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Summary of Contents for KTM 144 SX
- Page 1 OWNER’S MANUAL 2008 125 SX 144 SX 250 SX 3211225en...
- Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
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Page 3: Intended Purpose
» INTRODUCTION INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. -
Page 4: Warranty
SPARE PARTS, ACCESSORIES For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. TRANSPORT When transporting your motorcycle, secure it with elastic straps or other mechanical devices in an upright position. -
Page 5: Table Of Contents
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE .......9 Instructions for your first ride ....9 Running in . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. -
Page 7: Short Circuit Button
OPERATION INSTRUMENTS » Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: Press the release button [2] and turn the tank cap in a coun- terclockwise direction. -
Page 8: Shift Lever
OPERATION INSTRUMENTS 2,3,4,5, (6) » Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. Kickstarter The kickstarter is mounted on the left side of the engine. -
Page 9: Compression Damping Of Shock Absorber
(Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. -
Page 10: General Tips And Warnings For Starting The Motorcycle
Do not drive at full load for the first 500 kilometers (300 miles) or 5 hours! – Wear suitable clothing when driving a motorcycle. smart KTM drivers always wear a helmet, boots, gloves, and a jacket, regardless of whether driving all day or just go for a short ride. -
Page 11: Driving Instructions
Arrange for the braking system to be checked by an author- ized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings. -
Page 12: Starting When The Engine Is Cold
Always pro- vide adequate ventilation while the engine is running. Do not ride your motorcycle with full load and do not rev up the engine when cold. Since the piston warms up and expands faster than the water cooled cylinder, this might cause engine damage. -
Page 13: Shifting/Riding
– In the event that, while riding on your motorcycle, you notice any unusual operation-related noise, stop immediately, turn the engine off, and contact an authorized KTM dealer. Braking Turn off the gas and apply the hand and foot brakes at the same time. -
Page 14: Periodic Maintenance Schedule
Lubricate chain, Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours. Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver! »... - Page 15 » PERIODIC MAINTENANCE SCHEDULE 125/144/250 SX 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear...
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Page 16: Maintenance Work On Chassis And Engine
OFF position - if the motorcycle should fall over, no fuel can leak from the carburetor or fuel tank – Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank. Using other screws or longer screws can cause leaks in the tank through which fuel can flow out. -
Page 17: Basic Suspension Setup For The Weight Of The Driver
EXAMPLE: Motorcycle jacked up (dimension A) ..... .600 mm Motorcycle on ground, unloaded (dimension B) ... .– 567 mm Static sag . -
Page 18: Checking The Basic Setup Of The Telescopic Fork
The type number of the telescopic fork is embossed on the inside of the fork leg axle passage. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged. -
Page 19: Changing The Fork Offset (Caster)
MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course. -
Page 20: Checking And Adjusting The Steering Head Bearing
MAINTENANCE WORK ON CHASSIS AND ENGINE » Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw. Tighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages. -
Page 21: Check Chain Tension
The screws [4] must be secured with loctite 243. Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The dis- tance between the chain and the swing arm should be approx. -
Page 22: Correct Chain Tension
– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. -
Page 23: General Information About Ktm Disc Brakes
DOT 4 brake fluid. Do not, in any event, use DOT 5 brake fluid. It is based on silicone oil and is dyed purple. KTM motor- cycle gaskets and brake hoses are not designed for DOT 5 brake fluid. -
Page 24: Adjusting The Free Travel At The Hand Brake Lever
If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4]. -
Page 25: Replacing The Front Brake Pads
If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn. In this case, consult an author- ized KTM dealer immediately. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A]. -
Page 26: Changing The Basic Position Of The Foot Brake Pedal
MAINTENANCE WORK ON CHASSIS AND ENGINE 3-5mm min. 1 mm Changing the basic position of the foot brake pedal * To change the basic position of the foot brake lever, loosen the counternut [1] and turn the stop screw [2] as needed. Be sure to adjust the free travel of the foot brake lever. -
Page 27: Dismounting And Mounting The Front Wheel
– If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. -
