KTM 150 SX 2022 Owner Manual
Reklamë
Reklamë
OWNER'S MANUAL
2022
125 SX
150 SX
125 XC
Art. no. 3214411en
DEAR KTM CUSTOMER
DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports vehicle which, with appropriate care, will bring you pleasure for a long time to come.
We wish you good and safe riding at all times!
Enter the serial numbers of your vehicle below.
Vehicle identification number ( p. 13)
Dealer's stamp
The Owner's Manual contained the latest information for this model series at the time of publication. However, minor differences due to further developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, 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 figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2021 KTM Sportmotorcycle GmbH, 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)
KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
125 SX (F6101V0)
150 SX (F6101V1)
125 XC US (F6175V3)
*3214411en*
3214411en
05/2021
TABLE OF CONTENTS
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ...................... 5
Symbols used .................................... 5
Formats used..................................... 5
2 SAFETY ADVICE............................................ 6
Use definition – intended use.............. 6
Misuse.............................................. 6
Safety advice..................................... 6
Degrees of risk and symbols ................ 7
Tampering warning............................. 7
Safe operation ................................... 7
Protective clothing ............................. 8
Work rules......................................... 8
Environment...................................... 8
Owner's Manual ................................. 9
3 IMPORTANT NOTES.................................... 10
Manufacturer warranty, implied warranty.......................................... 10
Fuel, auxiliary substances ................. 10
Spare parts, technical accessories ..... 10
Service ........................................... 10
Figures ........................................... 10
Customer service.............................. 10
4 VIEW OF VEHICLE ...................................... 11
View of vehicle, front left (example) ... 11
(example)........................................ 12
5 SERIAL NUMBERS ..................................... 13
Vehicle identification number............ 13
Type label ....................................... 13
Engine number ................................ 13
Fork part number ............................. 13
Shock absorber article number .......... 14
6 CONTROLS................................................. 15
Clutch lever..................................... 15
Hand brake lever.............................. 15
Throttle grip .................................... 15
Stop button ..................................... 15
Start button (125 XC US) ................. 16
Opening the fuel tank filler cap ......... 16
Closing the fuel tank filler cap........... 17
Fuel tap (All SX models) ................... 18
Fuel tap (125 XC US)....................... 18
Choke ............................................. 19
Shift lever ....................................... 19
Kick starter lever.............................. 20
Foot brake lever ............................... 20
Plug-in stand (All SX models)............ 20
Side stand (125 XC US) ................... 20
Service hour counter ........................ 21
7 PREPARING FOR USE................................. 22
Advice on preparing for first use ........ 22
Running in the engine ...................... 23
Preparing the vehicle for difficult operating conditions......................... 23
Preparing the vehicle for riding on dry sand.......................................... 24
Preparing the vehicle for riding on wet sand ......................................... 25
Preparing the vehicle for riding on wet and muddy circuits .................... 27
Preparing vehicle for high temperatures or slow riding ............... 27
Preparing the vehicle for low temperatures or snow ....................... 28
8 RIDING INSTRUCTIONS.............................. 29
Checks and maintenance measures when preparing for use ..................... 29
Starting........................................... 29
Starting off...................................... 30
Shifting, riding ................................ 31
Applying the brakes.......................... 31
Stopping, parking............................. 32
Transporting .................................... 32
Refueling ........................................ 33
9 SERVICE SCHEDULE .................................. 35
Additional information...................... 35
Required work ................................. 35
Recommended work ......................... 36
10 TUNING THE CHASSIS ............................... 37
Checking the basic chassis setting with rider's weight............................ 37
Air suspension XACT 5448 ............... 37
Compression damping of the shock absorber.......................................... 38
Adjusting the rebound damping of the shock absorber........................... 39
Measuring the rear wheel dimension unloaded......................................... 40
Checking the static sag of the shock absorber.......................................... 41
Checking the riding sag of the shock absorber.......................................... 41
10.10 Adjusting the spring preload of the shock absorber ............................. 42
10.11 Adjusting the riding sag ................ 43
2
TABLE OF CONTENTS
10.12 Checking the basic setting of the fork ................................................ 43
10.13 Adjusting the fork air pressure........... 44
10.14 Adjusting the compression damping of the fork ....................................... 45
10.15 Adjusting the rebound damping of the fork........................................... 45
10.16 Handlebar position........................... 46
10.17 Adjusting the handlebar position .... 46
11 SERVICE WORK ON THE CHASSIS............... 48
Raising the motorcycle with a lift stand .............................................. 48
Removing the motorcycle from the lift stand ......................................... 48
Bleeding the fork legs....................... 49
Cleaning the dust boots of the fork legs ................................................ 49
Removing the fork legs .................. 50
Installing the fork legs .................. 50
Removing the fork protector .............. 51
Installing the fork protector............... 51
Removing the lower triple clamp .... 51
11.10 Installing the lower triple clamp ..... 52
11.11 Checking steering head bearing play ................................................ 54
11.12 Adjusting steering head bearing play ............................................ 55
11.13 Lubricating the steering head bearing ........................................ 55
11.14 Removing the start number plate....... 56
11.15 Installing the start number plate........ 56
11.16 Removing front fender ...................... 56
11.17 Installing front fender....................... 56
11.18 Removing the shock absorber ........ 57
11.19 Installing the shock absorber ......... 58
11.20 Removing the seat ........................... 60
11.21 Mounting the seat ............................ 60
11.22 Removing the air filter box cover ....... 61
11.23 Installing the air filter box cover ........ 62
11.24 Removing the air filter .................. 62
11.25 Cleaning the air filter and air filter box ............................................. 63
11.26 Installing the air filter ................... 64
11.27 Preparing air filter box cover for securing ...................................... 64
11.28 Removing the main silencer .............. 64
11.29 Installing the main silencer............... 65
11.30 Changing the glass fiber yarn filling in the main silencer ...................... 65
11.31 Removing the fuel tank ................. 66
11.32 Installing the fuel tank .................. 67
11.33 Checking the chain for dirt................ 68
11.34 Cleaning the chain ........................... 69
11.35 Checking the chain tension ............... 69
11.36 Adjusting the chain tension............... 70
11.37 Checking the chain, rear sprocket, engine sprocket, and chain guide ...... 71
11.38 Checking the frame ...................... 74
11.39 Checking the link fork ................... 74
11.40 Checking the throttle cable routing .... 74
11.41 Checking the rubber grip .................. 75
11.42 Adjusting the basic position of the clutch lever ..................................... 76
11.43 Checking/correcting the fluid level of the hydraulic clutch ......................... 76
11.44 Changing the hydraulic clutch fluid ............................................ 77
12 BRAKE SYSTEM ......................................... 79
Checking the free travel of the hand brake lever ...................................... 79
Adjusting the basic position of the hand brake lever .............................. 79
Checking the brake discs .................. 79
Checking the front brake fluid level ... 80
Adding front brake fluid ................ 81
Checking the front brake linings ........ 82
Changing the brake linings of the front brake ................................... 82
Checking the free travel of foot brake lever ............................................... 85
Adjusting the basic position of the foot brake lever ............................ 85
12.10 Checking the rear brake fluid level..... 86
12.11 Adding rear brake fluid ................. 86
12.12 Checking the brake linings of the rear brake........................................ 88
12.13 Changing the rear brake linings ...... 88
13 WHEELS, TIRES ......................................... 91
Removing the front wheel .............. 91
Installing the front wheel .............. 92
Removing the rear wheel ............... 92
Installing the rear wheel ................ 93
Checking the tire condition ............... 95
Checking tire pressure ...................... 95
Checking spoke tension .................... 96
14 ELECTRICAL SYSTEM ................................. 97
(125 XC US) ................................... 97
(125 XC US) ................................... 97
(125 XC US) ................................... 98
Changing main fuse (125 XC US) ...... 99
15 COOLING SYSTEM .................................... 101
Cooling system .............................. 101
Radiator cover ............................... 101
3
TABLE OF CONTENTS
Installing the radiator cover............. 101
Removing the radiator cover............ 102
Checking the antifreeze and coolant level .................................. 102
Checking the coolant level .............. 103
Draining the coolant ................... 104
Refilling with coolant .................. 105
Changing the coolant .................. 106
16 TUNING THE ENGINE............................... 108
Checking the play in the throttle cable ............................................ 108
Adjusting the play in the throttle cable ......................................... 108
Carburetor tuning........................... 109
Carburetor – idle setting ................. 111
Carburetor - adjusting the idle speed ........................................ 112
Plug-in connector of ignition timing map adjustment............................. 113
Changing the ignition timing map .... 113
Checking the basic position of the shift lever...................................... 113
Adjusting the basic position of the shift lever .................................. 114
17 SERVICE WORK ON THE ENGINE .............. 115
Emptying the carburetor float chamber .................................... 115
Checking the gear oil level .............. 116
Changing the gear oil .................. 116
Adding the gear oil ..................... 117
18 CLEANING, CARE ..................................... 119
Cleaning the motorcycle ................. 119
19 STORAGE................................................. 121
Storage ......................................... 121
Preparing for use after storage......... 122
20 TROUBLESHOOTING ................................ 123
21 TECHNICAL DATA..................................... 125
Engine .......................................... 125
All 125 models.......................... 125
150 SX..................................... 125
Engine tightening torques ............... 126
Carburetor ..................................... 128
125 SX..................................... 128
Carburetor tuning (125 SX)......... 128
150 SX..................................... 130
Carburetor tuning (150 SX)......... 130
Basic carburetor setting for sandy surfaces (150 SX)............. 131
125 XC US ............................... 132
Carburetor tuning (125 XC US) ... 132
Capacities ..................................... 134
Gear oil..................................... 134
Coolant ..................................... 134
Fuel ......................................... 134
Chassis ......................................... 134
Electrical system............................ 135
Tires ............................................. 135
Fork.............................................. 135
All SX models............................ 135
125 XC US ............................... 136
Shock absorber .............................. 136
All SX models............................ 136
125 XC US ............................... 137
21.10 Chassis tightening torques .............. 138
22 SUBSTANCES .......................................... 140
23 AUXILIARY SUBSTANCES ......................... 142
24 STANDARDS ............................................ 144
25 LIST OF ABBREVIATIONS.......................... 145
INDEX ............................................................. 146
4
MEANS OF REPRESENTATION 1
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of 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 performed by an authorized KTM workshop!
Your motorcycle will be optimally cared for there by specially trained experts using the auxiliary tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates the end of an activity, including potential rework.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name ®
Brand™
Underlined terms
Indicates a protected name.
Indicates a brand available on the open market.
Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.
5
2 SAFETY ADVICE
2.1
Use definition – intended use
(All SX models)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
(125 XC US)
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.
6
SAFETY ADVICE 2
2.4
Degrees of risk and symbols
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.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
7
2 SAFETY ADVICE
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.7
Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.8
Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g.
Loctite ® ) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote ® ) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
8
SAFETY ADVICE 2
2.10
Owner's Manual
Read this owner's manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and service your motorcycle. This is the only way to find out how best to customize the vehicle for your own use and how you can protect yourself from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be downloaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.
International KTM Website: KTM.COM
9
3 IMPORTANT NOTES
3.1
Manufacturer warranty, implied warranty
The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and confirmed in the KTM Dealer.net
, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2
Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3
Spare parts, technical accessories
For your own safety, only use spare parts and accessory products that are 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 accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.
The latest news KTM PowerParts on your vehicle can be found on the KTM website.
International KTM Website: KTM.COM
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: KTM.COM
10
4.1
View of vehicle, front left (example)
VIEW OF VEHICLE 4
S04779-10
1
2
3 Air filter box cover
4
5 Fuel tap
11
4 VIEW OF VEHICLE
4.2
View of vehicle, rear right (example)
1 Seat
2 Fuel tank filler cap
3
4
5
6
7 Shock absorber compression adjuster
8 Shock absorber rebound adjuster
9 Level viewer for brake fluid, rear
S04780-10
12
SERIAL NUMBERS 5
5.1
Vehicle identification number
The vehicle identification number of the steering head.
1 is stamped on the right side
5.2
Type label
401945-10
The type label 1 is fixed to the front of the steering head.
5.3
Engine number
401946-10
The engine number 1 is stamped on the left side of the engine under the engine sprocket.
