Instrukcja obsługi KTM 125 (2011)
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OWNER'S MANUAL 2011
125 SX
150 SX
250 SX
150 XC USA
250 XC EU/USA
300 XC EU/USA
Art. no. 3211596en
DEAR KTM CUSTOMER 1
DEAR KTMCUSTOMER
DEAR KTMCUSTOMER
DEAR KTMCUSTOMER
DEAR KTMCUSTOMERDEAR KTMCUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.
Chassis number ( p. 9) Dealer's stamp
Engine number ( p. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can, however, not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 2
TABLE OFCONTE NTS
TABLE OFCONTE NTS
TABLE OFCONTE NTS
TABLE OFCONTE NTSTABLE OFCONTE NTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT INFORMATION ................................................ 5
VIEW OF VEHICLE............................................................... 7
View of the vehicle from the left front (example)................. 7
View of the vehicle from the right rear (example) ................ 8
SERIAL NUMBERS.............................................................. 9
Chassis number............................................................... 9
Type label....................................................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
CONTROLS ....................................................................... 10
Clutch lever .................................................................. 10
Hand brake lever ........................................................... 10
Throttle grip.................................................................. 10
Kill switch .................................................................... 10
Electric starter button (250/300 XC) ............................... 11
Opening the filler cap .................................................... 11
Closing the filler cap...................................................... 11
Fuel tap (All XC models)................................................. 11
Fuel tap (All SX models)................................................. 12
Choke........................................................................... 12
Shift lever..................................................................... 12
Kickstarter .................................................................... 13
Foot brake lever............................................................. 13
Side stand (All XC models) ............................................. 13
Plug-in stand (All SX models) ......................................... 14
PUTTING INTO OPERATION............................................... 15
Advice on first use......................................................... 15
Running in the engine.................................................... 16
Preparing the vehicle for difficult operating conditions ...... 16
Preparations for riding on dry sand .................................. 16
Preparations for riding on wet sand ................................. 17
Preparations for riding on wet and muddy surfaces ........... 18
Preparations for riding at high temperatures and low
speeds.......................................................................... 19
Preparations for riding at low temperatures and in snow .... 19
RIDING INSTRUCTIONS .................................................... 20
Checks and maintenance work when preparing for use ...... 20
Starting ........................................................................ 20
Starting up ................................................................... 21
Shifting, riding .............................................................. 21
Braking ........................................................................ 21
Stopping, parking .......................................................... 22
Refueling...................................................................... 22
SERVICE SCHEDULE (SX).................................................. 24
Service schedule ........................................................... 24
Maintenance work (as an additional order) ....................... 25
SERVICE SCHEDULE (XC).................................................. 26
Service schedule ........................................................... 26
Maintenance work (as an additional order) ....................... 27
TUNING THE CHASSIS...................................................... 28
Checking the basic chassis setting with the rider's
weight .......................................................................... 28
Compression damping of shock absorber.......................... 28
Adjusting the low-speed compression damping of the
shock absorber.............................................................. 28
Adjusting the high-speed compression damping of the
shock absorber.............................................................. 29
Adjusting the rebound damping of the shock absorber....... 30
Measuring the sag of the unloaded rear wheel .................. 31
Checking the static sag of the shock absorber .................. 31
Checking the riding sag of the shock absorber .................. 31
Adjusting the spring preload of the shock absorber ...... 32x
Adjusting the riding sag ............................................. 32x
Checking the basic setting of the fork.............................. 33
Adjusting the compression damping of the fork ................ 34
Adjusting the rebound damping of the fork....................... 34
Handlebar position ........................................................ 35
Adjusting the handlebar position ................................ 35x
MAINTENANCE WORK ON THE CHASSIS ........................... 37
Raising the motorcycle with the lift stand ........................ 37
Removing the motorcycle from the lift stand .................... 37
Bleeding the fork legs .................................................... 37
Cleaning the dust boots of the fork legs ........................... 38
Loosening the fork protection.......................................... 38
Positioning the fork protection ........................................ 38
Removing the fork legs .............................................. 38x
Installing the fork legs ............................................... 39x
Removing the fork protector ....................................... 39x
Installing the fork protector ....................................... 40x
Removing the lower triple clamp ................................ 40x
Installing the lower triple clamp ................................. 40x
Checking the play of the steering head bearing................. 42
Adjusting the play of the steering head bearing ............ 42x
Greasing the steering head bearing ............................. 43x
Removing the start number plate .................................... 43
Installing the start number plate ..................................... 43
Removing the front fender.............................................. 43
Installing the front fender............................................... 43
Removing the shock absorber ..................................... 44x
Installing the shock absorber ..................................... 44x
Removing the seat......................................................... 44
Mounting the seat ......................................................... 44
Removing the air filter box lid......................................... 45
Installing the air filter box lid.......................................... 45
Removing the air filter ............................................... 45x
Installing the air filter ............................................... 46x
Cleaning the air filter and air filter box ........................ 46x
Removing the main silencer............................................ 46
Installing the main silencer ............................................ 47
Changing the glass fiber yarn filling of the main
silencer ................................................................... 47x
Removing the fuel tank ............................................. 48x
Installing the fuel tank .............................................. 48x
Checking the chain for dirt ............................................. 49
Cleaning the chain......................................................... 49
Checking the chain tension ............................................ 50
Adjusting the chain tension ............................................ 50
Checking the chain, rear sprocket, engine sprocket and
chain guide................................................................... 51
Adjusting the chain guide .......................................... 53x
Checking the throttle cable routing.................................. 53
Adjusting the basic position of the clutch lever................. 53
Checking the fluid level of the hydraulic clutch ................ 54
Changing the hydraulic clutch fluid ............................ 54x
BRAKES ........................................................................... 56
Checking the free travel of the hand brake lever ............... 56
Adjusting the basic position of the hand brake lever.......... 56
Checking the brake discs................................................ 56
Checking the front brake fluid level ................................. 57
Adding front brake fluid ............................................ 57x
Checking the front brake linings...................................... 58
TABLE OF CONTENTS 3
Changing the front brake linings ................................. 58x
Checking free travel of foot brake lever ............................ 60
Adjusting basic position of foot brake lever .................. 60x
Checking the rear brake fluid level .................................. 61
Adding brake fluid for the rear brake .......................... 61x
Checking the rear brake linings ....................................... 62
Changing the rear brake linings .................................. 62x
WHEELS, TIRES ............................................................... 64
Removing the front wheel .......................................... 64x
Installing the front wheel ........................................... 64x
Removing the rear wheel ........................................... 65x
Installing the rear wheel ............................................ 65x
Checking the tire condition............................................. 66
Checking the tire air pressure ......................................... 67
Checking the spoke tension ............................................ 67
ELECTRICAL SYSTEM ....................................................... 68
Removing the battery (250/300 XC) ........................... 68x
Installing the battery (250/300 XC) ............................ 68x
Recharging the battery (250/300 XC) ......................... 68x
Removing the main fuse (250/300 XC)............................ 69
Installing the main fuse (250/300 XC) ............................ 70
COOLING SYSTEM ............................................................ 71
Cooling system.............................................................. 71
Radiator cover (All SX models)........................................ 71
Removing the radiator cover (All SX models) .................... 71
Installing the radiator cover (All SX models) ..................... 72
Checking the antifreeze and coolant level ........................ 72
Checking the coolant level.............................................. 73
Draining the coolant .................................................. 73x
Refilling with coolant ................................................ 74x
TUNING THE ENGINE ....................................................... 75
Checking the play in the throttle cable............................. 75
Adjusting the play in the throttle cable ....................... 75x
Carburetor .................................................................... 75
Carburetor - adjusting the idle speed .......................... 76x
Emptying the carburetor float chamber ....................... 77x
Ignition curve plug connection........................................ 77
Changing the ignition curve ............................................ 78
Checking the basic position of the shift lever.................... 78
Adjusting the basic position of the shift lever .............. 78x
Engine characteristic - auxiliary spring
(All 250/300 models) .................................................... 78
Engine characteristic - adjust the auxiliary spring x
(All 250/300 models) .................................................... 79
MAINTENANCE WORK ON THE ENGINE............................. 80
Checking the gear oil level.............................................. 80
Changing the gear oil ................................................ 80x
Draining the gear oil ................................................. 81x
Refilling with gear oil ................................................ 81x
Adding gear oil ......................................................... 82x
CLEANING, CARE ............................................................. 83
Cleaning the motorcycle................................................. 83
STORAGE ......................................................................... 84
Storage......................................................................... 84
Putting into operation after storage ................................. 84
TROUBLESHOOTING......................................................... 85
TECHNICAL DATA - ENGINE .............................................. 87
125 SX......................................................................... 87
150 SX......................................................................... 87
150 XC USA ................................................................. 88
250 SX......................................................................... 88
250 XC EU/USA............................................................ 89
300 XC EU/USA............................................................ 90
Capacity - transmission oil.............................................. 90
Capacity - coolant.......................................................... 90
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 91
All 125/150 models ...................................................... 91
250 SX......................................................................... 91
250/300 XC.................................................................. 92
TECHNICAL DATA - CARBURETOR..................................... 94
125 SX......................................................................... 94
Carburetor - basic setting for sandy surfaces (125 SX) ...... 94
Carburetor configuration (125 SX)................................... 95
150 SX......................................................................... 96
Carburetor - basic setting for sandy surfaces (150 SX) ...... 96
Carburetor configuration (150 SX)................................... 97
250 SX......................................................................... 98
Carburetor - basic setting for sandy surfaces (250 SX) ...... 98
Carburetor configuration (250 SX)................................... 99
150 XC USA ............................................................... 100
Carburetor configuration (150 XC USA) ......................... 100
250 XC EU/USA.......................................................... 101
Carburetor configuration (250 XC EU/USA) .................... 102
300 XC EU/USA.......................................................... 103
Carburetor configuration (300 XC EU/USA) ............... 103x
TECHNICAL DATA - CHASSIS .......................................... 105
Tires .......................................................................... 105
Capacity - fuel............................................................. 106
TECHNICAL DATA - FORK................................................ 107
125/150 SX................................................................ 107
250 SX....................................................................... 107
150 XC USA ............................................................... 108
250/300 XC................................................................ 108
TECHNICAL DATA - SHOCK ABSORBER ........................... 109
125/150 SX................................................................ 109
250 SX....................................................................... 109
150 XC USA ............................................................... 110
250/300 XC................................................................ 110
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ...... 112
SUBSTANCES................................................................. 113
AUXILIARY SUBSTANCES................................................ 115
STANDARDS................................................................... 117
INDEX ............................................................................ 118
MEANS OF REPRESENTATION 4
Symbols used
The symbols used are explained below.
Indicates an expected reaction (e.g., to a work step or a function).
Indicates an unexpected reaction (e.g., to a work step or a function).
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.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand available on the open market.
IMPORTANT INFORMATION 5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only in closed off areas remote from public road traffic.
Service
A prerequisite for perfect operation and prevention of wear is that the engine and chassis service, care and adjustment work described
in the owner's manual is properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage
of components.
Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of compo-
nents such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the
limit specified in the service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
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.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
You will find the current for your vehicle on the KTM website.KTM PowerParts
International KTM Website: http://www.ktm.com
Work rules
Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parenthe-
ses. E.g.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash-
ers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
–Switch off the engine.