Page 28: Dismounting And Mounting The Rear Wheel
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle behaves. -
Page 29: Checking Spoke Tension
Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. – Spokes can tear if you continue to ride with them loose. This may lead to an unstable handling of your motorcycle. -
Page 30: Bleeding The Cooling System
[3] and filter support [4] from the filter box. – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter maintenance (Dirt Bio Remover and Liquid Bio Power). -
Page 31: Exhaust System
Exhaust system * If the end cap [1] can be removed, the silencer is filled with glass-fiber yarn. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to “burn out”. -
Page 32: Bleeding The Hydraulic Clutch
You will need to use a bleeding syringe (spe- cial tool). Make sure to use Motorex clutch fluid 75 for the 125/144 SX models and Motorex DOT. 5.1 brake fluid for the 250 SX models. Both are available from your KTM dealer. -
Page 33: Carburetor Adjustment
If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. 1:40 (125/144 SX), 1:60 (250 SX) > choose leaner carburetor adjustment >... -
Page 34: Draining The Float Chamber Of The Carburetor
MAINTENANCE WORK ON CHASSIS AND ENGINE 125 SX / SXS JET NEEDLE RANGE OF ACTION TYPE RICHER R1468D R1469D R1470D R1471D 144 SX JET NEEDLE RANGE OF ACTION TYPE RICHER R1470H R1471H R1472H 250 SX / SXS JET NEEDLE RANGE OF ACTION... -
Page 35: Adjusting The Engine Characteristic Via The Ignition Curve
Auxiliary spring for aggressive engine characteristic (included in scope of sup- ply). Spare part number 548.37.072.000, RED color mark To mount, tilt the motorcycle approx. 45° to the left, remove both screws [2], lift off the closing cover [3] and remove the springs including the spring insert [4] from the clutch cover. -
Page 36: Check Transmission Oil Level (125/144)
4T 15W50). Changing the transmission oil (125/144 SX) * To change the gear oil warm up the engine and park the motorcycle on a hor- izontal surface. Remove oil drain plugs [3] and [4] and drain the used oil into an appropriate container. -
Page 37: Cleaning
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes. -
Page 38: Technical Specifications - Chassis
925 mm (36.5 in) Ground clearance, unloaded 390 mm (15.3 in) Weight (without fuel) 90.8 kg (200.4 lbs) STANDARD ADJUSTMENT – FORK 125/144 SX WP 4860 MXMA CC WP 4860 MXMA CC 14.18.7D.01 Compression adjuster 14 clicks Rebound adjuster 21 clicks Spring 432.485.00.042W 432.485.00.044W... -
Page 39: Tightening Torques - Chassis
TECHNICAL SPECIFICATIONS – CHASSIS 125/144/250 SX 2008 TIGHTENING TORQUES – CHASSIS Collar screw, front wheel spindle Colear screws brake caliper, front Collar screws brake disks Clamping screws, upper fork bridge Clamping screws, lower fork bridge Clamping screws, upper steering stem Collar srcew top steering stem Collar screw bottom steering stem Clamping screws, fork stubs... -
Page 40: Technical Specifications - Engine
45 (48) Starting jet Jet needle R1469D (R1470D) Needle position from top Throttle valve Air adjustment srew open 144 SX 143.6 ccm 54 / 58.4 mm 1:40 2 half keystone rings 0.0 mm 1.4 mm (0.055 in) BTDC NGK BR9 ECMVX 43.1 mm (1.69 in) -
Page 41: Tightening Torques - Engine
Nuts-cylinder base (250 SX) Flywheel collar nut Nut for primary sprocket (125/144 SX) Nut for primary sprocket (250 SX) Nut for inner clutch hub (125/144 SX) Nut for inner clutch hub (250 SX) Bundschraube Kupplungsfeder Oil drain plug Oil drain plug (125/144 SX) clutch cover... -
Page 42: Carburetor Table 125
» CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 39 MEERESHÖHE TEMPERATUR - 20°C bis -7°C ALTITUDE TEMPERATURE -2°F to 20°F 3000 m 10000 ft NADEL NEEDLE R1469D 2301 m 7501 ft 2300 m 7500 ft NADEL NEEDLE R1469D 1501 m 5001 ft 1500 m 5000 ft... -
Page 43: Carburetor Table 144
= Leerlaufdüse POS = Nadel Clip Position von oben = Hauptdüse NICHT FÜR STRASSENBETRIEB Kraftstoff: Super Bleifrei ROZ 95 » 144 SX 2008 - 20°C bis -7°C - 6°C bis 5°C 6°C bis 15°C -2°F to 20°F 19°F to 41°F 42°F to 60°F... -
Page 44: Carburetor Table 250
» CARBURETOR TABLE VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK-S 36 AG MEERESHÖHE TEMPERATUR - 20°C bis -7°C ALTITUDE TEMPERATURE -2°F to 20°F 3000 m 10000 ft NADEL NEEDLE N1EI 2301 m 7501 ft 2300 m 7500 ft NADEL NEEDLE N1EH 1501 m 5001 ft 1500 m 5000 ft... -
Page 45: Wirung Diagramm
» SCHALTPLAN WIRING DIAGRAMM » red-white red-black green... - Page 46 » SCHALTPLAN WIRING DIAGRAMM ENGLISH CABLE COLOURS bl: black ye: yellow bu: blue gr: green re: red wh: white br: brown or: orange pi: pink gr: grey pu: purple ENGLISH CABLE COLOURS bl: black ye: yellow bu: blue gr: green re: red wh: white br: brown...
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Page 47: Changing The Oil Level Of Hydraulic Clutch 125/144 Sx
Fuel tap ........6 General information about KTM disc brakes ..22 General tips and wanrnings for starting the motorcycle .9... - Page 48 *3211225en* 3211225en KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com...
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