5.4
Fork part number
401949-10
The fork part number clamp.
1 is stamped on the inside of the axle
401947-10
13
5 SERIAL NUMBERS
5.5
Shock absorber article number
Shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the engine side.
401948-10
14
6.1
Clutch lever
CONTROLS 6
Clutch lever 1 is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
6.2
Hand brake lever
F00009-10
Hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
6.3
Throttle grip
F00001-10
Throttle grip 1 is fitted on the right side of the handlebar.
6.4
Stop button
F00001-11
F00002-10
The stop button 1 is fitted on the left side of the handlebar.
Possible states
• The stop button is in the basic position – In this position, the ignition circuit is closed and the engine can be started.
• Stop button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
15
6 CONTROLS
6.5
Start button (125 XC US)
Start button 1 is fitted on the right side of the handlebar.
Possible states
• The start button is in the basic position
• The start button is pressed – In this position, the starter motor is actuated.
6.6
K00487-10
Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
(All SX models)
– Turn fuel tank filler cap off.
1 counterclockwise and lift it
K01132-11
16
CONTROLS 6
(125 XC US)
–
Press release button 1 , turn the fuel tank filler cap counterclockwise, and lift it off.
6.7
K01334-10
Closing the fuel tank filler cap
(All SX models)
– Mount fuel tank filler cap 1 the fuel tank is tightly closed.
and turn it clockwise until
Info
Route fuel tank breather hose 2 without kinks.
K01132-10
(125 XC US)
– Mount filler cap button engages.
1 and turn it clockwise until the release
Info
Route fuel tank breather hose 2 without kinks.
K01334-11
17
6 CONTROLS
6.8
Fuel tap (All SX models)
The fuel tap is on the left side of the fuel tank.
Open or close the fuel supply to the carburetor using tap handle 1 on the fuel tap.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.
6.9
K01128-10
Fuel tap (125 XC US)
The fuel tap is on the left side of the fuel tank.
Open or close the fuel supply to the carburetor using tap handle 1 on the fuel tap.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties down to the reserve level.
• Fuel reserve supply open RES – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.
K00488-10
18
CONTROLS 6
6.10
Choke
(All SX models)
Choke 1 is fitted on the left side of the carburetor.
6.11
Shift lever
K01129-10
K01204-10
(125 XC US)
Choke 1 is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in 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.
Shift lever 1 is mounted on the left of the engine.
401950-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
401950-11
19
6 CONTROLS
6.12
Kick starter lever
Kick starter lever 1 is fitted on the right side of the engine.
The kick starter lever can be swiveled.
Info
Before riding, swing the kick starter lever inwards towards the engine.
6.13
Foot brake lever
401954-10
Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
6.14
6.15
401956-10
Plug-in stand (All SX models)
The holder for the plug-in stand 1 is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.
The plug-in stand is used as a fork locker when transporting the motorcycle.
Info
Remove the plug-in stand before riding.
H02629-10
Side stand (125 XC US)
The side stand 1 is located on the left of the vehicle.
401943-10
20
CONTROLS 6
The side stand is used for parking the motorcycle.
Info
When you are riding, side stand secured with rubber strap 2 .
1 must be folded up and
6.16
Service hour counter
401944-10
The service hour counter 1 is fitted in front of the handlebar.
It shows the total number of service hours of the engine.
The service hour counter begins counting when the engine is started and stops when the engine is switched off.
Info
The value indicated by the service hour counter cannot be cleared or adjusted.
K01135-10
21
7 PREPARING FOR USE
7.1
Advice on preparing for first use
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.
– Always wear protective clothing that is in good condition and meets the legal regulations.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style impairs the handling characteristic.
– Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Take your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Total weight and axle loads influence the handling characteristic.
– Do not exceed the maximum permissible overall weight or the axle loads.
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
You will receive a delivery certificate when the vehicle is handed over.
– Before riding for the first time, read the entire Owner's Manual carefully.
– Get to know the controls.
–
Adjust the basic position of the clutch lever. ( p. 76)
–
Adjust the basic position of the hand brake lever. ( p. 79)
22
PREPARING FOR USE 7
– Adjust the basic position of the foot brake lever.
– Adjust the basic position of the shift lever.
– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.
Info
Your motorcycle is not approved for use on public roads.
When offroad, it is recommended that you are accompanied by another person on another vehicle so that you can help each other.
– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.
– Do not make any off-road trips that exceed your ability and experience.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Do not take luggage along.
– Do not exceed the maximum permissible weight and the maximum permissible axle loads.
Guideline
Maximum permissible overall weight
Maximum permissible front axle load
Maximum permissible rear axle load
335 kg (739 lb.)
145 kg (320 lb.)
190 kg (419 lb.)
–
Check the spoke tension. ( p. 96)
Info
The spoke tension must be checked after half an hour of operation.
–
7.2
Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours
During the first 5 operating hours
< 70 %
< 100 %
– Avoid fully opening the throttle!
7.3
Preparing the vehicle for difficult operating conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
– Prepare air filter box cover for securing.
– Clean the air filter and air filter box.
Info
Check the air filter approx. every 30 minutes.
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.
» If humidity, corrosion, or damage is found:
23
7 PREPARING FOR USE
– Clean and dry the connector, or change it if necessary.
– Make sure that no radiator covers are installed.
Difficult operating conditions are:
–
–
–
Rides on wet and muddy circuits. ( p. 27)
–
Riding at high temperatures or slow riding. ( p. 27)
–
Riding at low temperatures and in snow. ( p. 28)
7.4
Preparing the vehicle for riding on dry sand
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
– Change the radiator cap.
– Mount the air filter dust cover.
Air filter dust cover (79006920000)
Info
Observe the fitting instructions for KTM PowerParts .
M01104-01
24
PREPARING FOR USE 7
– Mount the air filter sand cover.
Air filter sand cover (79006922000)
Info
Observe the fitting instructions for KTM PowerParts .
M01105-01
– Adjust the carburetor jetting and setting.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
M01107-01
600868-01
– Clean the chain.
– Mount the steel sprocket.
– Grease the chain.
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
7.5
Preparing the vehicle for riding on wet sand
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
25
7 PREPARING FOR USE
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
– Change the radiator cap.
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts .
M01106-01
– Adjust the carburetor jetting and setting.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
M01107-01
600868-01
– Clean the chain.
– Mount the steel sprocket.
– Grease the chain.
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
Condition
Regular use in sand
– Change the piston every 10 operating hours.
26
PREPARING FOR USE 7
7.6
Preparing the vehicle for riding on wet and muddy circuits
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts .
M01106-01
– Adjust the carburetor jetting and setting.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
M01107-01
– Mount the steel sprocket.
–
Clean the motorcycle. ( p. 119)
– Straighten the bent radiator fins carefully.
7.7
600868-01
Preparing vehicle for high temperatures or slow riding
– Check the radiator cap.
Value on the radiator cap 1.8 bar (26 psi)
» If the indicated value does not correspond to the setpoint value:
M01129-01
27
7 PREPARING FOR USE
7.8
600868-01
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
– Change the radiator cap.
– Adjust the secondary drive to the road conditions.
Info
The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary ratio.
– Clean the chain.
– Clean the radiator fins.
– Straighten the bent radiator fins carefully.
–
Check the coolant level. ( p. 103)
Preparing the vehicle for low temperatures or snow
– Mount the air filter rain cover.
Air filter rain cover (79006921000)
Info
Observe the fitting instructions for KTM PowerParts .
M01106-01
– Adjust the carburetor jetting and setting.
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
M01107-01
28
RIDING INSTRUCTIONS 8
8.1
Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
H02217-01
–
Check the gear oil level. ( p. 116)
–
Check the front brake fluid level. ( p. 80)
–
Check the rear brake fluid level. ( p. 86)
–
Check the front brake linings. ( p. 82)
–
Check the brake linings of the rear brake. ( p. 88)
– Check that the brake system is functioning properly.
–
Check the coolant level. ( p. 103)
–
Check the chain for dirt. ( p. 68)
– Check the chain, rear sprocket, engine sprocket, and chain
–
Check the chain tension. ( p. 69)
–
Check the tire condition. ( p. 95)
–
–
Check the spoke tension. ( p. 96)
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
–
Clean the dust boots of the fork legs. ( p. 49)
–
– 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 level.
8.2
Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
29
8 RIDING INSTRUCTIONS
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.
H02629-10
401944-10
The motorcycle has been out of use for more than 1 week
– Empty the carburetor float chamber.
(All SX models)
– Turn tap handle of the fuel tap to the ON position.
Fuel can flow from the fuel tank to the carburetor.
– Remove plug-in stand 1 .
– Shift the transmission into neutral.
Condition
The engine is cold
– Pull the choke lever out as far as possible.
– Press the kick starter lever robustly through its full range.
Info
Do not open the throttle.
(125 XC US)
– Turn tap handle of the fuel tap to the ON position.
Fuel can flow from the fuel tank to the carburetor.
–
Take the motorcycle off side stand stand with rubber strap 2 .
– Shift the transmission into neutral.
1 and secure the side
Condition
The engine is cold
– Pull the choke lever out as far as possible.
– Press the start button or press the kick starter lever forcefully all the way.
Info
Do not open the throttle.
8.3
Starting off
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 strap.
– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.
30
RIDING INSTRUCTIONS 8
8.4
Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Do not change into a low gear at high engine speed.
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 and for steep inclines.
– Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the choke function has been activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower.
– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
– To shift down, apply the brakes and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.
– Switch off the engine if running at idle speed or stationary for a long time.
Guideline
≥ 2 min
– Avoid frequent or lengthy slipping of the clutch. This causes the gear oil, engine and cooling system to heat up.
– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.
8.5
Applying the brakes
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Adjust application of the brakes to the respective riding situation and riding surface conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– On sandy, wet, or slippery surfaces, use the rear brake mostly if possible.
– Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed.
31
8 RIDING INSTRUCTIONS
– Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.
8.6
Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
– Apply the brakes on the motorcycle.
– Shift the transmission to neutral position.
– Press and hold the stop button while the engine is idling until the engine stops.
(All SX models)
– Turn tap handle of the fuel tap to the OFF position.
– Rest the vehicle on the plug-in stand.
(125 XC US)
– Turn tap handle of the fuel tap to the OFF position.
– Rest the vehicle on the side stand.
8.7
Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
32
RIDING INSTRUCTIONS 8
H02628-01
401475-01
(All SX models)
– Switch off the engine.
– Mount plug-in stand on the fork legs.
Plug-in stand (79029094000)
Info
The plug-in stand is included.
Make sure the brake line runs in front of the plug-in stand and does not become wedged.
– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.
Info
Only tighten the tension belts to the point that the plug-in stand is firmly in contact with the fender and the tires.
Pay attention to the alignment of the plug-in stand to the fender.
(125 XC US)
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.
8.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
– Switch off the engine.
–
Open the fuel tank filler cap. ( p. 16)
33
8 RIDING INSTRUCTIONS
400382-10
– Fill the fuel tank with fuel up to measurement A .
Guideline
Measurement of A 35 mm (1.38 in)
Total fuel tank capacity, approx. (All
SX models)
Total fuel tank capacity, approx.
(125 XC US)
7.5 l
(1.98 US gal)
10 l
(2.6 US gal)
Super unleaded
(98 octane) mixed with 2-stroke engine oil (1:40)
Super unleaded
(98 octane) mixed with 2-stroke engine oil (1:40)
Engine oil, 2-stroke ( p. 140)
–
Close the fuel tank filler cap. ( p. 17)
34
SERVICE SCHEDULE 9
9.1
Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
9.2
Required work
Check and charge the 12 V battery.
Change the gear oil.
Check the frame.
Check the link fork.
Check the fork bearing for play.
Check the shock absorber heim joint for play.
Check the shock absorber linkage.
Check the wheel hubs.
Check the rim run-out.
Check the front brake linings. (
Check the brake linings of the rear brake. (
Check the brake lines for damage and leakage.
Check the rear brake fluid level. (
Check the free travel of the foot brake lever. (
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation.
Check/correct the fluid level of the hydraulic clutch. ( p. 76)
leaks, and incorrect routing.
Check the wheel bearing for play.