(All SX models)
–Turn handle of the fuel tap to the position. (Figure 601185-10 p. 12)OFF
(All XC models)
–Turn handle of the fuel tap to the position. (Figure 601157-11 p. 11)OFF
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
IMPORTANT INFORMATION 6
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. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and
tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle
to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on ser-
vicing the motorcycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
VIEW OF VEHICLE 7
3.1
3.1
3.1
3.13.1View of the vehicle from the left front (example)
601175-10
1 Hand brake lever ( p. 10)
2 Kill switch ( p. 10)
3 Clutch lever ( p. 10)
4 Air filter box lid
5 Fuel tap
6 Choke ( p. 12)
7 Shift lever ( p. 12)
8 Chain guide
VIEW OF VEHICLE 8
3.2
3.2
3.2
3.23.2View of the vehicle from the right rear (example)
601176-10
1 Seat
2 Filler cap
3 Handlebar cushion
4 Throttle grip ( p. 10)
5 Shock absorber, rebound adjustment
6 Level viewer, rear brake fluid
7 Shock absorber, compression adjustment
8 Foot brake lever ( p. 13)
9 Kickstarter ( p. 13)
SERIAL NUMBERS 9
4.1
4.1
4.1
4.14.1Chassis number
601177-10
The chassis number is stamped on the right side of the steering head.
4.2
4.2
4.2
4.24.2Type label
601177-11
The type label is fixed to the front of the steering head.
4.3
4.3
4.3
4.34.3Engine number
601178-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.4
4.4
4.4
4.44.4Fork part number
B00265-01
The fork part number is stamped on the inner side of the fork stub.
4.5
4.5
4.5
4.54.5Shock absorber part number
601179-10
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
CONTROLS 10
5.1
5.1
5.1
5.15.1Clutch lever
B00001-10
(All 125/150 models)
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00009-10
(All 250/300 models)
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
5.2
5.2
5.2
5.25.2Hand brake lever
400196-10
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
5.3
5.3
5.3
5.35.3Throttle grip
B00060-10
Throttle grip is fitted on the right side of the handlebar.
5.4
5.4
5.4
5.45.4Kill switch
B00002-10
The kill switch is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position In this position, the ignition circuit is closed, and–
the engine can be started.
• Kill switch pressed In this position, the ignition circuit is interrupted, a run-–
ning engine stops, and a non-running engine will not start.
CONTROLS 11
5.5
5.5
5.5
5.55.5Electric starter button (250/300 XC)
B00080-10
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed In this position, the electric starter is actuated.–
5.6
5.6
5.6
5.65.6Opening the filler cap
B00277-10
–Press release button , turn the filler cap counterclockwise and lift it free.
5.7
5.7
5.7
5.75.7Closing the filler cap
B00278-10
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Run the fuel tank breather hose without kinks.
5.8
5.8
5.8
5.85.8Fuel tap (All XC models)
601157-11
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 No fuel can flow from the tank to the carburetor.OFF –
• Fuel supply open Fuel can flow from the tank to the carburetor. The fuel tankON –
empties down to the reserve.
• Reserve fuel supply open Fuel can flow from the tank to the carburetor. TheRES –
fuel tank empties completely.
CONTROLS 12
5.9
5.9
5.9
5.95.9Fuel tap (All SX models)
601185-10
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 No fuel can flow from the tank to the carburetor.OFF –
• Fuel supply open Fuel can flow from the tank to the carburetor. The fuel tankON –
empties completely.
5.10
5.10
5.10
5.105.10Choke
601180-10
The choke is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated The choke lever is pulled out to the stop.–
• Choke function deactivated The choke lever is pushed in to the stop.–
5.11
5.11
5.11
5.115.11Shift lever
B00005-10
Shift lever is mounted on the left side of the engine.
B00005-12
(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.
CONTROLS 13
B00005-11
(250 SX)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
5.12
5.12
5.12
5.125.12Kickstarter
601181-10
The kickstarter is fitted on the right side of the engine. The top part can be
swiveled.
5.13
5.13
5.13
5.135.13Foot brake lever
B00007-10
Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
5.14
5.14
5.14
5.145.14Side stand (All XC models)
601188-10
The side stand is on the left side of the vehicle.
601189-10
The side stand is used to park the motorcycle.
Info
When you are riding, side stand must be folded up and secured with rubber
band .
CONTROLS 14
5.15
5.15
5.15
5.155.15Plug-in stand (All SX models)
100950-10
The holder for plug-in stand is on the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
PUTTING INTO OPERATION 15
6.1
6.1
6.1
6.16.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
–The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
–Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
–Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
–If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take
your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Unstable riding behavior.
–Do not exceed the maximum permissible weight and axle loads.
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.
Info
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.
–Before your first trip, read the entire operating instructions carefully.
–Get to know the controls.
–Adjust the basic position of the clutch lever. ( p. 53)
–Adjust the basic position of the hand brake lever. ( p. 56)
–Adjust the basic position of the foot brake lever. ( p. 60)x
–Become accustomed to the handling of the motorcycle on suitable terrain.
Info
Your motorcycle is not authorized for riding on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
–Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
–Do not make any offroad trips that over-stress your ability and experience.
–Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–Do not transport luggage.
–Do not exceed the overall maximum permitted weight and the axle loads.
PUTTING INTO OPERATION 16
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. 67)
Info
The spoke tension must be checked after riding the motorcycle for one half hour.
–Run the engine in.
6.2
6.2
6.2
6.26.2Running in the engine
–During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 service hours < 70 %
During the first 5 service hours < 100 %
–Avoid fully opening the throttle!
6.3
6.3
6.3
6.36.3Preparing the vehicle for difficult operating conditions
–The use of motorcycles under difficult operating conditions can lead to above-average wear of components such as the drive train
or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is
reached.
Difficult operating conditions are:
–Riding on dry sand. ( p. 16)
–Riding on wet sand. ( p. 17)
–Riding on wet and muddy surfaces. ( p. 18)
–Riding at high temperatures and low speeds. ( p. 19)
–Riding at low temperatures and in snow. ( p. 19)
6.4
6.4
6.4
6.46.4Preparations for riding on dry sand
600872-10
–Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the displayed value does not equal the setpoint value:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter and air filter box. ( p. 46)x
Info
Check the air filter approx. every 30 minutes.
PUTTING INTO OPERATION 17
B00435-01
–Mount the dust cover for the air filter.
Dust cover for air filter (59006019000)
Info
Read the KTM PowerParts installation instructions.
B00436-01
–Mount the dust cover for the air filter for sand.
Sand cover for air filter (59006022000)
Info
Read the KTM PowerParts installation instructions.
–Adjust the carburetor jetting and setting.
Info
Recommendations on the carburetor setting are available from your autho-
rized KTM workshop.
600868-01
–Clean the chain.
Chain cleaner ( p. 115)
–Mount the steel sprocket.
Tip
Do not grease the chain.
–Clean the radiator fins.
–Carefully align bent radiator fins.
–If used in sand regularly, replace the piston every 10 operating hours.
6.5
6.5
6.5
6.56.5Preparations for riding on wet sand
600872-10
–Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the displayed value does not equal the setpoint value:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter and air filter box. ( p. 46)x
Info
Check the air filter approx. every 30 minutes.
PUTTING INTO OPERATION 18
B00437-01
–Mount the rain cover for the air filter.
Rain cover for air filter (59006021000)
Info
Read the KTM PowerParts installation instructions.
–Adjust the carburetor jetting and setting.
Info
Recommendations on the carburetor setting are available from your autho-
rized KTM workshop.
600868-01
–Clean the chain.
Chain cleaner ( p. 115)
–Mount the steel sprocket.
Tip
Do not grease the chain.
–Clean the radiator fins.
–Carefully align bent radiator fins.
–If used in sand regularly, replace the piston every 10 operating hours.
6.6
6.6
6.6
6.66.6Preparations for riding on wet and muddy surfaces
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter and air filter box. ( p. 46)x
Info
Check the air filter approx. every 30 minutes.
B00437-01
–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
The recommended carburetor tuning is available from your authorized KTM
workshop.
600868-01
–Mount the steel sprocket.
–Clean the motorcycle. ( p. 83)
–Carefully align bent radiator fins.
PUTTING INTO OPERATION 19
6.7
6.7
6.7
6.76.7Preparations for riding at high temperatures and low speeds
600872-10
–Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the displayed value does not equal the setpoint value:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter and air filter box. ( p. 46)x
Info
Check the air filter approx. every 30 minutes.
600868-01
–Adjust the secondary ratio to the terrain.
Info
The engine oil heats up rapidly if the clutch needs to be operated too fre-
quently because the secondary ratio is too long.
–Clean the chain.
Chain cleaner ( p. 115)
–Clean the radiator fins.
–Carefully align bent radiator fins.
–Check the coolant level. ( p. 73)
6.8
6.8
6.8
6.86.8Preparations for riding at low temperatures and in snow
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter and air filter box. ( p. 46)x
Info
Check the air filter approx. every 30 minutes.
B00437-01
–Mount the rain cover for the air filter.
Rain cover for air filter (59006021000)
Info
Follow the mounting instructions.KTM PowerParts
–Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized KTM
workshop.
RIDING INSTRUCTIONS 20
7.1
7.1
7.1
7.17.1Checks 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. 80)
–Check the front brake fluid level. ( p. 57)
–Check the rear brake fluid level. ( p. 61)
–Check the front brake linings. ( p. 58)
–Check the rear brake linings. ( p. 62)
–Check that the brake system is functioning properly.
–Check the coolant level. ( p. 73)
–Check the chain for dirt. ( p. 49)
–Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 51)
–Check the chain tension. ( p. 50)
–Check the tire condition. ( p. 66)
–Check the tire air pressure. ( p. 67)
–Clean the dust boots of the fork legs. ( p. 38)
–Bleed the fork legs. ( p. 37)
–Check the air filter.
–Check the settings of all controls and ensure that they can be operated smoothly.
–Check all screws, nuts and hose clamps regularly for tightness.
–Check the fuel supply.
7.2
7.2
7.2
7.27.2Starting
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 ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Engine has been out of use for more than 1 week
–Empty the carburetor float chamber. ( p. 77)x
(All SX models)
–Turn handle of the fuel tap to the position. (Figure 601185-10 p. 12)ON
Fuel can flow from the fuel tank to the carburetor.
(All XC models)
–Turn handle of the fuel tap to the position. (Figure 601157-11 p. 11)ON
Fuel can flow from the fuel tank to the carburetor.
–Remove the motorcycle from the stand.
–Shift gear to neutral.
The engine is cold
–Pull choke lever out as far as possible.
–Press the electric starter button or press the kickstarter robustly through its full range.
Info
Do not open the throttle.
RIDING INSTRUCTIONS 21
7.3
7.3
7.3
7.37.3Starting up
Info
The plug-in stand must be removed before riding.
When you are riding, the side stand must be folded up and secured with the rubber band.
–Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
7.4
7.4
7.4
7.47.4Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
–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.
–When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
–If the choke function was activated, deactivate it after the engine has warmed up.
–When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces
vehicle speed but lowers fuel consumption considerably.
– –Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption.
–To shift down, brake and close the throttle at the same time.
–Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
–Switch off the engine if you expect to be standing for a long time.
Guideline
≥2 min
–Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
–Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
7.5
7.5
7.5
7.57.5Braking
Warning
Danger of accidents If you brake too hard, the wheels can lock.
–Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
–Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
–Clean or dry dirty or wet brakes by riding and braking gently.
–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.
RIDING INSTRUCTIONS 22
7.6
7.6
7.6
7.67.6Stopping, 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 become very hot when the vehicle is operated.
–Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
–The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side
stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
–Brake the motorcycle.
–Shift gear to neutral.
–Press and hold the kill switch while the engine is idling until the engine stops.
(All XC models)
–Turn handle of the fuel tap to the position. (Figure 601157-11 p. 11)OFF
(All SX models)
–Turn handle of the fuel tap to the position. (Figure 601185-10 p. 12)OFF
–Park the vehicle on the side stand.
7.7
7.7
7.7
7.77.7Refueling
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.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
–Switch off the engine.
–Open the filler cap. ( p. 11)
RIDING INSTRUCTIONS 23
AA
400382-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Total fuel tank
capacity, approx.
