 124) 125/150 models) Gear oil (All 0.80 l (0.85 qt.) Engine oil (15W/50) ( p.
  • Page 96 SERVICE WORK ON THE ENGINE – Mount and tighten screw cap Finishing work Danger Danger of poisoning Exhaust gases are toxic 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 97: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 98: Storage

    76) – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends lifting the motorcycle. – Raise the motorcycle with the lift stand. ( p. 40) – Cover the vehicle with a tarp or cover that is permeable to air.

  • Page 99: 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. 23) (250/300 XC) – Battery discharged Recharge the battery. p. 77) – Check the charging voltage. –...
  • Page 100 TROUBLESHOOTING Faults Possible cause Action (All SX models) Engine stalls or is popping into the Lack of fuel – carburetor Turn handle of the fuel tap to the ON position. (Figure 601185-10 p. 14) (All XC models) – Turn handle of the fuel tap to the ON position.

  • Page 101: Technical Data

    TECHNICAL DATA 21.1 Engine 21.1.1 125 SX EU, 125 SX USA 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...

  • Page 102: Sx Eu, 250 Sx Usa

    TECHNICAL DATA 5th gear 19:23 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 21.1.3...

  • Page 103: Xc Eu/Usa

    TECHNICAL DATA X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 44.3 mm (1.744 in) Primary transmission 23:73 Clutch Multidisc clutch in oil bath/hydraulically activated Gearbox 6-gear, claw shifted Transmission ratio 1st gear 13:32...

  • Page 104: Xc Eu/Usa

    TECHNICAL DATA 21.1.6 300 XC EU/USA 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 Exhaust valve - end of adjustment with yellow auxiliary spring...

  • Page 105: 250 Sx Eu, 250 Sx Usa

    TECHNICAL DATA – Screw, clutch spring 10 Nm (7.4 lbf ft) – Screw, engine case 10 Nm (7.4 lbf ft) – Screw, exhaust control 10 Nm (7.4 lbf ft) – Screw, gear oil level check 10 Nm (7.4 lbf ft) –...

  • Page 106: 250/300 Xc

    TECHNICAL DATA – Screw, slave cylinder of the clutch 10 Nm (7.4 lbf ft) – 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 243™...

  • Page 107: Carburetor

    Starting jet Idle air adjusting screw Open 1.5 turns Throttle slide 7 with cut-out 21.3.2 Carburetor - basic setting for sandy surfaces (125 SX EU, 125 SX USA) Idle air adjusting screw Open 1.5 turns Idling jet Jet needle NOZH...

  • Page 108: Carburetor Tuning (125 Sx Eu, 125 Sx Usa)

    TECHNICAL DATA 21.3.3 Carburetor tuning (125 SX EU, 125 SX USA) 400709-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor tuning depends on the defined ambient and operating conditions.

  • Page 109: Sx Eu, 150 Sx Usa

    TECHNICAL DATA 21.3.4 150 SX EU, 150 SX USA Carburetor type KEIHIN PWK 38S AG Carburetor identification number BC0_0 Needle position 2nd position from top Jet needle NOZI (NOZH, NOZJ) Main jet 182 (180, 185) Idling jet 40 (42) Starting jet Idle air adjusting screw Open 2 turns...

  • Page 110: Carburetor Tuning (150 Sx Eu, 150 Sx Usa)

    TECHNICAL DATA 21.3.6 Carburetor tuning (150 SX EU, 150 SX USA) 401037-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor tuning depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...

  • Page 111: Sx Eu, 250 Sx Usa

    TECHNICAL DATA 21.3.7 250 SX EU, 250 SX USA 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...

  • Page 112: Carburetor Tuning (250 Sx Eu, 250 Sx Usa)

    TECHNICAL DATA 21.3.9 Carburetor tuning (250 SX EU, 250 SX USA) 401038-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor tuning depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...

  • Page 113: 21.3.10 150 Xc Usa

    TECHNICAL DATA 21.3.10 150 XC USA 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 Throttle slide...