Check the chain, rear sprocket, engine sprocket, and chain guide. (
Check the chain tension. ( p. 69)
Check the front brake fluid level. (
Check steering head bearing play. (
(125 XC US)
Check the free travel of the hand brake lever. (
Change the spark plug and spark plug connector.
after every race
Every 40 operating hours
Every 20 operating hours
Every 10 operating hours
After 1 operating hour
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking,
Check the antifreeze and coolant level. ( p. 102)
Check the cables for damage and for routing without kinks.
● ●
● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ●
● ● ● ●
● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
● ● ● ●
● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
● ● ● ●
○ ● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
● ● ● ●
○ ● ● ● ●
● ● ●
○ ● ● ● ●
○ ●
●
●
●
●
●
●
●
35
9 SERVICE SCHEDULE
Clean the air filter and air filter box.
Change the glass fiber yarn filling in the main silencer.
Service the fork.
Perform the shock absorber service.
Check the tightness of the easily accessible, safety-relevant screws and nuts.
after every race
Every 40 operating hours
Every 20 operating hours
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
Every 10 operating hours
After 1 operating hour
○ ● ● ● ●
● ● ● ●
● ●
●
●
Check the idle speed.
Final check: Check the vehicle for operating safety and take a test ride.
Make a service entry in the KTM Dealer.net
.
○ ● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
○ ● ● ● ●
○ One-time interval
● Periodic interval
9.3
Recommended work
Change the front brake fluid.
Change the rear brake fluid.
Change the hydraulic clutch fluid.
Lubricate the steering head bearing.
Service the fork.
every 48 months every 12 months after every race
Every 40 operating hours
After 20 operating hours / Every 20 operating hours
After 10 operating hours / Every 10 operating hours
○
● ●
● ●
● ●
● ●
Perform the shock absorber service.
Check the electric starter drive.
(125 XC US)
○
Check/adjust the carburetor components.
Change the needle jet.
Change the coolant.
● ●
●
●
● ●
●
● ● ● ● Perform minor engine service. (Check the inlet membrane. Check the clutch. Under difficult operating conditions: Change the piston and check the cylinder and Z dimension.)
Perform the intermediate engine service. (Change the piston and check the cylinder and Z dimension. Check the exhaust control for functioning and smooth operation.)
● ●
● Perform major engine service including removing and installing the engine. (Change the connecting rod, conrod bearing, and crank pin. Check the transmission and shift mechanism. Change all engine bearings.)
○ One-time interval
● Periodic interval
36
TUNING THE CHASSIS 10
10.1
Checking the basic chassis setting with rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.
– As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing).
Guideline
Standard rider weight 75 … 85 kg (165 …
187 lb.)
– If the rider's weight is above or below this 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.
401030-01
10.2
Air suspension XACT 5448
M01110-01
Air suspension WP Suspension XACT 5448 is used in the fork.
In this system, suspension is located in the left fork leg and damping in the right fork leg.
As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks. The response on slightly uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion. A steel spring is located in the left fork leg as an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the fork must be increased to avoid damage to the fork and frame.
The air pressure in the fork can be quickly adjusted to the rider's weight, surface conditions and the rider's preference using a fork airpump. The fork does not have to be dismantled. The time consuming mounting of harder or softer fork springs is not required.
If the air chamber loses air due to a damaged seal, the fork will still not sag. In this case the air is retained in the fork. The suspension travel is maintained as far as possible. The damping becomes harder and the riding comfort reduces.
As with a conventional fork, the damping can be adjusted in rebound and compression stages.
The rebound adjuster is located at the lower end of the right fork leg.
37
10 TUNING THE CHASSIS
The compression adjuster is located at the upper end of the right fork leg.
10.3
Compression damping of the 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 compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.
10.4
Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.
K01130-10
– Turn adjusting screw 1 the last perceptible click.
clockwise with a screwdriver as far as
Info
Do not loosen fitting 2 !
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Lowspeed compression damping (All SX models)
Comfort 17 clicks
Standard
Sport
15 clicks
13 clicks
Lowspeed compression damping (125 XC US)
Comfort
Standard
Sport
17 clicks
15 clicks
13 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
38
TUNING THE CHASSIS 10
10.5
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
K01195-10
– Turn adjusting screw wrench.
1 all the way clockwise with a socket
Info
Do not loosen fitting 2 !
– Turn counterclockwise by the number of turns corresponding to the shock absorber type.
Guideline
Highspeed compression damping (All SX models)
Comfort
Standard
2 turns
1.5 turns
Sport 1 turn
Highspeed compression damping (125 XC US)
Comfort 2.5 turns
Standard
Sport
2 turns
1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.6
Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
39
10 TUNING THE CHASSIS
K01131-10
– Turn adjusting screw click.
1 clockwise up to the last perceptible
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Rebound damping (All SX models)
Comfort
Standard
Sport
17 clicks
15 clicks
13 clicks
Rebound damping (125 XC US)
Comfort 17 clicks
Standard
Sport
15 clicks
13 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.7
Measuring the rear wheel dimension unloaded
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender.
Sag gauge (00029090000)
Pin, sag scale (00029990010)
– Note down the value as dimension A .
402415-10
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
40
TUNING THE CHASSIS 10
10.8
Checking the static sag of the shock absorber
– Measure dimension A
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage.
– Note the value as dimension B .
Info
The static sag is the difference between measurements A and B .
– Check the static sag.
Static sag (All SX models) 35 mm (1.38 in)
Static sag (125 XC US) 35 mm (1.38 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
402416-10
10.9
Checking the riding sag of the shock absorber
–
Measure dimension A
of rear wheel unloaded. ( p. 40)
– With another person holding the motorcycle, the rider, wearing full protective clothing, 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 again measures the distance between the rear axle and marking SAG on the rear fender using the sag gage.
– Note the value as dimension C .
402417-10
Info
The riding sag is the difference between measurements A and C .
– Check riding sag.
Guideline
Riding sag (All SX models)
Riding sag (125 XC US)
105 mm (4.13 in)
105 mm (4.13 in)
» If the riding sag differs from the specified measurement:
– Adjust the riding sag.
41
10 TUNING THE CHASSIS
10.10
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow 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 spring length.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
– Remove the shock absorber.
– After removing the shock absorber, clean it thoroughly.
Main work
– Loosen screw 1 .
– Turn adjusting ring sion.
2 until the spring is no longer under ten-
Hook wrench (90129051000)
402659-10
Info
If the spring cannot be fully released, the spring must be removed to accurately measure the spring length.
– Measure the total spring length while the spring is not under tension.
– Tension the spring by turning adjusting ring dimension A .
2 to specified
Guideline
Spring preload (All SX models)
7 mm (0.28 in)
Spring preload (125 XC US) 7 mm (0.28 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 1 .
Guideline
Screw, shock absorber adjusting ring
M5 5 Nm (3.7 lbf ft)
Finishing work
– Install the shock absorber.
–
Remove the motorcycle from the lift stand. ( p. 48)
42
TUNING THE CHASSIS 10
10.11
Adjusting the riding sag
B00292-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
– Remove the shock absorber.
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate (All SX models)
Weight of rider: 65 …
75 kg (143 … 165 lb.)
36 N/mm (206 lb/in)
39 N/mm (223 lb/in) Weight of rider: 75 …
85 kg (165 … 187 lb.)
Weight of rider: 85 …
95 kg (187 … 209 lb.)
Spring rate (125 XC US)
Weight of rider: 65 …
75 kg (143 … 165 lb.)
42 N/mm (240 lb/in)
36 N/mm (206 lb/in)
Weight of rider: 75 …
85 kg (165 … 187 lb.)
Weight of rider: 85 …
95 kg (187 … 209 lb.)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
Info
The spring rate is shown on the outside of the spring.
Finishing work
– Install the shock absorber.
–
Remove the motorcycle from the lift stand. ( p. 48)
–
Check the static sag of the shock absorber. ( p. 41)
–
Check the riding sag of the shock absorber. ( p. 41)
–
Adjust the rebound damping of the shock absorber. ( p. 39)
10.12
Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
– Smaller differences in the rider's weight can be compensated for by the fork air pressure.
– However, if the fork frequently bottoms out (hard end stop on compression), the fork air pressure must be increased, within the specified values, to avoid damage to the fork and frame.
– If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.
401000-01
43
10 TUNING THE CHASSIS
10.13
Adjusting the fork air pressure
Warning
Danger of accident Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components.
– Only make adjustments within the recommended range.
– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.
Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Remove protection cap 1 .
– Push together fork airpump 2 fully.
Fork airpump (79412966100)
V01522-10
Info
The fork airpump is included as part of the motorcycle's accessory pack.
– Connect the fork airpump to the left fork leg.
The fork airpump indicator switches on automatically.
A little air escapes from the fork leg when connecting.
Info
This is due to the volume of the hose and not due to a defect in the fork airpump or the fork.
Read the accompanying KTM PowerParts instructions.
– Adjust the air pressure as specified.
Guideline
Air pressure (All SX models) 8.3 bar (120 psi)
Air pressure (125 XC US) 8 bar (116 psi)
0.2 bar (3 psi) Gradual changing of the air pressure in steps of
Minimum air pressure
Maximum air pressure
7 bar (102 psi)
12 bar (174 psi)
Info
Never adjust the air pressure to a value outside the stated range.
– Disconnect the fork airpump from the left fork leg.
44
TUNING THE CHASSIS 10
When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air.
The fork airpump indicator switches off automatically after
80 seconds.
– Mount the protection cap.
Info
Only mount the protection cap by hand.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
10.14
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
V01523-10
– Turn adjusting screw 1 clockwise all the way.
Info
Adjusting screw right fork leg.
1 is located at the upper end of the
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping (All SX models)
Comfort 17 clicks
Standard
Sport
12 clicks
7 clicks
Compression damping (125 XC US)
Comfort 17 clicks
Standard
Sport
12 clicks
7 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.
10.15
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
45
10 TUNING THE CHASSIS
Z01370-10
– Turn adjusting screw 1 clockwise all the way.
Info
Adjusting screw right fork leg.
1 is located at the lower end of the
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping (All SX models)
Comfort 17 clicks
Standard
Sport
12 clicks
7 clicks
Rebound damping (125 XC US)
Comfort 30 clicks
Standard
Sport
25 clicks
20 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.16
Handlebar position
The holes on the handlebar supports are placed at a distance of A from the center.
Hole distance A 3.5 mm (0.138 in)
The handlebar can be mounted in 2 different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider.
H01188-10
10.17
Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.
Preparatory work
– Remove the handlebar cushion.
46
TUNING THE CHASSIS 10
H01189-10
Main work
–
Remove screws 1 . Remove the handlebar clamp. Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
– Remove screws 2 . Take off handlebar supports
– Position rubber bushings below.
4
3 and push through nuts
.
– Place the handlebar supports in the required position.
5 from
Info
The handlebar supports are longer and higher on one side.
Position the left and right handlebar supports evenly.
–
Mount and tighten screws
Guideline
Screw, handlebar support
M10
2 .
– Position the handlebar.
40 Nm (29.5 lbf ft)
Loctite ® 243™
Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamp.
– Mount screws 1 but do not tighten yet.
– First bolt the handlebar clamp with screws 1 onto the longer, higher side of the handlebar supports so that both parts touch.
Guideline
Screw, handlebar clamp
M8 20 Nm (14.8 lbf ft)
– Tighten screws 1 evenly.
Guideline
Screw, handlebar clamp
M8 20 Nm (14.8 lbf ft)
Finishing work
– Mount the handlebar cushion.
47
11 SERVICE WORK ON THE CHASSIS
11.1
Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
– Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
– Secure the motorcycle against falling over.
401942-01
11.2
Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
(All SX models)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, insert plug-in stand left side of the wheel spindle.
1 into the
Info
Remove the plug-in stand before riding.
H02629-10
(125 XC US)
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, press side stand 1 with your foot and lean the motorcycle on it.
to the ground
Info
When you are riding, the side stand must be folded up and secured with the rubber strap.
401943-10
48
SERVICE WORK ON THE CHASSIS 11
11.3
Bleeding the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Release bleeder screws 1 .
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
H01182-12
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
11.4
Cleaning the dust boots of the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
–
Remove the fork protector. ( p. 51)
Main work
– Push dust boots 1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.
M01134-10
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
– Clean and oil the dust boots and inner fork tubes of both fork legs.
– Press the dust boots back into their normal position.