7.5 l
(1.98 US gal)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:40) ( p. 114)
(125/150 SX)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 114)
(250 SX)
Total fuel tank
capacity, approx.
11.5 l
(3.04 US gal)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:40) ( p. 114)
(150 XC USA)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 114)
(250/300 XC)
2-stroke engine oil ( p. 113)
–Close the filler cap. ( p. 11)
SERVICE SCHEDULE (SX) 24
8.1
8.1
8.1
8.18.1Service schedule
S10A S20A S30A
Change the gear oil. (125/150 SX)x• • •
Change the gear oil. (250 SX)x•
Check the front brake linings. ( p. 58) • • •
Check the rear brake linings. ( p. 62) • • •
Check the brake discs. ( p. 56) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. ( p. 61) • • •
Change the foot brake cylinder seals. x•
Check the free travel of the foot brake lever. ( p. 60) • • •
Check the frame and swingarm. x• • •
Check the swingarm bearing. x•
Check the heim joints at the top and bottom of the shock absorber. x• • •
Conduct a minor fork service. (All SX models) x• • •
Conduct a major fork service. (All SX models) x•
Check the tire condition. ( p. 66) • • •
Check the tire air pressure. ( p. 67) • • •
Check the wheel bearing for play. x• • •
Check the wheel hub. x• • •
Check the rim run-out. x• • •
Check the spoke tension. ( p. 67) • • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 51) • • •
Check the chain tension. ( p. 50) • • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x• • •
Check the fluid level of the hydraulic clutch. ( p. 54) • • •
Check the front brake fluid level. ( p. 57) • • •
Check the free travel of the hand brake lever. ( p. 56) • • •
Check the play of the steering head bearing. ( p. 42) • • •
Change the piston and check the cylinder. x•
Change the piston and check the cylinder. (under difficult riding conditions) x• • •
Change the spark plug and spark plug connector. (125/150 SX)x• • •
Change the spark plug and spark plug connector. (250 SX)x•
Check the intake diaphragm. x• • •
Check the exhaust control for functioning and smooth operation. x•
Check the clutch. x• • •
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, tightness and correct
routing. x• • •
Check the antifreeze and coolant level. ( p. 72) • • •
Check the cables for damage and routing without sharp bends. x• • •
Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • • •
Clean the air filter and air filter box. x• • •
Change the glass fiber yarn filling of the main silencer. ( p. 47)x•
Check the screws and nuts for tightness. x• • •
Check the idle. x• • •
Final check: Check the vehicle for safe operation and take a test ride. • • •
Make the service entry in and in the service record.KTM DEALER.NET x• • •
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)
SERVICE SCHEDULE (SX) 25
8.2
8.2
8.2
8.28.2Maintenance work (as an additional order)
S20N S40A J1A
Change the front brake fluid. x•
Change the rear brake fluid. x•
Change the hydraulic clutch fluid. ( p. 54)x•
Grease the steering head bearing. ( p. 43)x•
Check/set the carburetor components. x• •
Perform a shock absorber service. (All SX models) x• •
Change the connecting rod, conrod bearing and crank pin. x•
Check the transmission and shift mechanism. x•
Change all engine bearings. x•
S20N: Once after 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)
J1A: Annually
SERVICE SCHEDULE (XC) 26
9.1
9.1
9.1
9.19.1Service schedule
S20A S40A
Check and charge the battery. (250/300 XC)x• •
Change the gear oil. x• •
Check the front brake linings. ( p. 58) • •
Check the rear brake linings. ( p. 62) • •
Check the brake discs. ( p. 56) • •
Check the brake lines for damage and leakage. • •
Check the rear brake fluid level. ( p. 61) • •
Check the free travel of the foot brake lever. ( p. 60) • •
Check the frame and swingarm. x• •
Check the swingarm bearing. x•
Check the heim joints at the top and bottom of the shock absorber. x• •
Conduct a minor fork service. (All XC models) x• •
Check the tire condition. ( p. 66) • •
Check the tire air pressure. ( p. 67) • •
Check the wheel bearing for play. x• •
Check the wheel hub. x• •
Check the rim run-out. x• •
Check the spoke tension. ( p. 67) • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 51) • •
Check the chain tension. ( p. 50) • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x• •
Check the fluid level of the hydraulic clutch. ( p. 54) • •
Check the front brake fluid level. ( p. 57) • •
Check the free travel of the hand brake lever. ( p. 56) • •
Check the play of the steering head bearing. ( p. 42) • •
Change the spark plug and spark plug connector. x• •
Check the intake diaphragm. x• •
Check the exhaust control for functioning and smooth operation. x•
Check the clutch. x•
Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for tearing, tightness and correct routing. x• •
Check the antifreeze and coolant level. ( p. 72) • •
Check the cables for damage and routing without sharp bends. x• •
Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • •
Clean the air filter and air filter box. x• •
Change the glass fiber yarn filling of the main silencer. ( p. 47)x• •
Check the screws and nuts for tightness. x• •
Check the idle. x• •
Final check: Check the vehicle for safe operation and take a test ride. • •
Make the service entry in and in the service record.KTM DEALER.NET x• •
S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal) / after each race
SERVICE SCHEDULE (XC) 27
9.2
9.2
9.2
9.29.2Maintenance work (as an additional order)
S40A S80A J1A
Change the front brake fluid. x•
Change the rear brake fluid. x•
Change the foot brake cylinder seals. x•
Change the hydraulic clutch fluid. ( p. 54)x•
Grease the steering head bearing. ( p. 43)x•
Check/set the carburetor components. x• •
Conduct a major fork service. (All XC models) x• •
Perform a shock absorber service. (All XC models) x• •
Check the starter drive. (250/300 XC)x• •
Change the piston and check the cylinder. (All 125/150 models)x• •
Change the connecting rod, conrod bearing and crank pin. x•
Check the transmission and shift mechanism. x•
Change all engine bearings. x•
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)
S80A: Every 80 service hours - corresponds to about 560 liters of fuel (148 US gal) / every 40 service hours after sporting use - corre-
sponds to about 280 liters of fuel (74 US gal)
J1A: Annually
TUNING THE CHASSIS 28
10.1
10.1
10.1
10.110.1Checking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
401030-01
–For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.
–As delivered, KTM offroad motorcycles are adjusted for a standard rider weight
(with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
–If the rider's weight is above or below the standard range, the basic setting of the
suspension components must be adjusted accordingly.
–Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.
10.2
10.2
10.2
10.210.2Compression damping of shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, affects the compression when landing after a jump: the rear wheel suspension compresses more
quickly.
The low-speed setting, for example, affects the compression when riding over long ground swells: the rear wheel suspension com-
presses more slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
10.3
10.3
10.3
10.310.3Adjusting the low-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 low-speed setting can be seen during the slow to normal compression of the shock absorber.
601182-11
–Turn adjusting screw clockwise with a screwdriver to the last click.
Info
Do not loosen nut !
–Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
TUNING THE CHASSIS 29
Guideline
Compression damping, low-speed (125/150 SX)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (250 SX)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (150 XC USA)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Compression damping, low-speed (250/300 XC)
Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
10.4
10.4
10.4
10.410.4Adjusting 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.
601183-10
–Turn adjusting screw all the way clockwise using a socket wrench.
Info
Do not loosen nut !
–Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
TUNING THE CHASSIS 30
Guideline
Compression damping, high-speed (125/150 SX)
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Compression damping, high-speed (250 SX)
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Compression damping, high-speed (150 XC USA)
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Compression damping, high-speed (250/300 XC)
Comfort 2 turns
Standard 1.5 turns
Sport 1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
10.5
10.5
10.5
10.510.5Adjusting 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.)
400210-10
–Turn adjusting screw clockwise with a screwdriver to the last click.
Info
Do not loosen nut !
–Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping (125/150 SX)
Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks
Rebound damping (250 SX)
Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks
Rebound damping (150 XC USA)
Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks
Rebound damping (250/300 XC)
Comfort 24 clicks
Standard 22 clicks
Sport 22 clicks
TUNING THE CHASSIS 31
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
10.6
10.6
10.6
10.610.6Measuring the sag of the unloaded rear wheel
–Raise the motorcycle with the lift stand. ( p. 37)
0
0
0
0
00AA
400988-10
– – –Measure the distance as vertical as possible between the rear axle and a fixed
point, for example, a mark on the side cover.
–Note down the value as dimension .
–Remove the motorcycle from the lift stand. ( p. 37)
10.7
10.7
10.7
10.710.7Checking the static sag of the shock absorber
0
0
0
0
00AA
0
0
0
0
00BB
400989-10
–Measure distance of the unloaded rear wheel. ( p. 31)
–Hold the motorcycle upright with the aid of an assistant.
–Measure the distance between the rear axle and the fixed point again.
–Note down the value as dimension .
Info
The static sag is the difference between measurements and .
–Check the static sag.
Static sag (125/150 SX) 33 mm (1.3 in)
Static sag (250 SX) 33 mm (1.3 in)
Static sag (150 XC USA) 33 mm (1.3 in)
Static sag (250/300 XC) 33 mm (1.3 in)
» If the static sag is less or more than the specified value:
–Adjust the spring preload of the shock absorber. ( p. 32)x
10.8
10.8
10.8
10.810.8Checking the riding sag of the shock absorber
0
0
0
0
00AA
0
0
0
0
00CC
400990-10
–Measure distance of the unloaded rear wheel. ( p. 31)
–With another person holding the motorcycle, the rider, wearing full protective cloth-
ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.
The rear wheel suspension levels out.
–Another person now measures the distance between the rear axle and a fixed point.
–Note down the value as dimension .
Info
The riding sag is the difference between measurements and .
–Check the riding sag.
Guideline
Riding sag (125/150 SX) 109 mm (4.29 in)
Riding sag (250 SX) 105 mm (4.13 in)
Riding sag (150 XC USA) 109 mm (4.29 in)
Riding sag (250/300 XC) 105 mm (4.13 in)
TUNING THE CHASSIS 32
» If the riding sag differs from the specified measurement:
–Adjust the riding sag. ( p. 32)x
10.9
10.9
10.9
10.910.9Adjusting the spring preload of the shock absorber x
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.
–Remove the shock absorber. ( p. 44)x
– After removing the shock absorber, clean it thoroughly.
401026-10
– Loosen screw .
– Turn adjusting ring until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length when not under tension.
– Tighten the spring by turning adjusting ring to measurement .
Guideline
Spring preload (125/150 SX) 5 mm (0.2 in)
Spring preload (250 SX)
Comfort 5 mm
Standard 3 mm
Sport 5 mm
Spring preload (150 XC USA) 7 mm (0.28 in)
Spring preload (250/300 XC) 5 mm (0.2 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
– Tighten screw .
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
–Install the shock absorber. ( p. 44)x
10.10
10.10
10.10
10.1010.10Adjusting the riding sag x
–Remove the shock absorber. ( p. 44)x
– After removing the shock absorber, clean it thoroughly.
B00292-10
– Choose and mount a suitable spring.
TUNING THE CHASSIS 33
Guideline
Spring rate (125/150 SX)
Weight of rider: 65… 75 kg (143…
165 lb.)
60 N/mm (343 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
63 N/mm (360 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
66 N/mm (377 lb/in)
Spring rate (250 SX)
Weight of rider: 65… 75 kg (143…
165 lb.)
66 N/mm (377 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
69 N/mm (394 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
72 N/mm (411 lb/in)
Spring rate (150 XC USA)
Weight of rider: 65… 75 kg (143…
165 lb.)
60 N/mm (343 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
63 N/mm (360 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
66 N/mm (377 lb/in)
Spring rate (250/300 XC)
Weight of rider: 65… 75 kg (143…
165 lb.)