  • Page 114: 21.3.12 250 Xc Eu/Usa

    TECHNICAL DATA Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor tuning 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 115: Carburetor Tuning (250 Xc Eu/Usa)

    TECHNICAL DATA 21.3.13 Carburetor tuning (250 XC EU/USA) 401040-01 M/FT ASL Sea level TEMP Temperature Idle air adjusting screw open Idling jet Needle Needle position from above Main jet 1... 5 Needle position from above The carburetor tuning depends on the defined ambient and operating conditions. 0 0 1 0 0 2 Info...

  • Page 116: 21.3.14 300 Xc Eu/Usa

    TECHNICAL DATA 21.3.14 300 XC EU/USA 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 7 with cut-out...

  • Page 117: Capacities

    WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 300 mm (11.81 in) Suspension travel (125 SX EU, 150 SX EU, 250 SX EU) Rear 330 mm (12.99 in) Suspension travel (All XC models, 125 SX USA, 150 SX USA, 250 SX USA) Rear 317 mm (12.48 in)

  • Page 118: Electrical System

    Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Secondary ratio (125 SX EU, 125 SX USA, 150 XC USA) 13:50 Secondary ratio (250/300 XC, 150 SX EU, 150 SX USA) 14:50 Secondary ratio (250 SX EU, 250 SX USA)

  • Page 119: Fork

    TECHNICAL DATA 21.8 Fork 21.8.1 125 SX EU, 150 SX EU Fork part number 14.18.7M.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...

  • Page 120: Sx Usa

    TECHNICAL DATA Standard 12 clicks Sport 10 clicks Rebound damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Spring length with preload spacer(s) 497 mm (19.57 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.2 N/mm (24 lb/in) Weight of rider: 75…...

  • Page 121: 250/300 Xc

    380 ml (12.85 fl. oz.) Fork oil (SAE 4) (48601166S1) ( p. 124) cartridge 21.9 Shock absorber 21.9.1 125 SX EU, 150 SX EU Shock absorber part number 18.18.7M.01 WP Suspension 5018 BAVP DCC Shock absorber Compression damping, low-speed Comfort...

  • Page 122: Sx Usa, 150 Sx Usa

    TECHNICAL DATA Weight of rider: 75… 85 kg (165… 187 lb.) 48 N/mm (274 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 51 N/mm (291 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag...

  • Page 123: Sx Usa

    TECHNICAL DATA Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 51 N/mm (291 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 54 N/mm (308 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 57 N/mm (325 lb/in) Spring length 260 mm (10.24 in) Gas pressure...

  • Page 124: 250/300 Xc

    TECHNICAL DATA Sport 13 clicks Spring preload 12 mm (0.47 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 45 N/mm (257 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 48 N/mm (274 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 51 N/mm (291 lb/in) Spring length 260 mm (10.24 in)
  • Page 125 TECHNICAL DATA ® Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite 243™ – Screw, throttle grip 3 Nm (2.2 lbf ft) – Nut, foot brake lever stop 20 Nm (14.8 lbf ft) Nut, rear sprocket screw 35 Nm (25.8 lbf ft) Loctite ®...

  • Page 126: Substances

    SUBSTANCES 2-stroke engine oil According to – JASO FC ( p. 129) 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 127 Hydraulic fluid (15) According to – 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 ® –...
  • Page 128 SUBSTANCES Super unleaded gasoline (98 octane), mixed with 2-stroke engine oil (1:40) According to – DIN EN 228 – JASO FC ( p. 129) (1:40) Mixture ratio 1:40 2-stroke engine oil ( p. 124) Super unleaded (ROZ 98 / RON 98 / PON 94) ( p.

  • Page 129: 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 130 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motorex ®...

  • Page 131: 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 132: Index

    INDEX Clutch INDEX fluid level, checking/correcting ....62 Accessories ........8 fluid, changing .
  • Page 133 INDEX installing ....... . . 42 Motorcycle removing ....... . . 42 cleaning .
  • Page 134 INDEX Starting ........23 Steering head bearing greasing .
  • Page 135 *3211857en* 3211857en 07/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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