– Remove excess oil.
Finishing work
–
Install the fork protector. ( p. 51)
–
Remove the motorcycle from the lift stand. ( p. 48)
49
11 SERVICE WORK ON THE CHASSIS
11.5
Removing the fork legs
K01143-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
– Remove the front wheel.
Main work
– Remove screws 1 and take off the clamp.
– Remove screws 2 and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the side.
Info
Do not actuate the hand brake lever when the front wheel is removed.
–
Loosen screws
– Loosen screws
3 . Remove the left fork leg.
4 . Remove the right fork leg.
11.6
K01174-10
Installing the fork legs
H01182-10
Main work
– Position the fork legs.
Air bleeder screw the front.
1 of the right fork leg is positioned to
Valve A of the left fork leg faces the front.
Info
Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.
The air suspension is located in the left fork leg. The pressure and rebound damping is located in the right fork leg.
– Tighten screws 2 .
Guideline
Screw, top triple clamp
– Tighten screws 3 .
Guideline
Screw, bottom triple clamp
M8
M8
17 Nm (12.5 lbf ft)
12 Nm (8.9 lbf ft)
K01174-11
50
SERVICE WORK ON THE CHASSIS 11
– Position the brake caliper. Mount and tighten screws
Guideline
4 .
Screw, front brake caliper
M8 25 Nm (18.4 lbf ft)
Loctite ® 243™
– Position the brake line and the clamp. Mount and tighten screws 5 .
K01143-11
Finishing work
– Install the front wheel.
11.7
Removing the fork protector
– Remove screws
– Remove screws
1 . Remove the clamp.
2 . Take off the left fork protector.
– Remove screws 3 . Take off the right fork protector.
F00024-10
11.8
Installing the fork protector
F00024-11
– Position the fork protection on the left fork leg. Mount and tighten screws 1 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
– Position the brake line and clamp. Mount and tighten screws 2 .
– Position the fork protector on the right fork leg. Mount and tighten screws 3 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
11.9
Removing the lower triple clamp
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
– Remove the front wheel.
– Remove the fork legs.
–
Remove the start number plate. ( p. 56)
–
– Remove the handlebar cushion.
51
11 SERVICE WORK ON THE CHASSIS
K01149-10
Main work
–
Remove screw
– Remove screw
1
2 .
.
– Take off the upper triple clamp with the handlebar and hang them to the side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
– Remove O-ring 3 . Remove protective ring 4 .
– Take off the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
M01117-10
11.10
Installing the lower triple clamp
Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 142)
– Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.
– Check whether upper steering head seal tioned.
– Slide on protective ring 2 and O-ring
1
3 .
is correctly posi-
102146-10
– Position the upper triple clamp with the handlebar.
–
Mount screw 4 , but do not tighten yet.
K01150-10
52
SERVICE WORK ON THE CHASSIS 11
H01182-11
– Position the fork legs.
Air bleeder screw the front.
5 of the right fork leg is positioned to
Valve A of the left fork leg faces the front.
Info
The air suspension AER valve is located in the left fork leg.
Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.
– Tighten screws 6 .
Guideline
Screw, bottom triple clamp
M8 12 Nm (8.9 lbf ft)
K01175-10
– Tighten screw 4 .
Guideline
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
V01530-10
– Mount and tighten screw 7 .
Guideline
Screw, top steering stem
M8 20 Nm (14.8 lbf ft)
Loctite ® 243™
V01531-10
– Tighten screws 8 .
Guideline
Screw, top triple clamp
M8 17 Nm (12.5 lbf ft)
K01175-11
53
11 SERVICE WORK ON THE CHASSIS
– Position the brake caliper. Mount and tighten screws 9 .
Guideline
Screw, front brake caliper
M8 25 Nm (18.4 lbf ft)
Loctite ® 243™
– Position the brake line and the clamp. Mount and tighten screws bk .
K01143-12
Finishing work
– Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly.
–
Install front fender. ( p. 56)
– Install the front wheel.
–
Check steering head bearing play. ( p. 54)
–
Remove the motorcycle from the lift stand. ( p. 48)
–
Install the start number plate. ( p. 56)
– Mount the handlebar cushion.
11.11
Checking steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
H01167-01
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust steering head bearing play.
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions.
» If detent positions are detected:
– Adjust steering head bearing play.
– Check the steering head bearing and change if necessary.
54
SERVICE WORK ON THE CHASSIS 11
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
11.12
Adjusting steering head bearing play
V01524-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
– Remove the handlebar cushion.
Main work
– Loosen screws 1 .
– Remove screw
–
2 .
Loosen and retighten screw 3 .
Guideline
Screw, top steering head
M20x1.5
12 Nm (8.9 lbf ft)
–
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
– Tighten screws 1 .
Guideline
Screw, top triple clamp
M8 17 Nm (12.5 lbf ft)
Mount and tighten screw
Guideline
Screw, top steering stem
M8
2 .
20 Nm (14.8 lbf ft)
Loctite ® 243™
Finishing work
–
Check steering head bearing play. ( p. 54)
–
Remove the motorcycle from the lift stand. ( p. 48)
– Mount the handlebar cushion.
11.13
Lubricating the steering head bearing
– Remove the lower triple clamp.
– Install the lower triple clamp.
Info
The steering head bearing is cleaned and lubricated in the course of removal and installation.
H02387-01
55
11 SERVICE WORK ON THE CHASSIS
11.14
Removing the start number plate
– Remove screw 1 .
– Disconnect the brake line at the start number plate. Take off the start number plate.
F00012-10
11.15
Installing the start number plate
– Connect the brake line at the start number plate.
– Position the start number plate.
The holding lugs engage in the fender.
– Mount and tighten screw 1 .
F00013-10
11.16
Removing front fender
Preparatory work
–
Remove the start number plate. ( p. 56)
Main work
– Remove screws 1 and 2 . Remove front fender.
M01144-10
11.17
Installing front fender
Main work
– Position front fender. Mount and tighten screws 1 and 2 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
M01144-10
Finishing work
–
Install the start number plate. ( p. 56)
56
SERVICE WORK ON THE CHASSIS 11
11.18
Removing the shock absorber
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Remove the cable ties.
– Remove screws 1 with the washers.
– Remove screw 2 .
– Take off the left frame protector.
– Push the right frame protector to the front and take off at the bottom.
V01525-10
– Remove screw
– Remove fitting
3 .
4 .
Info
Raise the wheel slightly to be able to remove the screws more easily.
K01134-10
– Press angle lever
–
Press linkage lever
5 toward the rear.
6 downward.
K01136-10
– Remove screws rod.
7 and pull foot brake cylinder off the push
K01137-10
– Remove the connecting link of the chain.
– Take off the chain.
Info
Cover the components to protect them against damage.
M01149-01
57
11 SERVICE WORK ON THE CHASSIS
– Remove nut 8 and pull out the fork pivot.
– Push the link fork back and secure it against falling over.
V01526-10
– Hold the shock absorber and remove screw 9 .
K01139-10
– Remove the shock absorber carefully at the bottom.
K01140-10
11.19
Installing the shock absorber
Main work
– Carefully position the shock absorber into the vehicle from the bottom.
K01140-11
–
Mount and tighten screw 1 .
Guideline
Screw, top shock absorber
M10 60 Nm (44.3 lbf ft)
Loctite ® 2701™
K01139-11
58
SERVICE WORK ON THE CHASSIS 11
V01527-10
– Position link fork and mount fork pivot.
Info
Pay attention to flat area A .
– Mount and tighten nut 2 .
Guideline
Nut, fork pivot M16x1.5
100 Nm
(73.8 lbf ft)
– Mount the chain.
– Connect the chain with the connecting link.
Guideline
The closed side of the chain joint lock must face in the direction of travel.
M01149-01
– Position the foot brake cylinder.
Push rod 3 engages in the foot brake cylinder.
The dust boot is correctly positioned.
– Mount and tighten screws 4 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
K01148-10
K00864-10
– Position the angle lever and linkage lever.
– Mount and tighten fitting 5 .
Guideline
Nut, linkage lever on angle lever
M14x1.5
60 Nm (44.3 lbf ft)
Info
Pay attention to flat area B .
– Mount and tighten screw
Guideline
6 .
Screw, bottom shock absorber
M10 60 Nm (44.3 lbf ft)
Loctite ® 2701™
Info
Raise the wheel slightly to be able to mount the screw more easily.
59
11 SERVICE WORK ON THE CHASSIS
11.20
Removing the seat
V01525-11
– Position left frame protector.
– Insert right frame protector from below and push to the rear.
– Mount and tighten screws 7 with the washers.
Guideline
Screw, frame protector
M5 3 Nm (2.2 lbf ft)
– Mount and tighten screw 8 .
Guideline
Screw, frame protector
M5 3 Nm (2.2 lbf ft)
– Mount the new cable ties.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
– Remove screw 1 .
K01133-10
– Raise the rear of the seat, pull the seat back, and lift it off.
11.21
Mounting the seat
H02218-10
– Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward.
– Make sure that the seat is locked in correctly.
H02218-11
60
SERVICE WORK ON THE CHASSIS 11
– Mount and tighten screw
Guideline
1 .
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
K01133-10
11.22
Removing the air filter box cover
Condition
The air filter box cover is secured.
–
– Remove screw 1 .
K01153-10
–
Pull off the air filter box cover in area take off toward the front.
A sideways and
K01154-10
Condition
The air filter box cover is not secured.
– Pull off the air filter box cover in area take off toward the front.
A sideways and
K01155-10
61
11 SERVICE WORK ON THE CHASSIS
11.23
Installing the air filter box cover
Condition
The air filter box cover is secured.
–
Insert the air filter box cover in area area B .
A and clip it into
K01154-11
– Mount and tighten screw 1 .
Guideline
Screw, air filter box cover
EJOT PT ®
K60x20-Z
–
3 Nm (2.2 lbf ft)
K01153-10
Condition
The air filter box cover is not secured.
– Insert the air filter box cover in area area B .
A and clip it into
K01155-11
11.24
Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Only operate the vehicle if it is equipped with an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Preparatory work
–
Remove the air filter box cover. ( p. 61)
62
SERVICE WORK ON THE CHASSIS 11
Main work
–
Detach retaining tab port.
1 . Remove air filter with air filter sup-
– Take off air filter from air filter support.
K01156-10
11.25
Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
K00518-01
Preparatory work
–
Remove the air filter box cover. ( p. 61)
– Remove the air filter.
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Info
Only press the air filter to dry it, never wring it out.
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 142)
– Clean the air filter box.
– Clean the intake flange and check it for damage and tightness.
Finishing work
– Install the air filter.
–
Install the air filter box cover. ( p. 62)
63
11 SERVICE WORK ON THE CHASSIS
11.26
Installing the air filter
Main work
– Mount the clean air filter on the air filter support.
–
Grease the air filter in area A .
102178-10
K01186-10
– Insert the air filter and position the top retaining pin bushing B .
1 in
The air filter is correctly positioned.
– Secure the bottom retaining pin with holding tab 2 .
Info
If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.
Finishing work
–
Install the air filter box cover. ( p. 62)
11.27
Preparing air filter box cover for securing
Preparatory work
–
Remove the air filter box cover. ( p. 61)
Main work
– Drill a hole at marking A .
Guideline
Diameter 6 mm (0.24 in)
S02308-10
Finishing work
–
Install the air filter box cover. ( p. 62)
11.28
Removing 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 before performing any work on the vehicle.
64
SERVICE WORK ON THE CHASSIS 11
– Remove screws 1 with the washers.
– Pull off the main silencer from the manifold at exhaust sleeve 2 .
K01187-10
11.29
Installing the main silencer
–
Position the main silencer in exhaust sleeve
– Mount and tighten screws 2
1 with the washers.
.
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
K01188-10
11.30
Changing the glass fiber yarn filling in 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 before performing any work on the vehicle.
Info
Over time, the fibers of the rock wool escape into the air, and the main silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.
Preparatory work
–
Remove the main silencer. ( p. 64)
65
11 SERVICE WORK ON THE CHASSIS
Main work
–
Remove screws 1 . Pull out inner tube 2 .
– Remove the glass fiber yarn filling 3 from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
– Fit the new glass fiber yarn filling 3 into the inner tube.
– Slide outer tube fiber yarn filling.