66 N/mm (377 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
69 N/mm (394 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
72 N/mm (411 lb/in)
Info
The spring rate is shown on the outside of the spring.
–Install the shock absorber. ( p. 44)x
–Check the static sag of the shock absorber. ( p. 31)
–Check the riding sag of the shock absorber. ( p. 31)
–Adjust the rebound damping of the shock absorber. ( p. 30)
10.11
10.11
10.11
10.1110.11Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the forks.
401000-01
–As with the shock absorber, smaller differences in the rider's weight can be com-
pensated by the spring preload.
–However, if the fork is often overloaded (hard end stop on compression), harder
springs must be fit to avoid damage to the fork and frame.
TUNING THE CHASSIS 34
10.12
10.12
10.12
10.1210.12Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
B00294-10
–Turn adjusting screws clockwise all the way.
Info
Adjusting screws are located at the top end of the fork legs.
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)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Compression damping (250 SX)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Compression damping (150 XC USA)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Compression damping (250/300 XC)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
10.13
10.13
10.13
10.1310.13Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
B00295-10
–Remove protection covers .
–Turn adjusting screws clockwise all the way.
Info
Adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–Turn back counterclockwise by the number of clicks corresponding to the fork type.
TUNING THE CHASSIS 35
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
Sport 10 clicks
Rebound damping (250/300 XC)
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
–Mount protection covers .
10.14
10.14
10.14
10.1410.14Handlebar position
0
0
0
0
00BB
0
0
0
0
00AA
B00025-11
On the upper triple clamp, there are two holes a distance of apart.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. In this way, the handlebar
can be mounted in the position that is most comfortable for the rider.
10.15
10.15
10.15
10.1510.15Adjusting the handlebar position x
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.
0
0
0
0
0022
0
0
0
0
0011
0
0
0
0
0022
11
B00375-10
–Remove screws . Remove the handlebar clamp. Remove the handlebar and lay it
to one side.
Info
Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.
–Remove screws . Remove the handlebar support.
–Place the handlebar support in the required position. Mount and tighten screws .
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
TUNING THE CHASSIS 36
–Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
–Position the handlebar clamp. Mount and tighten screws .
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
MAINTENANCE WORK ON THE CHASSIS 37
11.1
11.1
11.1
11.111.1Raising the motorcycle with the lift stand
601193-01
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.
Lift stand (54829055000)
The wheels must no longer touch the ground.
–Secure the motorcycle against falling over.
11.2
11.2
11.2
11.211.2Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
100950-10
(All SX models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, insert plug-in stand into the left side of the wheel
spindle.
Info
Remove the plug-in stand before riding.
601188-10
(All XC models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand to the ground with your foot and
lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with
the rubber band.
11.3
11.3
11.3
11.311.3Bleeding the fork legs
–Raise the motorcycle with the lift stand. ( p. 37)
601204-10
–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)
MAINTENANCE WORK ON THE CHASSIS 38
11.4
11.4
11.4
11.411.4Cleaning the dust boots of the fork legs
–Raise the motorcycle with the lift stand. ( p. 37)
–Loosen the fork protection. ( p. 38)
B00297-10
–Push dust boots of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind can start to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 116)
–Press the dust boots back into their normal position.
–Remove excess oil.
–Position the fork protection. ( p. 38)
–Remove the motorcycle from the lift stand. ( p. 37)
11.5
11.5
11.5
11.511.5Loosening the fork protection
B00013-11
–Remove screws and take off the clamp.
–Remove screws on the left fork leg. Push the fork protection downwards.
–Remove the screws on the right fork leg. Push the fork protection downwards.
11.6
11.6
11.6
11.611.6Positioning the fork protection
B00013-10
–Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the brake line. Position the clamp and mount and tighten screws .
–Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
11.7
11.7
11.7
11.711.7Removing the fork legs x
–Remove the front wheel. ( p. 64)x
B00020-10
–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.
MAINTENANCE WORK ON THE CHASSIS 39
B00021-10
–Unscrew screws . Take out the left fork leg.
–Unscrew screws . Take out the right fork leg.
11.8
11.8
11.8
11.811.8Installing the fork legs x
601204-10
–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.
B00021-11
–Tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
–Tighten screws .
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
B00020-11
–Position the brake caliper and mount and tighten screws .
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite®243™
–Position the brake line. Put the clamp on, and mount and tighten screws .
–Install the front wheel. ( p. 64)x
11.9
11.9
11.9
11.911.9Removing the fork protector x
–Remove the fork legs. ( p. 38)x
B00306-10
–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.
MAINTENANCE WORK ON THE CHASSIS 40
11.10
11.10
11.10
11.1011.10Installing the fork protector x
B00306-10
–Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Install the fork legs. ( p. 39)x
11.11
11.11
11.11
11.1111.11Removing the lower triple clamp x
–Remove the fork legs. ( p. 38)x
–Remove the start number plate. ( p. 43)
–Remove the front fender. ( p. 43)
B00022-10
–Remove screws and hang the CDI control unit to the side.
Info
Do not unplug the CDI control unit.
–Remove screw . Remove screw , take off the top triple clamp with the handle-
bar and place it on one side.
Info
Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.
B00023-11
–Remove O-ring . Remove protective ring .
–Take out the lower triple clamp with the steering stem.
–Take out the upper steering head bearing.
11.12
11.12
11.12
11.1211.12Installing the lower triple clamp x
0
0
0
0
0022
0
0
0
0
0011
0
0
0
0
0033
B00024-10
–Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 115)
–Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
–Check whether the top steering head seal is correctly positioned.
–Push up protective ring and O-ring .
MAINTENANCE WORK ON THE CHASSIS 41
B00022-11
–Position the upper triple clamp with the steering.
–Mount screw but do not tighten yet.
–Install the CDI controller with screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
601199-11
–Position the fork legs.
Info
The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the front.
B00378-12
–Tighten screws .
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
B00380-10
–Tighten screw .
Guideline
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)
B00380-12
–Mount and tighten screw .
Guideline
Screw, top steering stem M8 17 Nm
(12.5 lbf ft)
Loctite®243™
B00378-13
–Tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
MAINTENANCE WORK ON THE CHASSIS 42
B00379-11
–Position the brake calipers. Mount and tighten screws .
Guideline
Screw, front brake caliper M8 25 Nm
(18.4 lbf ft)
Loctite®243™
–Position the brake line and clamp. Mount and tighten screws .
–Install the front fender. ( p. 43)
–Install the start number plate. ( p. 43)
–Check that the wiring harness, throttle cables and brake and clutch lines can move
freely and are routed correctly.
–Install the front wheel. ( p. 64)x
–Check the play of the steering head bearing. ( p. 42)
11.13
11.13
11.13
11.1311.13Checking the play of the steering head bearing
Warning
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.
–Raise the motorcycle with the lift stand. ( p. 37)
400738-11
–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:
–Adjust the play of the steering head bearing. ( p. 42)x
–Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. There
should be no perceptible detent positions.
» If detent positions are noticeable:
–Adjust the play of the steering head bearing. ( p. 42)x
–Check the steering head bearing and replace if required.
–Remove the motorcycle from the lift stand. ( p. 37)
11.14
11.14
11.14
11.1411.14Adjusting the play of the steering head bearing x
–Raise the motorcycle with the lift stand. ( p. 37)
B00299-10
–Loosen screws . Remove screw .
–Loosen and retighten screw .
Guideline
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft)
–Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
–Tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
–Mount and tighten screw .
Guideline
Screw, top steering stem M8 17 Nm
(12.5 lbf ft)
Loctite®243™
–Check the play of the steering head bearing. ( p. 42)
MAINTENANCE WORK ON THE CHASSIS 43
11.15
11.15
11.15
11.1511.15Greasing the steering head bearing x
800010-10
–Remove the lower triple clamp. ( p. 40)x
–Install the lower triple clamp. ( p. 40)x
11.16
11.16
11.16
11.1611.16Removing the start number plate
B00308-10
–Remove screw and take off the clamp.
–Remove screw . Take off the start number plate.
11.17
11.17
11.17
11.1711.17Installing the start number plate
B00308-11
–Position the start number plate. Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Ensure that the holding lugs engage in the fender.
–Position the brake line. Position the clamp and mount and tighten screw .
11.18
11.18
11.18
11.1811.18Removing the front fender
B00307-10
–Remove screws . Remove the front fender.
–Make sure the spacers remain in place.
11.19
11.19
11.19
11.1911.19Installing the front fender
B00307-10
–Ensure that the spacers are mounted in the fender.
–Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the start number plate.
MAINTENANCE WORK ON THE CHASSIS 44
11.20
11.20
11.20
11.2011.20Removing the shock absorber x
–Raise the motorcycle with the lift stand. ( p. 37)
601191-10
–Remove screw and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
–Remove screw , push splash protector to the side, and remove the shock
absorber.
11.21
11.21
11.21
11.2111.21Installing the shock absorber x
601191-11
–Push splash protector to the side and position the shock absorber. Mount and
tighten screw .
Guideline
Screw, top shock absorber M12 80 Nm
(59 lbf ft)
Loctite®2701
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M12 80 Nm
(59 lbf ft)
Loctite®2701
Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.
–Remove the motorcycle from the lift stand. ( p. 37)
11.22
11.22
11.22
11.2211.22Removing the seat
601192-10
–Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
11.23
11.23
11.23
11.2311.23Mounting the seat
B00318-01
–Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear
and simultaneously push forward.
–Make sure that the seat is correctly locked in.
MAINTENANCE WORK ON THE CHASSIS 45
601192-10
–Mount and tighten screw of the seat fixation.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
11.24
11.24
11.24
11.2411.24Removing the air filter box lid
601195-10
–Pull off the air filter box lid in area sideways and remove it toward the front.
11.25
11.25
11.25
11.2511.25Installing the air filter box lid
601195-11
–Insert the air filter box lid into the rear area and clip it into the front area .
11.26
11.26
11.26
11.2611.26Removing the air filter x
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.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
–Remove the air filter box lid. ( p. 45)
601196-10
–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.
MAINTENANCE WORK ON THE CHASSIS 46
11.27
11.27
11.27
11.2711.27Installing the air filter x
301262-10
–Mount the clean air filter onto the air filter support.
–Grease the air filter in area .
Long-life grease ( p. 115)
601196-10
–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.
–Install the air filter box lid. ( p. 45)
11.28
11.28
11.28
11.2811.28Cleaning the air filter and air filter box x
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.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
–Remove the air filter. ( p. 45)x
B00325-01
–Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner ( p. 115)
Info
Only press the air filter to dry it; never wring it out.
–Oil the dry air filter with a high quality filter oil.
Oil for foam air filter ( p. 115)
–Clean the air filter box.
–Check the carburetor connection boot for damage and tightness.
–Install the air filter. ( p. 46)x
11.29
11.29
11.29
11.2911.29Removing the main silencer
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.
MAINTENANCE WORK ON THE CHASSIS 47
601184-10
–Remove screws .
–Pull the main silencer off of the manifold at the rubber sleeve .
11.30
11.30
11.30
11.3011.30Installing the main silencer
601184-11
–Mount the main silencer with rubber sleeve .
–Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
11.31
11.31
11.31
11.3111.31Changing the glass fiber yarn filling of the main silencer x
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.
Info
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.
–Remove the main silencer. ( p. 46)
0
0
0
0
0033
0
0
0
0
0022
0
0
0
0
0044
0
0
0
0
0011
401045-10
–Remove screws . Pull out inside tube .
–Pull the glass fiber yarn filling from the inner tube.
–Clean the parts that are to be reinstalled.
–Mount the new glass fiber yarn filling on the inner tube.
–Slide outer tube over the inner tube with the new glass fiber yarn filling.
–Mount and tighten all screws .
–Install the main silencer. ( p. 47)
MAINTENANCE WORK ON THE CHASSIS 48
11.32
11.32
11.32
11.3211.32Removing the fuel tank x
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.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
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. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
–Remove the seat. ( p. 44)
B00315-12
–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.
B00316-12
–Remove screw with the collar sleeve.
–Remove the tube from the fuel tank vent line.
B00319-10
–Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.
11.33
11.33
11.33
11.3311.33Installing the fuel tank x
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.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
MAINTENANCE WORK ON THE CHASSIS 49
–Check the throttle cable routing. ( p. 53)
B00319-10
–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.
B00316-11
–Mount the fuel tank vent hose.
–Mount and tighten screw with the collar bushing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
B00315-13
–Mount and tighten screws with the collar sleeve.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Connect the fuel hose.
–Mount the seat. ( p. 44)
11.34
11.34
11.34
11.3411.34Checking the chain for dirt
400678-01
–Check the chain for heavy soiling.
» If the chain is very dirty:
–Clean the chain. ( p. 49)
11.35
11.35
11.35
11.3511.35Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
–Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
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.
Info
The service life of the chain depends largely on its maintenance.
MAINTENANCE WORK ON THE CHASSIS 50
400725-01
–Clean the chain regularly and then treat with chain spray.
Chain cleaner ( p. 115)
Off-road chain spray ( p. 115)
11.36
11.36
11.36
11.3611.36Checking the chain tension
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. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–Raise the motorcycle with the lift stand. ( p. 37)
B00421-10
–Push the chain at the end of the chain sliding component upwards to measure
chain tension .
Info
The bottom chain section must be taut.
Chain wear is not always even; repeat this measurement at different chain
positions.
Chain tension 55… 58 mm (2.17… 2.28 in)
» If the chain tension does not meet specifications:
–Adjust the chain tension. ( p. 50)
–Remove the motorcycle from the lift stand. ( p. 37)
11.37
11.37
11.37
11.3711.37Adjusting the chain tension
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. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–Raise the motorcycle with the lift stand. ( p. 37)
–Check the chain tension. ( p. 50)
MAINTENANCE WORK ON THE CHASSIS 51
B00343-11
–Loosen nut .
–Loosen nuts .
–Adjust the chain tension by turning the adjusting screws to the 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 reference marks .
The rear wheel is then correctly aligned.
–Tighten nuts .
–Make sure that chain adjusters are fitted correctly on adjusting screws .
–Tighten nut .
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary ratios with the same chain length.
Chain adjusters can be turned by 180°.
–Remove the motorcycle from the lift stand. ( p. 37)
11.38
11.38
11.38
11.3811.38Checking the chain, rear sprocket, engine sprocket and chain guide
–Raise the motorcycle with the lift stand. ( p. 37)
400227-01
–Shift gear to neutral.
–Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket or engine sprocket is worn:
–Change the rear sprocket or engine sprocket. x
Info
The engine sprocket, rear sprocket and chain should always be
changed together.
1 2 3 16 17 18
00
0
0
0
0
BB
0
0
0
0
00AA
400987-10
–Pull on the upper part of the chain with the specified weight .
Guideline
Weight, chain wear measurement 10… 15 kg (22… 33 lb.)
–Measure the distance of 18 chain links in the lower chain section.
Info
Chain wear is not always even; repeat this measurement at different chain
positions.
Maximum distance at the longest
chain section
272 mm (10.71 in)
» If the distance is greater than the specified measurement:
–Change the chain. x
Info
When you mount a new chain, you should also change the rear
sprocket and engine sprocket.
New chains wear out faster on old, worn sprockets.
MAINTENANCE WORK ON THE CHASSIS 52
401056-01
– Check the chain sliding guard for wear.
» If the lower bolt edge of the chain is in line with or below the chain sliding
guard:
–Change the chain sliding guard. x
– Check the chain sliding guard for tightness.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
Guideline
Screw, chain sliding
guard
M6 6 Nm
(4.4 lbf ft)
Loctite®243™
401057-01
– Check the chain sliding piece for wear.
» If the lower bolt edge of the chain is in line with or below the chain sliding
piece:
–Change the chain sliding piece. x
– Check the chain sliding piece for tightness.
» If the chain sliding piece is loose:
– Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)
400984-10
– Measure the material thickness on the bottom of the chain guide.
Minimum distance at the lowest
point
12 mm (0.47 in)
» If the distance is less than the specified measurement:
–Change the chain guide. x
B00347-01
– Check the chain guide for tightness.
» If the chain guide is loose:
– Tighten the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
– Remove the motorcycle from the lift stand. ( p. 37)
MAINTENANCE WORK ON THE CHASSIS 53
11.39
11.39
11.39
11.3911.39Adjusting the chain guide x
B00348-10
–Unscrew screw . Remove screw . Swing the chain guide down.
Condition
Number of teeth: 44 teeth≤
–Insert collar bushing in hole . Position the chain guide.
–Mount and tighten screw . Tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
Condition
Number of teeth: 45 teeth≥
–Insert collar bushing in hole . Position the chain guide.
–Mount and tighten screw . Tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
11.40
11.40
11.40
11.4011.40Checking the throttle cable routing
–Remove the fuel tank. ( p. 48)x
601197-01
–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:
–Correct the throttle cable routing.
–Install the fuel tank. ( p. 48)x
11.41
11.41
11.41
11.4111.41Adjusting the basic position of the clutch lever
B00001-11
(All 125/150 models)
–Adjust the basic setting of the clutch lever to your hand size by turning adjust-
ing screw .
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.
Do not make any adjustments while riding!
MAINTENANCE WORK ON THE CHASSIS 54
B00009-11
(All 250/300 models)
–Adjust the basic setting of the clutch lever to your hand size by turning adjust-
ing screw .
Info
Turn the adjusting screw counterclockwise to decrease the distance
between the clutch lever and the handlebar.
Turn the adjusting screw clockwise to increase 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.
Do not make any adjustments while riding!
11.42
11.42
11.42
11.4211.42Checking the fluid level of the hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch lining discs.
400245-10
(All 125/150 models)
–Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-
tion.
–Remove screws .
–Remove cover with membrane .
–Check the fluid level.
Fluid level under top edge of con-
tainer
4 mm (0.16 in)
» If the level of the fluid does not meet specifications:
–Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 114)
–Position the cover with the membrane. Mount and tighten the screws.
B00040-10
(All 250/300 models)
–Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-
tion.
–Remove screws .
–Remove cover with membrane .
–Check the fluid level.
Fluid level under top edge of con-
tainer
4 mm (0.16 in)
» 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. 113)
–Position the cover with the membrane. Mount and tighten the screws.
11.43
11.43
11.43
11.4311.43Changing the hydraulic clutch fluid x
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.
MAINTENANCE WORK ON THE CHASSIS 55
400245-10
(All 125/150 models)
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-
tion.
– Remove screws .
– Remove cover with membrane .
B00041-10
– Fill bleeding syringe with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
Hydraulic fluid (15) ( p. 114)
–On the slave cylinder, remove bleeder screw and mount bleeding syringe .
400247-10
– 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.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level under top edge of con-
tainer
4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
B00040-10
(All 250/300 models)
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi-
tion.
– Remove screws .
– Remove cover with membrane .
B00064-10
– Fill bleeding syringe with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 113)
– On the slave cylinder, remove bleeder screw and mount bleeding syringe .
B00042-10
– 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.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level under top edge of con-
tainer
4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
BRAKES 56
12.1
12.1
12.1
12.112.1Checking the free travel of the hand brake lever
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due
to overheating. Adjust free travel on hand brake lever according to specifications.
400196-11
– Push the hand brake lever forward and check free travel .
Free travel of hand brake lever 3 mm ( 0.12 in)≥ ≥
» If the free travel does not meet specifications:
– Adjust the basic position of the hand brake lever. ( p. 56)
12.2
12.2
12.2
12.212.2Adjusting the basic position of the hand brake lever
400196-12
– Check the free travel of the hand brake lever. ( p. 56)
– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing screw .
Info
Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
12.3
12.3
12.3
12.312.3Checking the brake discs
Warning
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.)
A
A
A
A
A
400257-10
– Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement .
Info
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit
Front 2.5 mm (0.098 in)
Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the brake disc.
– Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc exhibits damage, cracking or deformation:
– Change the brake disc.
BRAKES 57
12.4
12.4
12.4
12.412.4Checking the front brake fluid level
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
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.)
B00070-10
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the viewer .
» If the brake fluid is below the marking:MIN
–Add front brake fluid. ( p. 57)x
12.5
12.5
12.5
12.512.5Adding front brake fluid x
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
BRAKES 58
600706-10
–Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screws .
–Remove cover with membrane .
–Add brake fluid to level .
Guideline
Dimension (brake fluid level below
top edge of container)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 113)
–Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
12.6
12.6
12.6
12.612.6Checking the front brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
B00350-10
–Check the brake linings for minimum thickness .
Minimum thickness 1 mm ( 0.04 in)≥ ≥
» If the minimum thickness is less than specified:
–Change the front brake linings. ( p. 58)x
–Check the brake linings for damage and cracking.
» If damage or cracking is visible:
–Change the front brake linings. ( p. 58)x
12.7
12.7
12.7
12.712.7Changing the front brake linings x
Warning
Danger of accident Brake system failure.
–Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
BRAKES 59
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved 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. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
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.
Info
Never use DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
100395-10
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover with membrane .
– Press the brake caliper onto the brake disc by hand in order to push back the brake
pistons. Ensure that brake fluid does not overflow from the brake fluid reservoir,
using suction to remove it if it does.
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
100396-10
– Remove locking split pins , withdraw bolt , and take out the brake linings.
– Clean the brake caliper and brake caliper support.
0
0
0
0
00
77
0
0
0
0
00 66
100397-01
– Check that leaf spring in the brake caliper and sliding plate in the brake
caliper support are seated correctly.
100398-10
– Fit the brake linings, insert the bolt, and mount the locking split pins.
– Operate the hand brake lever several times until the brake linings are lying correctly
against on the brake disc and there is a pressure point.
BRAKES 60
100399-10
– Correct the brake fluid quantity to level .
Guideline
Dimension (brake fluid level below
top edge of container)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 113)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
12.8
12.8
12.8
12.812.8Checking free travel of foot brake lever
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
B00028-10
– Disconnect spring .
– Move the foot brake lever backwards and forwards between the end stop and the
foot brake cylinder piston bracket and check free travel .
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
–Adjust the basic position of the foot brake lever. ( p. 60)x
– Reconnect spring .
12.9
12.9
12.9
12.912.9Adjusting basic position of foot brake lever x
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
B00008-10
– Disconnect spring .
– Loosen nut and, with push rod , turn it back until you have maximum free
travel.
– To adjust the basic position of the foot brake lever individually, loosen nut and
turn screw accordingly.
Info
The range of adjustment is limited.
– Turn push rod accordingly until you have free travel . If necessary, adjust the
basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
– Hold screw and tighten nut .
Guideline
Nut, foot brake lever stop M8 20 Nm
(14.8 lbf ft)
– Hold push rod and tighten nut .
Guideline
Remaining nuts, chassis M6 15 Nm
(11.1 lbf ft)
BRAKES 61
–Reconnect spring .
12.10
12.10
12.10
12.1012.10Checking the rear brake fluid level
Warning
Danger of accidents Failure of the brake system.
–If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
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.)
400234-10
–Stand the vehicle upright.
–Check the brake fluid level in the viewer .
» If an air bubble is visible in viewer :
–Add brake fluid for the rear brake. ( p. 61)x
12.11
12.11
12.11
12.1112.11Adding brake fluid for the rear brake x
Warning
Danger of accidents Failure of the brake system.
–If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
BRAKES 62
B00360-10
–Stand the vehicle upright.
–Remove screw cap with membrane and the O-ring.
–Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 113)
–Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
12.12
12.12
12.12
12.1212.12Checking the rear brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
B00355-10
–Check the brake linings for minimum thickness .
Minimum thickness 1 mm ( 0.04 in)≥ ≥
» If the minimum thickness is less than specified:
–Change the rear brake linings. ( p. 62)x
–Check the brake linings for damage and cracking.
» If damage or cracking is visible:
–Change the rear brake linings. ( p. 62)x
12.13
12.13
12.13
12.1312.13Changing the rear brake linings x
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
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.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
B00356-10
–Stand the vehicle upright.
–Remove screw cap with membrane and the O-ring.
BRAKES 63
B00357-10
–Press the brake caliper toward the brake disc to push back the brake piston and
ensure that no brake fluid runs out of the brake fluid reservoir, sucking it off if it
does.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
–Remove locking split pins , withdraw bolt , and take out the brake linings.
–Clean the brake caliper and brake caliper support.
B00358-10
–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.
B00359-10
–Insert the brake linings, insert pin , and mount locking split pins .
Info
Make sure that decoupling plate is mounted on the piston side of the
brake lining.
–Operate the foot brake lever several times until the brake linings are lying correctly
against the brake disc and there is a pressure point.
B00360-10
–Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 113)
–Mount and tighten screw cap with membrane and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
WHEELS, TIRES 64
13.1
13.1
13.1
13.113.1Removing the front wheel x
–Raise the motorcycle with the lift stand. ( p. 37)
B00301-10
–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.
B00302-10
–Remove screw .
–Loosen screws .
B00303-10
–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.
B00304-10
–Remove spacers .
13.2
13.2
13.2
13.213.2Installing the front wheel x
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
B00304-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing. x
–Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 115)
–Insert the spacers.
WHEELS, TIRES 65
B00302-11
–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.
–Remove the motorcycle from the lift stand. ( p. 37)
–Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
13.3
13.3
13.3
13.313.3Removing the rear wheel x
–Raise the motorcycle with the lift stand. ( p. 37)
B00340-10
–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.
–Remove nut .
–Remove chain adjuster . Withdraw wheel spindle only enough to allow the rear
wheel to be pushed forward.
–Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
–Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
B00341-10
–Remove spacers .
13.4
13.4
13.4
13.413.4Installing the rear wheel x
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
WHEELS, TIRES 66
B00341-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing. x
–Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 115)
–Insert the spacers.
B00342-10
–Lift the rear wheel into the swing arm, position it, and insert wheel spindle .
–Apply the chain.
B00343-10
–Position chain adjuster . Mount nut , but do not tighten it yet.
–Make sure that chain adjusters are fitted correctly on adjusting screws .
–Check the chain tension. ( p. 50)
–Tighten nut .
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
Chain adjusters can be turned by 180°.
–Operate the foot brake lever several times until the brake linings are lying correctly
against the brake disc and there is a pressure point.
–Remove the motorcycle from the lift stand. ( p. 37)
13.5
13.5
13.5
13.513.5Checking 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.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
400602-10
–Check the front and rear tires for cuts, run-in objects and other damage.
» If the tire exhibits cuts, run-in objects or other damage:
–Change the tire.
–Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth 2 mm ( 0.08 in)≥ ≥
» If the tread depth is less than the minimum permissible depth:
WHEELS, TIRES 67
–Change the tire.
–Check the tire age.
Info
The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the marking. The first two digits indi-DOT
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.
» If the tire is older than five years:
–Change the tire.
13.6
13.6
13.6
13.613.6Checking the tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
400695-01
–Remove the dust cap.
–Check the tire air pressure when the tires are cold.
Tire air pressure off road
Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
–Correct the tire pressure.
–Mount the dust cap.
13.7
13.7
13.7
13.713.7Checking the spoke tension
Warning
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.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
400694-01
–Briefly strike each spoke with the tip of a screwdriver.
Info
The tone frequency depends on the length of the spoke and the spoke diam-
eter.
If you hear different tone frequencies from different spokes of equal length
and diameter, this is an indication of different spoke tensions.
You should hear a high note.
» If the spoke tension varies:
–Correct the spoke tension. x
–Check the spoke torque.
Guideline
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)
Torque wrench with various accessories in set (58429094000)
ELECTRICAL SYSTEM 68
14.1
14.1
14.1
14.114.1Removing the battery (250/300 XC)x
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–Flush with copious amounts of water in case of skin contact. If battery acid comes into contact with the eyes, flush the
eyes with water for at least 15 minutes and consult a physician.
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 44)
B00361-10
–Disconnect negative cable of the battery.
–Pull back the positive terminal cover and disconnect the positive cable of the
battery.
–Detach rubber band at the bottom.
–Lift the battery up.
14.2
14.2
14.2
14.214.2Installing the battery (250/300 XC)x
B00361-11
–Place the battery in the battery holder.
Battery (YTX4L-BS) ( p. 105)
–Reconnect rubber band .
–Attach the positive cable and replace the positive terminal cover .
–Attach negative cable .
–Mount the seat. ( p. 44)
14.3
14.3
14.3
14.314.3Recharging the battery (250/300 XC)x
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–Flush with copious amounts of water in case of skin contact. If battery acid comes into contact with the eyes, flush the
eyes with water for at least 15 minutes and consult a physician.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
–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.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
ELECTRICAL SYSTEM 69
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. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 44)
–Disconnect the negative cable of the battery to avoid damage to the motorcycle's
electronics.
400240-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove lid .
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing .
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
–Mount the seat. ( p. 44)
14.4
14.4
14.4
14.414.4Removing the main fuse (250/300 XC)
–Switch off all power consumers and switch off the engine.
–Remove the air filter box lid. ( p. 45)
B00362-10
–Pull starter relay off of the bracket.
Info
The main fuse is located in the starter relay under the filter box cover.
B00363-10
–Remove the protection cover .
–Remove main fuse.
ELECTRICAL SYSTEM 70
14.5
14.5
14.5
14.514.5Installing the main fuse (250/300 XC)
Warning
Fire hazard The electrical system can be overloaded by the use of incorrect fuses.
–Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
B00363-11
–Insert the main fuse.
Fuse (58011109110)
Info
A reserve fuse is located in the starter relay.
Replace a faulty fuse by an equivalent fuse only.
–Replace the protection cover.
–Mount the starter relay on the holder.
–Install the air filter box lid. ( p. 45)
COOLING SYSTEM 71
15.1
15.1
15.1
15.115.1Cooling system
601186-10
(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.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the
cooling effect.
601187-10
(All 250/300 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.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the
cooling effect.
15.2
15.2
15.2
15.215.2Radiator cover (All SX models)
601198-10
The radiator cover is mounted in front of the left radiator between the radiator shield
and radiator.
The radiator cover keeps the coolant temperature in the correct range.
Coolant temperature 65… 70 °C (149… 158 °F)
401055-10
The radiator cover is installed in front of the left radiator, depending on the ambient
temperature.
Radiator cover without
notch
< 7 °C (< 45 °F)
Radiator cover with
notch
7… 16 °C (45… 61 °F)
Without radiator cover > 16 °C (> 61 °F)
Info
Do not use both radiator covers at the same time.
15.3
15.3
15.3
15.315.3Removing the radiator cover (All SX models)
–Remove the fuel tank. ( p. 48)x
601202-10
–Detach radiator shield at mounting points and remove it. Remove radiator
cover .
COOLING SYSTEM 72
601203-10
–Attach the radiator shield at holding lugs . Attach mounting points at the radi-
ator.
–Install the fuel tank. ( p. 48)x
15.4
15.4
15.4
15.415.4Installing the radiator cover (All SX models)
–Remove the fuel tank. ( p. 48)x
601200-10
–Detach radiator shield at mounting points and remove it.
601201-10
–Position the corresponding radiator cover and attach the radiator shield at hold-
ing lugs . Attach mounting points at the radiator.
–Install the fuel tank. ( p. 48)x
15.5
15.5
15.5
15.515.5Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
400243-10
–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.
–Check the coolant level in the radiator.
Coolant level above the radiator fins. 10 mm (0.39 in)
COOLING SYSTEM 73
» If the level of the coolant does not meet specifications:
–Correct the coolant level.
Alternative 1
Coolant ( p. 113)
Alternative 2
Coolant (mixed ready to use) ( p. 113)
–Mount the radiator cap.
15.6
15.6
15.6
15.615.6Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
400243-10
–Stand the motorcycle upright on a horizontal surface.
–Remove the radiator cap.
–Check the coolant level in the radiator.
Coolant level above the radiator fins. 10 mm (0.39 in)
» If the level of the coolant does not meet specifications:
–Correct the coolant level.
Alternative 1
Coolant ( p. 113)
Alternative 2
Coolant (mixed ready to use) ( p. 113)
–Mount the radiator cap.
15.7
15.7
15.7
15.715.7Draining the coolant x
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
–Position the motorcycle upright.
–Place a suitable container under the water pump cover.
COOLING SYSTEM 74
601186-11
(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)
601187-11
(All 250/300 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)
15.8
15.8
15.8
15.815.8Refilling with coolant x
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
B00071-10
(All 125/150 models)
–Make sure that screw is tightened.
B00072-10
(All 250/300 models)
–Make sure that screw is tightened.
B00073-10
–Position the motorcycle upright.
–Fill the radiator completely with coolant.
Coolant 1.2 l (1.3 qt.) Coolant ( p. 113)
Coolant (mixed ready to use)
( p. 113)
–Mount radiator cap .
–Run the engine until it is warm.
–Check the coolant level. ( p. 73)
TUNING THE ENGINE 75
16.1
16.1
16.1
16.116.1Checking the play in the throttle cable
B00026-10
–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 .
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
–Adjust the play in the throttle cable. ( p. 75)x
–Slide on sleeve . Check the throttle grip for smooth operation.
16.2
16.2
16.2
16.216.2Adjusting the play in the throttle cable x
B00026-11
–Move the handlebar to the straight-ahead position.
–Push back bellows .
–Loosen nut . Turn adjusting screw in as far as possible.
–Turn the adjusting screw so that there is play at the outer casing of the throttle
cable.
Guideline
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
–Tighten the nut.
–Slide on sleeve . Check the throttle grip for smooth operation.
16.3
16.3
16.3
16.316.3Carburetor
B00048-11
The idle setting of the carburetor has a big influence on the starting behavior, stable
idling and the response to throttle opening. This means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.
Info
The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.
The factory setting for the carburetor is set for the following values.
(All 125/150 models)
Elevation above sea level 500 m (1,640 ft)
Ambient temperature 20 °C (68 °F)
Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) ( p. 114)
(All 250/300 models)
Elevation 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. 114)
The idle speed is adjusted with adjusting screw .
The idle mixture is adjusted with the idle air adjusting screw .
00
0
0
0
0DD
0
0
0
0
00CC
0
0
0
0
00BB
0
0
0
0
00AA
500282-01
Idle air range A
Operation with the throttle slide closed. This range is influenced by adjusting screw
and the idle air adjusting screw .
Transition range B
Behavior of the engine when the throttle slide is being opened. This range is influenced
by the idling jet and by the form of the throttle slide.
If the engine sputters and smokes heavily when it starts despite a good idle and part-
load setting, and if it abruptly reaches full power at a high rpm, the carburetor setting
is too rich, or the float level is too high or the float needle valve is leaky.
Part-load range C
Operation with the throttle slide partially open. This range is influenced by the jet
needle (form and position). The idle setting influences the engine tuning in the lower
range, and the main jet influences the engine tuning in the upper range.
If the engine stutters when accelerating with a partially open throttle slide, the jet nee-
dle must be lowered by one notch. If the engine knocks when accelerating at the full
power rpm range, the jet needle must be raised. If the above events occur on idle or
TUNING THE ENGINE 76
just above it, the idle system must be set to a leaner setting if the engine is stuttering
or to a richer setting if the engine is knocking.