4 over the inner tube with the new glass
– Mount and tighten all screws 1 .
Guideline
Screws on main silencer
M5 7 Nm (5.2 lbf ft)
H01759-10
Finishing work
–
Install the main silencer. ( p. 65)
11.31
Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–
(All SX models)
– Turn tap handle of the fuel tap to the OFF position.
(125 XC US)
– Turn tap handle of the fuel tap to the OFF position.
66
SERVICE WORK ON THE CHASSIS 11
Main work
– Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
– Remove screws 1 .
K01189-10
– Remove screw 2 with the rubber bushing.
– Pull the fuel tank breather hose off the fuel tank lid.
K01190-10
– Pull both spoilers laterally off the radiator and take off the fuel tank upwards.
K01191-01
11.32
Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
67
11 SERVICE WORK ON THE CHASSIS
Main work
–
Check the throttle cable routing. ( p. 74)
– Position the fuel tank and fit the two spoilers laterally to the radiator.
– Make sure that no cables or throttle cables are trapped or damaged.
K01191-02
– Attach the fuel tank breather hose.
– Mount and tighten screw 1 with the rubber bushing.
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
K01190-11
– Mount and tighten screws 2 .
Guideline
Remaining screws, chassis
M6
– Connect the fuel hose.
K01189-11
Finishing work
–
11.33
Checking the chain for dirt
– Check the chain for heavy soiling.
» If the chain is very dirty:
–
10 Nm (7.4 lbf ft)
400678-01
68
SERVICE WORK ON THE CHASSIS 11
11.34
Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
– After drying, apply chain spray.
Off-road chain spray ( p. 142)
400725-01
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
11.35
Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
69
11 SERVICE WORK ON THE CHASSIS
K01197-10
Main work
– Pull the chain at the end of the chain sliding piece upward to measure chain tension A .
Guideline
Lower chain section 1 must be taut.
Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Chain tension 55 … 58 mm (2.17 …
2.28 in)
» If the chain tension does not meet the specification:
–
Adjust the chain tension. ( p. 70)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
11.36
Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
–
Check the chain tension. ( p. 69)
70
SERVICE WORK ON THE CHASSIS 11
H00016-10
Main work
–
Loosen nut
– Loosen nuts
1 .
2 .
– Adjust the chain tension by turning adjusting screws and right.
3 left
Guideline
Chain tension 55 … 58 mm (2.17 …
2.28 in)
Turn adjusting screws 3 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 A . The rear wheel is then correctly aligned.
–
Tighten nuts 2 .
– Make sure that chain adjusters adjusting screws 3 .
4 are fitted correctly on
– Tighten nut 1 .
Guideline
Nut, rear wheel spindle
M25x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios with the same chain length.
Chain adjusters 4 can be turned by 180°.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
11.37
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Shift the transmission into neutral.
– Check the chain, rear sprocket, and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.
400227-01
Info
The engine sprocket, rear sprocket, and chain should always be replaced together.
71
11 SERVICE WORK ON THE CHASSIS
400987-10
–
– Pull on the top section of the chain with the specified weight A .
Guideline
Weight, chain wear measurement
10 … 15 kg (22 … 33 lb.)
Measure distance section.
B of 18 chain rollers in the lower chain
Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Maximum distance B
18 chain rollers at the from longest chain section
272 mm (10.71 in)
» If distance B is greater than the specified measurement:
– Change the drivetrain kit.
Info
When a new chain is mounted, the rear sprocket and engine sprocket should also be changed.
New chains wear out faster on an old, worn rear sprocket or engine sprocket.
– Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with, or below, the chain sliding guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten screws on the chain sliding guard.
Guideline
Screw, chain sliding guard
M6 10 Nm (7.4 lbf ft)
Loctite ® 243™
V01528-10
72
SERVICE WORK ON THE CHASSIS 11
– Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below the chain sliding piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten screw on the chain sliding piece.
Guideline
Screw, chain sliding piece
M8 15 Nm
(11.1 lbf ft)
K01199-10
–
Check the chain guide with a slide gage for dimension C .
Minimum thickness the chain guide
C of 6 mm (0.24 in)
» If the measured value is less than the specification:
– Change the chain guide.
402421-10
102192-01
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the screws on the chain guide.
Guideline
Remaining screws, chassis
M6 10 Nm
(7.4 lbf ft)
Remaining nuts, chassis
M6 10 Nm
(7.4 lbf ft)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
73
11 SERVICE WORK ON THE CHASSIS
11.38
Checking the frame
– Check the frame for damage, cracks, and deformation.
» If the frame shows signs of damage, cracks, or deformation:
– Change the frame.
Guideline
Repairs on the frame are not permitted.
S02306-01
11.39
Checking the link fork
– Check the link fork for damage, cracks, and deformation.
» If the link fork shows signs of damage, cracks, or deformation:
– Change the link fork.
Guideline
Repairs on the link fork are not permitted.
S02305-01
11.40
Checking the throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specification.
Preparatory work
–
(All SX models)
– Turn tap handle of the fuel tap to the OFF position.
(125 XC US)
– Turn tap handle of the fuel tap to the OFF position.
– Remove the fuel tank.
74
SERVICE WORK ON THE CHASSIS 11
Main work
– Check the throttle cable routing.
The throttle cable must be routed along the back of the handlebar, to the right of the frame, above the fuel tank bracket, and to the carburetor. The throttle cable must be secured on the fuel tank bracket with a rubber strap.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
K01192-10
Finishing work
– Install the fuel tank.
–
11.41
Checking the rubber grip
401197-01
– Check the rubber grips on the handlebar for damage, wear, and looseness.
Info
The rubber grips are vulcanized onto a sleeve on the left and onto the handle tube of the throttle grip on the right. The left sleeve is clamped onto the handlebar.
The rubber grip can only be replaced with the sleeve or the throttle tube.
» If a rubber grip is damaged or worn:
– Change the rubber grip.
– Check that screw 1 is firmly seated.
Guideline
Screw, fixed grip
M4 5 Nm (3.7 lbf ft)
Loctite ® 243™
Diamond A must be located at the top.
102245-10
75
11 SERVICE WORK ON THE CHASSIS
11.42
Adjusting the basic position of the clutch lever
– Adjust the basic position of the clutch lever to your hand size by turning adjusting screw 1 .
F00009-11
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.
11.43
Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
H01330-10
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws 1 .
– Remove cover 2 with membrane 3 .
– Check the fluid level.
Fluid level below container rim
4 mm (0.16 in)
» If the fluid level does not meet specifications:
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 140)
– Position the cover with the membrane. Mount and tighten the screws.
76
SERVICE WORK ON THE CHASSIS 11
Info
Clean up overflowed or spilled brake fluid immediately with water.
11.44
Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
– Remove cover
1 .
2 with membrane 3 .
H01330-10
–
Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 140)
– On the clutch slave cylinder, remove bleeder screw mount bleeding syringe 4 .
5 and
S04304-10
77
11 SERVICE WORK ON THE CHASSIS
L01223-10
– Now inject the liquid into the system until it emerges from the drill hole 6 of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir to prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim
4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
78
BRAKE SYSTEM 12
12.1
Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
– Push the hand brake lever forward and check free travel A .
Free travel of hand brake lever
≥ 3 mm ( ≥ 0.12 in)
» If the free travel does not match the specification:
– Adjust the basic position of the hand brake lever.
K00453-11
12.2
Adjusting the basic position of the hand brake lever
–
Check the free travel of the hand brake lever. ( p. 79)
– Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw 1 .
K00453-10
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.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
12.3
Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
79
12 BRAKE SYSTEM
H00938-10
– Check the front and rear brake disc thickness at multiple points for the dimension A .
Info
Wear reduces the thickness of the brake disc around the contact surface of the brake linings.
Brake discs - wear limit front rear
2.5 mm (0.098 in)
3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc.
– Change the rear 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 front brake disc.
– Change the rear brake disc.
12.4
Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Preparatory work
–
Check the front brake linings. ( p. 82)
Main work
– Move the brake reservoir mounted on the handlebar to a horizontal position.
–
Check the brake fluid level in level viewer 1 .
» If the brake fluid level has dropped below the marking
– Add front brake fluid.
A :
H01332-10
80
BRAKE SYSTEM 12
12.5
Adding front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the 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.
Only use clean brake fluid from a sealed container.
Preparatory work
–
Check the front brake linings. ( p. 82)
81
12 BRAKE SYSTEM
12.6
K00470-10
Checking the front brake linings
Main work
– Move the brake reservoir mounted on the handlebar to a horizontal position.
–
Remove screws 1 .
– Take off cover 2 with membrane 3 .
– Add brake fluid to level A .
Guideline
Level A (brake fluid level below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 140)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
H01333-10
– Check the brake linings for minimum thickness A .
Minimum thickness A ≥ 1 mm ( ≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the brake linings of the front brake.
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the brake linings of the front brake.
12.7
Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
82
BRAKE SYSTEM 12
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the 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 corrodes paint.
Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
–
Take off cover
1 .
2 with membrane 3 .
– Manually press the brake caliper toward the brake disc to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir, extract some if necessary.
K00469-10
83
12 BRAKE SYSTEM
Info
Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.
– Remove cotter pins brake linings.
4 , pull out pin 5 , and remove the
– Clean the brake caliper and the brake caliper bracket.
101737-10
– Check that spring plate sliding plate
6 in the brake caliper and brake pad
7 in the brake caliper bracket are seated correctly.
100397-01
– Insert the new brake linings, insert pin, and mount cotter pins.
Info
Always change the brake linings in pairs.
– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
101738-01
K00521-10
– Correct the brake fluid level to level A .
Guideline
Level A (brake fluid level below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 140)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Use water to immediately clean up any brake fluid that has overflowed or spilled.
84
BRAKE SYSTEM 12
12.8
Checking the free travel of foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
402026-10
– Disconnect spring 1 .
– Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A .
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.
– Reconnect spring 1 .
12.9
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
K00523-10
– Detach spring 1 .
– Loosen nut 2 and, with push rod have maximum free travel.
3 , turn it back until you
– To adjust the basic position of the foot brake lever to individual requirements, loosen nut 4 and turn screw 5 accordingly.
Info
The range of adjustment is limited.
– Turn push rod 3 accordingly until you have free travel A necessary, adjust the basic position of the foot brake lever.
. If
Guideline
Free travel at foot brake lever 3 … 5 mm (0.12 … 0.2 in)
– Hold screw 5 and tighten nut 4 .
Guideline
Nut, foot brake lever stop
M8 20 Nm (14.8 lbf ft)
– Hold push rod 3 and tighten nut 2 .
85
12 BRAKE SYSTEM
Guideline
Remaining nuts, chassis
– Attach spring 1 .
M6 10 Nm (7.4 lbf ft)
12.10
Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Preparatory work
–
Check the brake linings of the rear brake. ( p. 88)
Main work
– Stand the vehicle upright.
– Check the brake fluid level in level viewer 1 .
» If the brake fluid has dropped below marking
– Add rear brake fluid.
A :
K01183-10
12.11
Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
86
BRAKE SYSTEM 12
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the 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.
Only use clean brake fluid from a sealed container.
K01185-10
Preparatory work
–
Check the brake linings of the rear brake. ( p. 88)
Main work
– Stand the vehicle upright.
– Remove screw cap 1
– Add brake fluid to level with membrane
A .
2 and the O-ring.
Brake fluid DOT 4 / DOT 5.1 ( p. 140)
– Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilled brake fluid immediately with water.
87
12 BRAKE SYSTEM
12.12
Checking the brake linings of the rear brake
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
– Check the brake linings for minimum thickness A .
Minimum thickness A ≥ 1 mm ( ≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings.
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the rear brake linings.
M01180-10
12.13
Changing the rear brake linings
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
88
BRAKE SYSTEM 12
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 corrodes paint.
Only use clean brake fluid from a sealed container.
– Position the vehicle vertically.
–
Remove screw cap 1 with membrane 2 and the O-ring.
K01196-10
101740-10
– Manually press the brake caliper toward the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.
Info
Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.
–
–
Remove cotter pins brake linings.
3 , pull out pin 4 , and remove the
– Clean the brake caliper and the brake caliper bracket.
Check that spring plate sliding plate rectly.