Full-load range D
Operation with the throttle slide open (full throttle). This range is influenced by the
main jet and jet needle.
If the insulator of a new spark plug is very light-colored or white after a brief ride at full
throttle, or if the engine knocks, a larger main jet needs to be used. If the insulator is
dark brown or sooty, a smaller main jet needs to be used.
16.4
16.4
16.4
16.416.4Carburetor - adjusting the idle speed x
B00048-11
–Screw in idle air adjusting screw all the way and turn it to the specified basic
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)
Open 1.5 turns
Idle air adjusting screw (250 SX)
Open 1.0 turn
Idle air adjusting screw (250 XC EU/USA)
Open 1.5 turns
Idle air adjusting screw (300 XC EU/USA)
Open 2 turns
–Run the engine until warm.
Guideline
Warm-up time 5 min≥
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.
–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
begins to fall.
–Note the position and turn the idle air adjusting screw slowly counterclockwise until
the idle speed falls again.
–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.
If you can turn the idle air adjusting screw to the end without any change of
engine speed, you need to install a smaller idling jet.
After changing the idling jet, repeat the adjusting steps from the beginning.
Following extreme air temperature or altitude changes, adjust the idle speed
again.
TUNING THE ENGINE 77
16.5
16.5
16.5
16.516.5Emptying the carburetor float chamber x
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.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
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. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.
(All SX models)
–Turn handle of the fuel tap to the position. (Figure 601185-10 p. 12)OFF
No more fuel flows from the tank to the carburetor.
(All XC models)
–Turn handle of the fuel tap to the position. (Figure 601157-11 p. 11)OFF
No more fuel flows from the tank to the carburetor.
601194-10
–Place a cloth beneath the carburetor to soak up emerging fuel.
–Remove plug .
–Completely drain the fuel.
–Mount and tighten the plug.
16.6
16.6
16.6
16.616.6Ignition curve plug connection
601190-10
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 The plug connection is connected to achieve better performance.–
TUNING THE ENGINE 78
16.7
16.7
16.7
16.716.7Changing the ignition curve
Change the ignition curve from Performance to Soft.
–Disconnect plug connection . (Figure 601190-10 p. 77)
Soft better rideability–
Change the ignition curve from Soft to Performance.
–Connect plug connection . (Figure 601190-10 p. 77)
Performance better performance–
16.8
16.8
16.8
16.816.8Checking the basic position of the shift lever
00
0
0
0
0AA
400692-10
–Sit on the vehicle in the riding position and determine the distance between the
upper edge of your boot and the shift lever.
Distance between shift lever and upper
edge of boot
10… 20 mm (0.39… 0.79 in)
» If the distance does not meet specifications:
–Adjust the basic position of the shift lever. ( p. 78)x
16.9
16.9
16.9
16.916.9Adjusting the basic position of the shift lever x
B00065-10
–Remove screw and remove shift lever .
B00066-10
–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.
–Mount and tighten the screw.
Guideline
Screw, shift lever M6 14 Nm
(10.3 lbf ft)
Loctite®243™
16.10
16.10
16.10
16.1016.10Engine characteristic - auxiliary spring (All 250/300 models)
00
0
0
0
011
B00056-10
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–
medium tuning (standard) for good rideability.
• Auxiliary spring with green marking Auxiliary spring contained in the separate–
enclosure for softer performance.
• Auxiliary spring with red marking Auxiliary spring contained in the separate–
enclosure for more aggressive performance.
The engine characteristic can be influenced by different spring strengths of the auxil-
iary spring .
TUNING THE ENGINE 79
16.11
16.11
16.11
16.1116.11Engine characteristic - adjust the auxiliary spring (All 250/300 models)x
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
–Tilt the motorcycle approx. 45º to the left and secure it in this position to prevent it
from falling over.
B00057-10
–Remove screws .
00
0
0
0
044
0
0
0
0
0033
0
0
0
0
0055
0
0
0
0
0022
B00056-11
–Take locking cap , adjusting spring , auxiliary spring and spring insert out
of the clutch cover.
–Pull both springs off of the spring insert.
B00058-10
–Mount the desired auxiliary spring and adjusting spring and slide them into
the clutch cover together.
Auxiliary spring with yellow marking (54837072300)
Auxiliary spring with green marking (54837072100)
Auxiliary spring with red marking (54837072000)
The cut-out of spring insert engages in the angle lever.
Info
Under no circumstances should screw be turned as this would have a
negative effect on the engine characteristic.
–Check the O-ring in the locking cap.
–Position the locking cap.
–Mount and tighten the screws.
Guideline
Screw, exhaust control cover M5 5 Nm (3.7 lbf ft)
MAINTENANCE WORK ON THE ENGINE 80
17.1
17.1
17.1
17.117.1Checking the gear oil level
Info
The gear oil level must be checked when the engine is cold.
–Stand the motorcycle upright on a horizontal surface.
B00049-10
(All 125/150 models)
–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:
–Add gear oil. ( p. 82)x
–Mount and tighten the gear oil level check screw.
Guideline
Screw, gear oil level check M6 10 Nm
(7.4 lbf ft)
B00050-10
(All 250/300 models)
–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:
–Add gear oil. ( p. 82)x
–Mount and tighten the gear oil level check screw.
Guideline
Screw, gear oil level check M6 10 Nm
(7.4 lbf ft)
17.2
17.2
17.2
17.217.2Changing the gear oil x
400721-01
–Drain the gear oil. ( p. 81)x
400722-01
–Refill with gear oil. ( p. 81)x
MAINTENANCE WORK ON THE ENGINE 81
17.3
17.3
17.3
17.317.3Draining the gear oil x
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.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the gear oil only when the engine is warm.
–Place the motorcycle on a level surface.
–Place a suitable container under the engine.
B00051-10
(All 125/150 models)
–Remove the gear oil drain plug with magnet .
–Remove the gear oil drain plug .
–Completely drain the gear oil.
–Clean the gear oil drain plug thoroughly.
–Clean the sealing area on the engine.
–Mount the gear oil drain plug with magnet and the seal ring and tighten it.
Guideline
Gear oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
–Mount gear oil drain plug with the seal ring and tighten it.
Guideline
Gear oil drain plug M10x1 15 Nm
(11.1 lbf ft)
B00052-10
(All 250/300 models)
–Remove the gear oil drain plug with magnet .
–Completely drain the gear oil.
–Thoroughly clean the gear oil drain plug with a magnet.
–Clean the sealing area on the engine.
–Mount the gear oil drain plug with magnet and the seal ring and tighten it.
Guideline
Gear oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
17.4
17.4
17.4
17.417.4Refilling with gear oil x
Info
Too little gear oil or poor-quality oil results in premature wear of the transmission.
B00053-10
–Remove screw cap and fill up gear oil.
Gear oil
(All 125/150
models)
0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 113)
Gear oil
(All 250/300 mod-
els)
0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 113)
–Mount and tighten the screw cap.
MAINTENANCE WORK ON THE ENGINE 82
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.
–Start the engine and check that it is oil-tight.
–Check the gear oil level. ( p. 80)
17.5
17.5
17.5
17.517.5Adding gear oil x
Info
Too little gear oil or poor-quality oil results in premature wear of the transmission.
The gear oil must be added when the engine is cold.
–Place the motorcycle on a level surface.
B00049-10
(All 125/150 models)
–Remove gear oil level check screw .
B00050-10
(All 250/300 models)
–Remove gear oil level check screw .
B00053-11
–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. 113)
–Mount and tighten the gear oil level check screw.
Guideline
Screw, gear oil level check M6 10 Nm (7.4 lbf ft)
–Mount and tighten screw cap .
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.
–Start the engine and check that it is oil-tight.
CLEANING, CARE 83
18.1
18.1
18.1
18.118.1Cleaning the motorcycle
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.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunlight on the motorcycle during cleaning.
–Close off the exhaust system to prevent water from entering.
–Remove coarse dirt particles by spraying gently with water.
–Spray very dirty areas with a normal motorcycle cleaner and then clean with a soft brush.
Motorcycle cleaner ( p. 115)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
–After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
–Empty the carburetor float chamber. ( p. 77)x
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
–Clean or dry dirty or wet brakes by riding and braking gently.
–After cleaning, take a short ride until the engine reaches operating temperature.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
–Push back the protection caps on the handlebar controls to allow water that may have penetrated there to evaporate.
–After the motorcycle has cooled down, lubricate all moving parts and bearings.
–Clean the chain. ( p. 49)
–Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 115)
–Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Cleaning and preserving materials for metal, rubber and plastic ( p. 115)
STORAGE 84
19.1
19.1
19.1
19.119.1Storage
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. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Info
If you want to put the motorcycle into storage for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
–Clean the motorcycle. ( p. 83)
–Change the gear oil. ( p. 80)x
–Check the antifreeze and coolant level. ( p. 72)
–Drain the fuel from the tank into a suitable container.
–Empty the carburetor float chamber. ( p. 77)x
–Check the tire air pressure. ( p. 67)
–Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
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.
Info
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced
during combustion will condense, causing engine parts and the exhaust system to rust.
19.2
19.2
19.2
19.219.2Putting into operation after storage
–Remove the motorcycle from the lift stand. ( p. 37)
–Refuel. ( p. 22)
–Perform checks and maintenance work when preparing the vehicle for use. ( p. 20)
–Make a test ride.
TROUBLESHOOTING 85
Faults Possible cause Action
The engine cannot be cranked (elec-
tric starter)
(250/300 XC)
Operating error Go through the steps of starting the engine.–
( p. 20)
Battery discharged –Recharge the battery. ( p. 68)x
–Check the charging voltage. x
–Check the closed current. x
–Check the alternator. x
Main fuse is blown Remove the main fuse. ( p. 69)–
–Install the main fuse. ( p. 70)
Starter relay faulty –Check the starter relay. x
Starter motor faulty –Check the starter motor. x
Engine turns but does not start Operating error Go through the steps of starting the engine.–
( p. 20)
Motorcycle was out of use for a long
time and there is old fuel in the float
chamber
–Empty the carburetor float chamber. x
( p. 77)
Fuel feed interrupted Check the fuel tank breather.–
–Clean the fuel tap.
–Check/set the carburetor components.
Spark plug oily or wet Clean and dry the spark plug, or change it if–
necessary.
Electrode distance (plug gap) of spark
plug too wide
–Adjust the plug gap.
Guideline
(All 125/150 models)
Spark plug electrode gap
0.60 mm (0.0236 in)
(All 250/300 models)
Spark plug electrode gap
0.60 mm (0.0236 in)
Fault in ignition system –Check the ignition system. x
Short circuit cable in wiring harness
frayed, kill switch defective
–Check the short circuit button. x
Socket connector or ignition coil is
loose or oxidized
–Clean the plug-in connector and treat it with
contact spray.
Water in carburetor or jets blocked Check/set the carburetor components.–
Engine has no idle Idling jet blocked Check/set the carburetor components.–
Adjusting screws on carburetor dis-
torted
–Carburetor - adjust the idle speed. x
( p. 76)
Spark plug defective Change the spark plug.–
Ignition system defective –Check the ignition coil. x
–Check the spark plug connector. x
Engine does not speed up Carburetor running over because float
needle dirty or worn
–Check/set the carburetor components.
Loose carburetor jets Check/set the carburetor components.–
Fault in ignition system –Check the ignition system. x
Engine has too little power Fuel feed interrupted Check the fuel tank breather.–
–Clean the fuel tap.
–Check/set the carburetor components.
Air filter very dirty –Clean the air filter and air filter box. x
( p. 46)
Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer
–Check exhaust system for damage.