5 in the brake caliper and brake pad
6 in the brake caliper bracket are seated cor-
Info
The arrow on the spring plate points in the direction of rotation of the brake disc.
101741-10
M01181-10
– Insert the new brake linings, insert pin pins 3 .
4 , and mount cotter
Info
Always change the brake linings in pairs.
Make sure that decoupling plate 7 is mounted on the piston side brake lining.
– Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
89
12 BRAKE SYSTEM
K01185-10
– Correct brake fluid level to marking A .
Brake fluid DOT 4 / DOT 5.1 ( p. 140)
– Mount and tighten screw cap
O-ring.
1 with membrane 2 and the
Info
Use water to immediately clean up any brake fluid that has overflowed or spilled.
90
WHEELS, TIRES 13
13.1
Removing the front wheel
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
Main work
– Manually press the brake caliper toward the brake disc to push back the brake pistons.
Info
Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.
H01337-10
– Loosen screw
– Loosen screws
1 by several rotations.
2 .
–
Press on screw clamp.
– Remove screw
1
1 .
to push the wheel spindle out of the axle
K00454-10
H01340-10
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Hold the front wheel and remove the wheel spindle. Take the front wheel out of the fork.
Info
Do not actuate the hand brake lever when the front wheel is removed.
–
Remove spacers 3 .
H00934-10
91
13 WHEELS, TIRES
13.2
Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
H00935-10
K00454-11
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change front wheel bearing.
– Clean and grease shaft seal rings of the spacers.
1 and contact surfaces A
– Insert the spacers.
– Clean and grease the wheel spindle.
– Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
– Mount and tighten screw 2 .
Guideline
Screw, front wheel spindle
M20x1.5
35 Nm (25.8 lbf ft)
– Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
–
Remove the motorcycle from the lift stand. ( p. 48)
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
– Tighten screws 3 .
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
13.3
Removing the rear wheel
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 48)
92
WHEELS, TIRES 13
Main work
– Manually press the brake caliper toward the brake disc to push back the brake piston.
Info
Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.
– Remove nut 1 .
–
Take off chain adjuster 2 . Pull out wheel spindle 3 enough to allow the rear wheel to be pushed forward.
far
– Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.
Info
Cover the components to protect them against damage.
H00027-10
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel is removed.
–
Remove spacers 4 .
H03002-10
13.4
Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
93
13 WHEELS, TIRES
H03001-10
Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease shaft seal rings of the spacers.
1 and contact surfaces A
– Insert the spacers.
– Clean and grease the wheel spindle.
– Position rear wheel and insert wheel spindle 2 .
The brake linings are correctly positioned.
– Mount the chain.
H00006-10
H00007-10
– Position chain adjuster it yet.
3 . Mount nut 4 , but do not tighten
– Make sure that chain adjusters adjusting screws 5 .
3 are fitted correctly on
–
Check the chain tension. ( p. 69)
– Tighten nut 4 .
Guideline
Nut, rear wheel spindle
M25x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters
(32 mm (1.26 in)) enables different secondary ratios with the same chain length.
Chain adjusters 3 can be turned by 180°.
– Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 48)
94
WHEELS, TIRES 13
13.5
Checking the tire condition
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
– Check the front and rear tires for cuts, run-in objects, and other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
400602-10
H01144-01
– Check the tire age.
Info
The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture.
KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.
» If the tires are more than 5 years old:
– Change the tires.
13.6
Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
400695-01
– Remove the protection cap.
– Check the tire pressure when the tires are cold.
Offroad tire pressure front rear
1.0 bar (15 psi)
1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the protection cap.
95
13 WHEELS, TIRES
13.7
Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)
400694-01
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length and spoke diameter.
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 differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple, front wheel
M4.5
Spoke nipple, rear wheel
M4.5
Torque wrench kit (58429094000)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
96
ELECTRICAL SYSTEM 14
14.1
Removing the 12-V battery (125 XC US)
Warning
Risk of injury 12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V batteries.
– Only charge 12 V batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
– Dispose of 12 V batteries with less than the minimum voltage correctly.
Preparatory work
–
Main work
– Disconnect negative cable
– Remove screw 3 .
1 from the 12-V battery.
– Pull back positive terminal cover tive cable from the 12-V battery.
2 and disconnect the posi-
– Pull holding bracket upwards.
4 forward and remove the 12-V battery
F00138-10
14.2
Installing the 12 V battery (125 XC US)
Main work
– Position the 12 V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 1 .
12-V battery (HJTZ5S-FP-C) ( p. 135)
– Mount and tighten screw 2 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
– Connect positive cable 3 to the 12 V battery.
Guideline
Screw, battery terminal
M5 2.5 Nm
(1.84 lbf ft)
H00386-10
Contact disks cable sockets nal.
A must be mounted under screws 5 and
6 with the claws toward the battery termi-
– Slide positive terminal cover
– Connect negative cable 4
7 over the positive terminal.
to the 12 V battery.
Guideline
Screw, battery terminal
M5 2.5 Nm
(1.84 lbf ft)
97
14 ELECTRICAL SYSTEM
Finishing work
–
14.3
Charging the 12-V battery (125 XC US)
Warning
Risk of injury 12 V batteries contain harmful substances.
– Keep 12 V batteries out of the reach of children.
– Keep sparks and open flames away from 12 V batteries.
– Only charge 12 V batteries in well-ventilated rooms.
– Maintain a minimum clearance from inflammable materials when charging 12 V batteries.
Minimum clearance 1 m (3 ft)
– Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
– Dispose of 12 V batteries with less than the minimum voltage correctly.
Note
Environmental hazard 12 V batteries contain environmentally hazardous materials.
– Do not dispose of 12 V batteries as household waste.
– Dispose of 12 V batteries at a collection point for used batteries.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Even when there is no load on the 12-V battery, it discharges steadily each day.
The charging level and the method of charging are very important for the service life of the 12-V battery.
Rapid recharging with a high charging current shortens the service life of the battery.
If the charging current, charging voltage, or charging time is exceeded, the 12-V battery will be destroyed.
If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.
If the 12-V battery is left in a discharged state for an extended period, it will become deeply discharged and suffer a loss of capacity, destroying the battery.
The 12-V battery is maintenance-free.
S00863-10
Preparatory work
–
– Remove the 12-V battery.
Main work
– Check the battery voltage.
» Battery voltage: < 9 V
– Do not charge the 12-V battery.
– Replace the 12-V battery and dispose of the old 12-V battery properly.
» If the specifications have been met:
Battery voltage: ≥ 9 V
– Charge the 12-V battery.
98
ELECTRICAL SYSTEM 14
Guideline
The charging current, charging voltage, and charging time must not be exceeded.
Maximum charging voltage
14.4 V
Maximum charging current
3.0 A
Maximum charging time 24 h
Recharge the 12-V battery regularly when the motorcycle is not being used
6 months
– Connect a battery charger to the 12-V battery. Switch on the battery charger.
(EU) battery charger (79629974000)
Alternative 1
(US) battery charger (79629974500)
This battery charger tests whether the 12-V battery retains its voltage. It is also impossible to overcharge the 12-V battery with this battery charger. The charging time may be longer at low temperatures.
This battery charger is only suitable for lithium iron phosphate batteries. Read the accompanying KTM Power Parts instructions.
Info
Never remove cover 1 .
– Switch off the battery charger after charging and disconnect from the 12-V battery.
Finishing work
– Install the 12 V battery.
–
14.4
Changing main fuse (125 XC US)
Warning
Fire hazard Incorrect fuses overload the electrical system.
– Only use fuses with the required ampere value.
– Do not bypass or repair fuses.
Info
The main fuse protects all electrical power consumers of the vehicle. It is located in the starter relay housing under the seat.
Preparatory work
–
99
14 ELECTRICAL SYSTEM
Main work
–
Pull starter relay 1 from the holder.
F00161-10
–
– Take off protection caps 2 .
Remove faulty main fuse 3 .
Info
A faulty fuse has a burned-out fuse wire
A spare fuse
A .
4 is located in the starter relay.
– Insert a new main fuse.
– Check that the electrical system is functioning properly.
Tip
Insert a spare fuse so that it is available if needed.
– Mount the protection caps.
– Mount the starter relay onto the holder and route the cable.
F00162-10
Finishing work
–
100
COOLING SYSTEM 15
15.1
Cooling system
K01177-10
Water pump 1 in the engine ensures forced circulation of the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap 2 . 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
Radiator cover
Info
Do not use radiator covers in difficult operating conditions.
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)
K00459-01
M01121-10
The radiator cover is installed in front of the left radiator, depending on the ambient temperature.
Full radiator cover 1
< 7 °C (< 45 °F)
7 … 16 °C (45 … 61 °F) Half radiator cover 2
No radiator cover > 16 °C (> 61 °F)
Info
Do not use both radiator covers at the same time.
15.3
Installing the radiator cover
– Remove screws
– Remove screws
–
1
2 .
.
Take off radiator shield 3 .
K00460-10
101
15 COOLING SYSTEM
–
Position the matching radiator cover ( p. 101).
The larger holding lug is located at the top left.
Info
Do not use both radiator covers at the same time.
H01341-10
K00460-10
– Position radiator shield
–
3
Mount and tighten screws
.
2 .
Guideline
Remaining screws, chassis
M6
– Mount and tighten screws 1 .
Guideline
Remaining screws, chassis
M6
15.4
Removing the radiator cover
K00460-10
– Remove screws
– Remove screws
1
2 .
.
– Take off radiator shield 3 .
– Remove the radiator cover.
–
Position radiator shield 3 .
– Mount and tighten screws 2 .
Guideline
Remaining screws, chassis
M6
– Mount and tighten screws 1 .
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
15.5
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
102
COOLING SYSTEM 15
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
400243-10
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant antifreeze.
− 25 … − 45 °C ( − 13 … − 49 °F)
» If the antifreeze in the coolant does not match the specified value:
– Correct the coolant antifreeze.
– Check the coolant level in the radiator.
Coolant level radiator fins
A above the 10 mm (0.39 in)
» If the coolant level does not match the specified value:
– Correct the coolant level.
– Mount the radiator cap.
15.6
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
103
15 COOLING SYSTEM
400243-10
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level radiator fins
A above the 10 mm (0.39 in)
» If the coolant level does not match the specified value:
– Correct the coolant level.
– Mount the radiator cap.
15.7
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1 . Take off radiator cap
– Completely drain the coolant.
2 .
– Mount and tighten screw 1 with a new seal ring.
Guideline
Drain plug, water pump cover
M6 10 Nm (7.4 lbf ft)
K01177-11
104
COOLING SYSTEM 15
15.8
Refilling with coolant
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
– Make sure that screw 1 is tightened.
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
K01178-10
– Loosen screw 2 until coolant escapes without bubbles.
– Mount and tighten screw 2 .
Guideline
Bleeder screw, cylinder head
M6 8 Nm (5.9 lbf ft)
– Completely fill the radiator with coolant.
K01180-10
K01179-10
– Mount radiator cap 3 .
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Allow the engine to warm up and cool down again.
–
Check the coolant level. ( p. 103)
105
15 COOLING SYSTEM
15.9
Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
K01177-11
Condition
The engine is cold.
– Remove screw 1 . Take off radiator cap 2 .
– Place an appropriate container under the water pump cover.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Screw, water pump cover
M6 10 Nm (7.4 lbf ft)
– Position the motorcycle upright.
– Completely fill the radiator with coolant.
– Loosen screw
–
3 until coolant escapes without bubbles.
Mount and tighten screw 3 .
Guideline
Bleeder screw, cylinder head
M6 8 Nm (5.9 lbf ft)
– Completely fill the radiator with coolant.
S04254-10
106
COOLING SYSTEM 15
S04253-10
– Mount radiator cap 2 .
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Allow the engine to warm up and cool down again.
– Check the cooling system for leaks.
–
Check the coolant level. ( p. 103)
107
16 TUNING THE ENGINE
16.1
Checking the play in the throttle cable
– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable A .
Play in throttle cable 2 … 3 mm (0.08 …
0.12 in)
» If the throttle cable play does not meet the specified value:
– Adjust the play in the throttle cable.
400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Start the engine and let it run at idle speed. Move the handlebar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable.
16.2
Adjusting the play in the throttle cable
Info
If the correct routing of the throttle cable has already been secured, the fuel tank does not need to be removed.