–Change the glass fiber yarn filling of the main
silencer. ( p. 47)x
Fault in ignition system –Check the ignition system. x
Diaphragm or reed valve housing
damaged
–Check the diaphragm and reed valve housing.
TROUBLESHOOTING 86
Faults Possible cause Action
Engine stalls or is popping into the
carburetor
Lack of fuel (All SX models)
–Turn handle of the fuel tap to theON
position. (Figure 601185-10 p. 12)
(All XC models)
–Turn handle of the fuel tap to theON
position. (Figure 601157-11 p. 11)
–Refuel. ( p. 22)
Engine takes in bad air Check the intake flange and carburetor for–
tightness.
Socket connector or ignition coil is
loose or oxidized
–Clean the plug-in connector and treat it with
contact spray.
Engine overheats Too little coolant in cooling system Check the cooling system for leakage.–
–Check the coolant level. ( p. 73)
Too little air stream Switch off engine when stationary.–
Radiator fins very dirty Clean the radiator fins.–
Foam formation in cooling system –Drain the coolant. ( p. 73)x
–Refill with coolant. ( p. 74)x
Damaged cylinder head or cylinder
head gasket
–Check the cylinder head or cylinder head gas-
ket.
Bent radiator hose –Change the radiator hose. x
Incorrect ignition point due to loose
stator
–Adjust the ignition. x
White smoke emission (steam in
exhaust gas)
Damaged cylinder head or cylinder
head gasket
–Check the cylinder head or cylinder head gas-
ket.
Gear oil exits at the vent hose Too much gear oil added Check the gear oil level. ( p. 80)–
Water in the gear oil Damaged shaft seal ring or water
pump
–Check the shaft seal ring and water pump.
TECHNICAL DATA - ENGINE 87
21.1
21.1
21.1
21.121.1125 SX
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 Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in)
Z (height of control flap) 43.7 mm (1.72 in)
Primary transmission 23:73
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear, claw shifted
Transmission ratio
1st gear 13:32
2nd gear 15:30
3rd gear 17:28
4th gear 20:28
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 Kickstarter
21.2
21.2
21.2
21.221.2150 SX
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)
Bore 56 mm (2.2 in)
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
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
2nd gear 15:30
3rd gear 17:28
4th gear 20:28
5th gear 19:23
TECHNICAL DATA - ENGINE 88
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 Kickstarter
21.3
21.3
21.3
21.321.3150 XC USA
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)
Bore 56 mm (2.2 in)
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
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
2nd gear 15:30
3rd gear 17:28
4th gear 19:26
5th gear 21:25
6th gear 22:23
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 Kickstarter
21.4
21.4
21.4
21.421.4250 SX
Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and
exhaust control
Displacement 249 cm³ (15.19 cu in)
Stroke 72 mm (2.83 in)
Bore 66.4 mm (2.614 in)
Exhaust valve - Beginning of adjustment 5,500 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,000 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,500 rpm
Exhaust valve - end of adjustment with green auxiliary spring 7,900 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
TECHNICAL DATA - ENGINE 89
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 14:28
2nd gear 15:24
3rd gear 18:24
4th gear 21:24
5th gear 22:21
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Ignition point (BTDC) 1.9 mm (0.075 in)
Spark plug NGK BR 8 ECM
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter
21.5
21.5
21.5
21.521.5250 XC EU/USA
Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and
exhaust control
Displacement 249 cm³ (15.19 cu in)
Stroke 72 mm (2.83 in)
Bore 66.4 mm (2.614 in)
Exhaust valve - Beginning of adjustment 5,500 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,300 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,800 rpm
Exhaust valve - end of adjustment with green auxiliary spring 8,300 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 half keystone rings
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 6-gear, claw shifted
Transmission ratio
1st gear 15:31
2nd gear 16:25
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Ignition point (BTDC) 1.9 mm (0.075 in)
Spark plug NGK BR 7 ES
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter and electric starter
TECHNICAL DATA - ENGINE 90
21.6
21.6
21.6
21.621.6300 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 5,500 rpm
Exhaust valve - end of adjustment with red auxiliary spring 7,300 rpm
Exhaust valve - end of adjustment with yellow auxiliary spring 7,800 rpm
Exhaust valve - end of adjustment with green auxiliary spring 8,300 rpm
Crankshaft bearing 1 grooved ball bearing/1 roller bearing
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 2 rectangular rings
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 6-gear, claw shifted
Transmission ratio
1st gear 15:31
2nd gear 16:25
3rd gear 20:25
4th gear 22:23
5th gear 25:22
6th gear 26:20
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Ignition point (BTDC) 1.9 mm (0.075 in)
Spark plug NGK BR 7 ES
Spark plug electrode gap 0.60 mm (0.0236 in)
Starting aid Kick starter and electric starter
21.7
21.7
21.7
21.721.7Capacity - transmission oil
Gear oil (All 125/150 models) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 113)
Gear oil (All 250/300 models) 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 113)
21.8
21.8
21.8
21.821.8Capacity - coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 113)
Coolant (mixed ready to use) ( p. 113)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 91
22.1
22.1
22.1
22.122.1All 125/150 models
Screw, membrane M4 2 Nm (1.5 lbf ft) Loctite®243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, alternator cover M5 5 Nm (3.7 lbf ft) –
Screw, exhaust control cover M5 5 Nm (3.7 lbf ft) –
Screw, exhaust flange M5 6 Nm (4.4 lbf ft) –
Screw, ignition system/stator M5 6 Nm (4.4 lbf ft) Loctite®222
Screw, lock washer, axle for control
flap
M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, water pump wheel M5 6 Nm (4.4 lbf ft) Loctite®243™
Bleeder screw, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, clutch spring M6 10 Nm (7.4 lbf ft) –
Screw, engine housing M6 10 Nm (7.4 lbf ft) –
Screw, exhaust control M6 10 Nm (7.4 lbf ft) –
Screw, gear oil level check M6 10 Nm (7.4 lbf ft) –
Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) –
Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, shifting gate M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, water pump cover M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, cylinder head M7 18 Nm (13.3 lbf ft) –
Axle for control flap, exhaust control M8 Step 1
3 Nm (2.2 lbf ft)
Step 2 (loosen, counter-
clockwise)
1/4 turn
–
Nut, cylinder base M8 30 Nm (22.1 lbf ft) –
Screw, cylinder base M8 35 Nm (25.8 lbf ft) –
Screw, kickstarter M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, shift drum locating M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite®2701
Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) –
Gear oil drain plug 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) –
Spark plug M14x1.25 25 Nm (18.4 lbf ft) –
Nut, primary gear M16LHx1.5 130 Nm (95.9 lbf ft) Loctite®243™
Nut, inner clutch hub M18x1.5 130 Nm (95.9 lbf ft) Loctite®243™
Nut, exhaust control, bearing support M26x1 35 Nm (25.8 lbf ft) –
22.2
22.2
22.2
22.222.2250 SX
Screw ,stator M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, alternator cover M5 5 Nm (3.7 lbf ft) –
Screw, angle lever, exhaust control M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, exhaust control cover M5 5 Nm (3.7 lbf ft) –
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, retaining bracket of exhaust
control
M5 7 Nm (5.2 lbf ft) Loctite®243™
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 93
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, starter motor M6 8 Nm (5.9 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Screw, cylinder head M8 27 Nm (19.9 lbf ft) –
Screw, kickstarter M8 25 Nm (18.4 lbf ft) Loctite®2701
Nut, cylinder base M10 35 Nm (25.8 lbf ft) –
Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite®2701
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) –
Spark plug M14x1.25 25 Nm (18.4 lbf ft) –
Nut, inner clutch hub M18x1.5 100 Nm (73.8 lbf ft) Loctite®2701
Nut, primary gear M18LHx1.5 150 Nm (110.6 lbf ft) Loctite®243™
TECHNICAL DATA - CARBURETOR 94
23.1
23.1
23.1
23.123.1125 SX
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 85
Idle air adjusting screw
Open 1.5 turns
Throttle slide 7 with cut-out
23.2
23.2
23.2
23.223.2Carburetor - basic setting for sandy surfaces (125 SX)
Idle air adjusting screw
Open 1.5 turns
Idling jet 45
Jet needle NOZH
Needle position 4th position from top
Main jet 208
Info
If the engine is not running smoothly, use a smaller main jet.
TECHNICAL DATA - CARBURETOR 95
23.3
23.3
23.3
23.323.3Carburetor configuration (125 SX)
400709-01
M/FT ASL Sea level
TEMP Temperature
ASO Idle air adjusting screw is open
IJ Idling jet
NDL Needle
POS Needle position from above
MJ Main jet
0
0
0
0
0044
0
0
0
0
0033
0
0
0
0
0055
0
0
0
0
0022
0
0
0
0
0011
B00075-10
1... 5 Needle position from above
The carburetor configuration depends on the defined ambient and operating conditions.
Info
Not for sandy surfaces
TECHNICAL DATA - CARBURETOR 96
23.4
23.4
23.4
23.423.4150 SX
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 85
Idle air adjusting screw
Open 2 turns
Throttle slide 6.5 with cut-out
23.5
23.5
23.5
23.523.5Carburetor - basic setting for sandy surfaces (150 SX)
Idle air adjusting screw
Open 1.5 turns
Idling jet 45
Jet needle NOZH
Needle position 3rd position from top
Main jet 208
Info
If the engine is not running smoothly, use a smaller main jet.
TECHNICAL DATA - CARBURETOR 97
23.6
23.6
23.6
23.623.6Carburetor configuration (150 SX)
401037-01
M/FT ASL Sea level
TEMP Temperature
ASO Idle air adjusting screw is open
IJ Idling jet
NDL Needle
POS Needle position from above
MJ Main jet
0
0
0
0
0044
0
0
0
0
0033
0
0
0
0
0055
0
0
0
0
0022
0
0
0
0
0011
B00075-10
1... 5 Needle position from above
The carburetor configuration depends on the defined ambient and operating conditions.
Info
Not for sandy surfaces
TECHNICAL DATA - CARBURETOR 98
23.7
23.7
23.7
23.723.7250 SX
Carburetor type KEIHIN PWK 36S AG
Carburetor identification number FK0180
Needle position 3rd position from top
Jet needle N1EI (N1EH, N1EJ)
Main jet 158 (155, 160)
Idling jet 42 (40)
Starting jet 85
Idle air adjusting screw
Open 1.0 turn
Throttle slide 6.5 with cut-out
23.8
23.8
23.8
23.823.8Carburetor - basic setting for sandy surfaces (250 SX)
Idle air adjusting screw
Open 1.0 turn
Idling jet 45
Jet needle NOZG
Needle position 4th position from top
Main jet 175
Info
If the engine is not running smoothly, use a smaller main jet.
TECHNICAL DATA - CARBURETOR 99
23.9
23.9
23.9
23.923.9Carburetor configuration (250 SX)
401038-01
M/FT ASL Sea level
TEMP Temperature
ASO Idle air adjusting screw is open
IJ Idling jet
NDL Needle
POS Needle position from above
MJ Main jet
0
0
0
0
0044
0
0
0
0
0033
0
0
0
0
0055
0
0
0
0
0022
0
0
0
0
0011
B00075-10
1... 5 Needle position from above
The carburetor configuration depends on the defined ambient and operating conditions.
Info
Not for sandy surfaces
TECHNICAL DATA - CARBURETOR 100
23.10
23.10
23.10
23.1023.10150 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 85
Idle air adjusting screw
Open 1.5 turns
Throttle slide 7 with cut-out
23.11
23.11
23.11
23.1123.11Carburetor configuration (150 XC USA)
401039-01
M/FT ASL Sea level
TEMP Temperature
ASO Idle air adjusting screw is open
IJ Idling jet
NDL Needle
Specyfikacje produktu
| Marka: | KTM |
| Kategoria: | Silnik |
| Model: | 125 (2011) |
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