Preparatory work
–
(All SX models)
– Turn tap handle of the fuel tap to the OFF position.
(125 XC US)
– Turn tap handle of the fuel tap to the OFF position.
– Remove the fuel tank.
–
Check the throttle cable routing. ( p. 74)
Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1 .
– Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster 2 .
– Loosen nut 3 .
K00457-10
108
16.3
Carburetor tuning
Effects of carburetor tuning
TUNING THE ENGINE 16
– Turn barrel adjuster 2 cable at the throttle grip.
so that there is play A in the throttle
Guideline
Play in throttle cable 2 … 3 mm (0.08 …
0.12 in)
– Tighten nut 3
– Slide on sleeve
.
1 .
400192-11
Finishing work
– Check the throttle grip for smooth operation.
– Install the fuel tank.
–
–
Check the play in the throttle cable. ( p. 108)
H01400-01
The different carburetor components must be tuned both to one another and for the use intended.
Main jet MJ
The main jet MJ has the greatest influence with the throttle slide open (full throttle).
If the insulator of a new spark plug is very light 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.
Needle position POS
The needle position has the greatest influence in the mid throttle slide range.
If the engine stutters when accelerating with a partially open throttle slide, the jet needle must be lowered. If the engine knocks when accelerating at the full power rpm range, the jet needle must be raised.
Cylindrical part of the needle CYL
The cylindrical part of the needle has the greatest influence when the throttle slide is almost closed.
109
16 TUNING THE ENGINE
Idling jet IJ
The idling jet has the greatest influence in the low to mid throttle slide range.
If the engine stutters at idle speed or when accelerating with a partially open throttle slide, a smaller idling jet must be used. If the engine knocks in this power range, then a larger idling jet must be used.
Idle air adjusting screw open ASO
The idle air adjusting screw has the greatest influence at idle speed.
Influence of throttle slide adjustment
K00495-01
The idling jet has the greatest influence when the throttle slide is closed. The first cylindrical part of the needle and the clip position have only minimal influence.
When the throttle slide is 1/8 open, the first cylindrical part of the needle, the idling jet and the clip position have the greatest influence.
K00496-01
When the throttle slide is 1/4 open, the idling jet and the clip position have the greatest influence. The influence of the first cylindrical part of the needle is less.
When the throttle slide is 1/2 open, the position of the needle has the greatest influence. The influence of the main jet and the idling jet is only minimal.
K00497-01
When the throttle slide is 3/4 open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.
When the throttle slide is fully open, the influence of the main jet is greatest. The clip position and the idling jet have only minimal influence.
Needle overview
The jet needles available are shown in the following table.
110
TUNING THE ENGINE 16
402674-01
Column 2 corresponds to a needle in the standard position.
Column 1 corresponds to a needle which is half a clip leaner.
Column 3 corresponds to a needle which is half a clip richer.
Column 4 specifies the diameter of the first cylindrical part of the needle. The smaller the diameter of the first cylindrical part of the needle, the richer the mixture preparation. The larger the diameter of the first cylindrical part of the needle, the leaner the mixture preparation. The first cylindrical part of the needle has the greatest influence in the lowest load range.
Info
The top right jet needle A3 corresponds to the richest setting of the carburetor, and the bottom left jet needle F1 corresponds to the leanest. The optimal carburetor tuning is shown under the respective model.
Clip position
1... 5 Clip position from above
The five possible clip positions are shown here.
The carburetor tuning depends on the defined ambient and operating conditions.
B00075-10
16.4
Carburetor – idle setting
402799-10
The idle setting of the carburetor significantly influences the vehicle’s starting behavior, the stability of the idle speed, and the vehicle’s response when accelerating. This means that an engine with a correctly set idle speed will be easier to start than one with an incorrectly set idle speed.
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.
Height above sea level
Ambient temperature
301 … 750 m (988 … 2,461 ft)
16 … 24 °C (61 … 75 °F)
Super unleaded (98 octane) mixed with 2-stroke engine oil
The idle speed is adjusted with adjusting screw 1 .
The idle mixture is adjusted using the idle air adjusting screw 2 .
111
16 TUNING THE ENGINE
16.5
Carburetor - adjusting the idle speed
– Screw in idle air adjusting screw the specified basic setting.
1 all the way and turn it to
402799-11
Info
The basic adjustment is shown under the respective model.
– Run the engine until warm.
Guideline
Warming-up phase ≥ 5 min
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Adjust the idle speed with adjusting screw 2 .
Guideline
Choke function deactivated – The choke lever is pushed in
Idle speed 1,400 … 1,500 rpm
– Turn idle air adjusting screw 1 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 again begins to fall.
– Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big 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, mount a smaller idling jet.
After changing the jet, start from the beginning with the adjusting steps.
Following extreme air temperature or altitude changes, adjust the idle speed again.
112
TUNING THE ENGINE 16
16.6
Plug-in connector of ignition timing map adjustment
(All SX models)
Plug-in connector 1 of the ignition timing map adjustment is located on the frame under the fuel tank.
K01181-10
K00509-10
(125 XC US)
Plug-in connector 1 of the ignition timing map adjustment is located on the frame under the fuel tank.
Possible states
(All SX models)
• Soft – The plug-in connector of the ignition timing map adjustment is disconnected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing map adjustment is joined to achieve higher performance.
(125 XC US)
• Soft – The plug-in connector of the ignition timing map adjustment is disconnected to achieve better rideability.
• Performance – The plug-in connector of the ignition timing map adjustment is joined to achieve higher performance.
16.7
Changing the ignition timing map
Switching the ignition timing map from Performance to Soft
(All SX models)
– Disconnect plug-in connector 1 of the ignition timing map adjustment.
Soft – better rideability
Switching the ignition timing map from Soft to Performance
(All SX models)
– Join plug-in connector 1
of the ignition timing map adjustment. (Figure K01181-10 p. 113)
Performance – better performance
16.8
Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
113
16 TUNING THE ENGINE
16.9
400692-10
– Sit on the vehicle in the riding position and determine distance A 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.
Adjusting the basic position of the shift lever
– Remove screw lever 2 .
1 with the washers and take off shift
401950-12
401951-10
– Clean gear teeth A of the shift lever and shift shaft.
– Mount the shift lever on the shift shaft in the required position and engage gearing.
–
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle components during the shift procedure.
Mount and tighten screw 1 with washers.
Guideline
Screw, shift lever
M6 14 Nm (10.3 lbf ft)
Loctite ® 243™
114
SERVICE WORK ON THE ENGINE 17
17.1
Emptying the carburetor float chamber
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Info
Carry out work with a cold engine.
Water in the float chamber results in malfunctioning.
Preparatory work
(All SX models)
– Turn tap handle of the fuel tap to the OFF position.
Fuel no longer flows from the fuel tank to the carburetor.
(125 XC US)
– Turn tap handle of the fuel tap to the OFF position.
Fuel no longer flows from the fuel tank to the carburetor.
Main work
– Place a cloth under the carburetor to capture the draining fuel.
–
Remove screw plug 1 .
– Fully drain the fuel.
– Mount and tighten the screw plug.
K00472-10
115
17 SERVICE WORK ON THE ENGINE
17.2
Checking the gear oil level
Info
The gear oil level must be checked when the engine is cold.
K01182-10
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Remove gear oil level monitoring screw
– Check the gear oil level.
1 .
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add the gear oil.
– Mount and tighten the gear oil level monitoring screw.
Guideline
Screw, gear oil level monitoring
M6 8 Nm (5.9 lbf ft)
17.3
Changing the gear oil
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Drain the gear oil while the engine is at operating temperature.
Preparatory work
– Park the motorcycle on a level surface.
– Position an appropriate container under the engine.
116
SERVICE WORK ON THE ENGINE 17
Main work
–
Remove gear oil drain plug
– Remove gear oil drain plug
– Let the gear oil drain fully.
1 with magnet.
2 .
– Thoroughly clean the gear oil drain plug.
– Clean the sealing surface on the engine.
– Mount and tighten gear oil drain plug a new seal ring.
1 with the magnet and
Guideline
Gear oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
– Mount and tighten gear oil drain plug 2 with a new seal ring.
Guideline
Gear oil drain plug M10x1 15 Nm (11.1 lbf ft)
V01532-10
K00530-10
–
Remove filler plug 3 with the O-ring, and fill up with gear oil.
Gear oil 0.80 l
(0.85 qt.)
Engine oil
(15W/50)
– Mount and tighten the filler plug together with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Start the engine and check for leaks.
Finishing work
–
Check the gear oil level. ( p. 116)
17.4
Adding the gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Gear oil must only be topped up when the engine is cold.
Preparatory work
– Park the motorcycle on a level surface.
117
17 SERVICE WORK ON THE ENGINE
Main work
–
Remove gear oil level monitoring screw 1 .
K01182-10
401955-11
– Remove filler plug 2 with the O-ring.
– Add gear oil until it emerges from the drill hole of the gear oil level monitoring screw.
– Mount and tighten the gear oil level monitoring screw.
Guideline
Screw, gear oil level monitoring
M6 8 Nm (5.9 lbf ft)
– Mount and tighten filler plug 2 together with the O-ring.
Finishing work
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Start the engine and check for leaks.
118
CLEANING, CARE 18
18.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
To maintain the value and appearance of the motorcycle over a long period, clean it regularly.
Avoid direct sunshine when cleaning the motorcycle.
– Close off exhaust system to keep water from entering.
– Remove the coarse dirt particles with a gentle water jet.
– Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush.
401061-01
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.
– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Empty the carburetor float chamber.
– Remove the closure of the exhaust system.
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– After cleaning, ride the vehicle a short distance until the engine warms up.
Info
The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.
119
18 CLEANING, CARE
– After the motorcycle has cooled down, lubricate all moving parts and pivot points.
–
– Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
– Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 143)
120
STORAGE 19
19.1
Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
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.
401058-01
– When refueling for the last time before taking the motorcycle out of service, add fuel additive.
–
–
Clean the motorcycle. ( p. 119)
– Change the gear oil.
–
Check the antifreeze and coolant level. ( p. 102)
– Empty the carburetor float chamber.
–
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.
–
Raise the motorcycle with a lift stand. ( p. 48)
– Cover the vehicle with a tarp or similar 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.
121
19 STORAGE
19.2
Preparing for use after storage
–
Remove the motorcycle from the lift stand. ( p. 48)
– Perform checks and maintenance measures when preparing for
– Take a test ride.
401059-01
122
TROUBLESHOOTING 20
Faults
The engine cannot be cranked
(starter motor)
(125 XC US)
Possible cause
Operating error
12-V battery discharged
Fault in ignition system
Action
–
Carry out start procedure. ( p. 29)
– Charge the 12-V battery.
– Check the charging voltage.
– Check the closed current.
– Check the alternator.
Main fuse blown
Starter relay faulty
Starter motor faulty
Engine turns but does not start Operating error
The motorcycle has been in disuse for an extended period and old fuel is in the float chamber
–
Change the main fuse. ( p. 99)
– Check the starter relay.
– Check the starter motor.
–
Carry out start procedure. ( p. 29)
– Empty the carburetor float chamber.
Fuel supply interrupted – Check the fuel tank breather.
– Clean the fuel tap.
– Check/adjust the carburetor components.
Spark plug sooty or wet – Clean and dry the spark plug and spark plug connector, or change if necessary.
Plug gap of spark plug too wide – Adjust plug gap.
Guideline
Spark plug electrode gap
0.60 mm (0.0236 in)
– Check the ignition system.
– Check the stop button.
Short-circuit cable in wiring harness frayed, stop button faulty
The connector or ignition coil is loose or oxidized
– Clean the connector and treat it with contact spray.
– Check/set the carburetor components.
Engine has no idle speed
Water in carburetor or jets blocked
Idling jet blocked
Engine does not speed up
Adjusting screws on carburetor distorted
Spark plug defective
Ignition system defective
Carburetor running over because float needle dirty or worn
– Check/set the carburetor components.
– Carburetor - adjust the idle speed.
– Change the spark plug.
– Check the ignition coil.
– Check the spark plug connector.
– Check/set the carburetor components.
Engine has too little power
Loose carburetor jets
Fault in ignition system
Fuel supply interrupted
Air filter very dirty
– Check/set the carburetor components.
– Check the ignition system.
– Check the fuel tank breather.
– Clean the fuel tap.
– Check/adjust the carburetor components.
– Clean the air filter and air filter box.
123
20 TROUBLESHOOTING
Faults
Engine has too little power
Engine stalls or is popping into the carburetor
Engine overheats
White smoke emission (steam in exhaust gas)
Gear oil exits at the vent hose
Water in the gear oil
Possible cause
Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer
Fault in ignition system
Diaphragm or reed valve housing damaged
Lack of fuel
Engine takes in bad air
The connector or ignition coil is loose or oxidized
Too little coolant in cooling system
Too little air stream
Radiator fins very dirty
Foam formation in cooling system
Damaged cylinder head or cylinder head gasket
Bent radiator hose
Damaged cylinder head or cylinder head gasket
Too much gear oil added
Damaged radial shaft seal ring or water pump
Action
– Check exhaust system for damage.
– Change the glass fiber yarn filling in the main silencer.
– Check the ignition system.
– Check the diaphragm and reed valve housing.
(All SX models)
– Turn tap handle of the fuel tap to the ON position.
(125 XC US)
– Turn tap handle of the fuel tap to the ON position.
(125 XC US)
– Turn tap handle of the fuel tap to the RES position.
–
– Check the intake flange and carburetor for tightness.
– Clean the connector and treat it with contact spray.
– Check the cooling system for leakage.
–
Check the coolant level. ( p. 103)
– Switch off engine when stationary.
– Clean the radiator fins.
– Drain the coolant.
– Refill with coolant.
– Check the cylinder head and cylinder head gasket.
– Change the radiator hose.
– Check the cylinder head and cylinder head gasket.
–
Check the gear oil level. ( p. 116)
– Check the radial shaft seal ring and the water pump.
124
TECHNICAL DATA 21
21.1
Engine
21.1.1
All 125 models
Design
Displacement
Stroke
Bore
Crankshaft bearing
Conrod bearing
Piston pin bearing
Pistons
Piston rings
X (upper edge of piston to upper edge of cylinder)
Z (height of control flap)
Primary transmission
Clutch
Gearbox
Transmission ratio first-gear second-gear third-gear fourth-gear fifth-gear sixth-gear
Ignition
Spark plug
Spark plug electrode gap
Starting aid (125 SX)
Starting aid (125 XC US)
21.1.2
150 SX
Design
Displacement
Stroke
Bore
Crankshaft bearing
Conrod bearing
Piston pin bearing
Pistons
Piston rings
X (upper edge of piston to upper edge of cylinder)
Z (height of control flap)
Primary transmission
1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
124.8 cm³ (7.616 cu in)
54.5 mm (2.146 in)
54 mm (2.13 in)
1 grooved ball bearing/1 roller bearing
Needle bearing
Needle bearing
Cast aluminum
2 half keystone rings
0 … 0.10 mm (0 … 0.0039 in)
36.5 mm (1.437 in)
23:73
Multidisc clutch in oil bath/hydraulically activated
6-gear transmission, claw shifted
14:32
15:30
17:28
19:27
19:23
22:24
Contactless controlled fully electronic ignition with digital ignition adjustment
NGK BR9 ECMVX
0.60 mm (0.0236 in)
Kick starter system
Electric starter system and kick starter system
1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
144 cm³ (8.79 cu in)
54.5 mm (2.146 in)
58 mm (2.28 in)
1 grooved ball bearing/1 roller bearing
Needle bearing
Needle bearing
Forged aluminum
2 half keystone rings
0 … 0.10 mm (0 … 0.0039 in)
36.5 mm (1.437 in)
23:73
125
21 TECHNICAL DATA
Clutch
Gearbox
Transmission ratio first-gear second-gear third-gear fourth-gear fifth-gear sixth-gear
Ignition
Spark plug
Spark plug electrode gap
Starting aid
Multidisc clutch in oil bath/hydraulically activated
6-gear transmission, claw shifted
21.2
Engine tightening torques
Screw, inner membrane sheets
Screw, membrane support plate
Screw, outer membrane sheets
Screw, clutch spring retainer
Screw, control lever, exhaust control
Screw, crankshaft speed sensor
EJOTDELTA PT ® 35x25
EJOTDELTA PT ® 30x12
EJOTDELTA PT ® 30x6
M5
M5
M5
Screw, exhaust control cap
Screw, exhaust control cover
Screw, locking lever
Screw, retaining bracket, rotary valve
Screw, stator (All SX models)
Screw, water pump wheel
M5
M5
M5
M5
M5
M5
Bleeder screw, cylinder head M6
Drain plug, water pump cover M6
Nut, adjusting screw, power valve M6
Screw, alternator cover
Screw, bearing retainer
M6
M6
Screw, clutch cover
Screw, clutch cover
Screw, clutch cover
Screw, clutch slave cylinder
Screw, control lever, exhaust control
Screw, engine case
M6x20
M6x25
M6x30
M6
M6
M6
14:32
15:30
17:28
19:27
19:23
22:24
Contactless controlled fully electronic ignition with digital ignition adjustment
NGK BR9 ECMVX
0.60 mm (0.0236 in)
Kick starter system
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
4 Nm (3 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
Loctite ® 243™
Loctite ® 243™
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
Loctite ® 243™
Loctite ® 2701™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
10 Nm (7.4 lbf ft)
126
Screw, exhaust flange
Screw, gear oil level monitoring
Screw, idler gear housing (125 XC
US)
Screw, intake flange/reed valve housing
Screw, kick starter stop plate
M6
M6
M6
M6
M6
Screw, outer clutch cover
Screw, outer clutch cover
Screw, shift drum locating
M6x20
M6x50
M6
Screw, shift lever M6
Screw, starter motor (125 XC US) M6
Screw, stator (125 XC US) M6
M6 Screw, stop plate of exhaust control
Screw, water pump cover
Vacuum connection, housing breather
Screw, cylinder head
Nut, cylinder base
Screw, cylinder base
Screw, kick starter lever
M6
M6
M7
M8
M8
M8
Screw, engine sprocket M10
Gear oil drain plug
Nut, rotor (All SX models)
Nut, rotor (125 XC US)
Gear oil drain plug with magnet
Spark plug
Nut, primary gear wheel
Nut, inner clutch hub
M10x1
M12x1
M12x1
M12x1.5
M14x1.25
M16LHx1.5
M18x1.5
TECHNICAL DATA 21
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
Loctite ® 243™
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
Loctite ® 243™
14 Nm (10.3 lbf ft)
Loctite ® 243™
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
Loctite ® 243™
10 Nm (7.4 lbf ft)
Loctite ® 243™
10 Nm (7.4 lbf ft)
2 Nm (1.5 lbf ft)
18 Nm (13.3 lbf ft)
23 Nm (17 lbf ft)
10 Nm (7.4 lbf ft)
25 Nm (18.4 lbf ft)
Loctite ® 2701™
60 Nm (44.3 lbf ft)
15 Nm (11.1 lbf ft)
60 Nm (44.3 lbf ft)
50 Nm (36.9 lbf ft)
20 Nm (14.8 lbf ft)
25 Nm (18.4 lbf ft)
130 Nm (95.9 lbf ft)
Loctite ® 2701™
Loctite ® 243™
100 Nm (73.8 lbf ft)
Loctite ® 243™
127
21 TECHNICAL DATA
21.3
Carburetor
21.3.1
125 SX
Carburetor type
Carburetor identification number
Needle position
Jet needle
Main jet
Idling jet
Choke nozzle
Needle jet
Idle air adjusting screw open
MIKUNI TMX 38
TMX 38 87
2nd position from top
6BFY43 ‑ 71 (6BFY42 ‑ 71)
500 (480, 490, 520, 540, 560)
35 (30 / 32.5 / 37.5 / 40)
80
S ‑ 7
1.5 turns
21.3.2
Carburetor tuning (125 SX)
MIKUNI TMX 38
ASL TEMP
− 20 … − 7 °C
( − 4 … 19 °F)
2,301 …
3,000 m
(7,549 …
9,843 ft)
1,501 …
2,300 m
(4,925 …
7,546 ft)
751 …
1,500 m
(2,464 …
4,921 ft)
301 …
750 m
(988 …
2,461 ft)
0 …
300 m (0
… 984 ft)
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
1.5
35
43-71
2
500
2
37.5
43-71
2
520
1.5
35
42-71
3
520
1.5
37.5
42-71
3
540
1.5
37.5
42-71
3
560
− 6 … 5 °C
(21 …
41 °F)
2
32.5
43-71
2
500
1.5
35
43-71
2
500
2
37.5
43-71
2
520
1.5
35
42-71
3
520
1.5
35
42-71
3
540
ASL
TEMP
ASO
IJ
NDL
6 … 15 °C
(43 …
59 °F)
2
30
43-71
2
490
2
32.5
43-71
2
500
1.5
35
43-71
2
500
2
37.5
43-71
2
520
2
37.5
43-71
2
540
Sea level
Temperature
Idle air adjusting screw open
Idling jet
Needle
1,5
35
43 ‑ 71
2
500
1.5
35
43-71
2
520
16 … 24 °C
(61 …
75 °F)
2
30
43-71
2
480
2
30
43-71
2
490
2
32.5
43-71
2
500
25 … 36 °C
(77 …
97 °F)
1.5
30
42-71
2
480
2
30
43-71
2
480
2
30
43-71
2
490
2
32.5
43-71
2
500
2
32.5
43-71
2
500
37 … 49 °C
(99 …
120 °F)
2
30
43-71
2
490
2
30
43-71
2
490
1.5
30
42-71
2
480
2
30
43-71
2
480
128
POS
MJ
Needle position from top
Main jet
Info
Do not use on sandy terrain.
21.3.3
Carburetor - basic setting for sandy surfaces (All 125 models)
Idle air adjusting screw
Open
Idling jet
Jet needle
Needle position
Main jet
2 turns
37.5
6BFY42 ‑ 71
3rd position from top
580
Info
If the engine is not running smoothly, use a smaller main jet.
TECHNICAL DATA 21
129
21 TECHNICAL DATA
21.3.4
150 SX
Carburetor type
Carburetor identification number
Needle position
Jet needle
Main jet
Idling jet
Choke nozzle
Needle jet
Idle air adjusting screw open
MIKUNI TMX 38
TMX 38 88
3rd position from top
6BFY42 ‑ 71 (6BFY43 ‑ 71)
470 (460, 480, 490, 500, 520)
30 (25 / 27.5 / 32.5 / 35)
80
S ‑ 4
1.5 turns
ASL
TEMP
ASO
IJ
NDL
POS
MJ
21.3.5
Carburetor tuning (150 SX)
MIKUNI TMX 38
ASL TEMP
− 20 … − 7 °C
( − 4 … 19 °F)
2,301 …
3,000 m
(7,549 …
9,843 ft)
1,501 …
2,300 m
(4,925 …
7,546 ft)
751 …
1,500 m
(2,464 …
4,921 ft)
301 …
750 m
(988 …
2,461 ft)
0 …
300 m (0
… 984 ft)
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
1.5
30
42-71
3
470
1.5
32.5
42-71
3
480
2
35
42-71
3
490
1.5
35
42-71
3
500
1.5
35
42-71
3
500
2
35
42-71
3
490
2
35
42-71
3
490
− 6 … 5 °C
(21 …
41 °F)
1.5
32.5
43-71
2
470
1.5
30
42-71
3
470
1.5
32.5
42-71
3
480
1.5
32.5
42-71
3
480
1.5
32.5
42-71
3
480
6 … 15 °C
(43 …
59 °F)
2
32.5
43-71
2
460
1.5
32.5
43-71
2
470
1.5
30
42-71
3
470
Sea level
Temperature
Idle air adjusting screw open
Idling jet
Needle
Needle position from top
Main jet
1.5
32.5
43-71
2
470
1,5
30
42 ‑ 71
3
470
1.5
30
42-71
3
470
16 … 24 °C
(61 …
75 °F)
2
30
43-71
2
460
2
32.5
43-71
2
460
1.5
32.5
43-71
2
470
1.5
32.5
43-71
2
470
25 … 36 °C
(77 …
97 °F)
1.5
27.5
43-71
2
450
2
30
43-71
2
460
2
32.5
43-71
2
460
37 … 49 °C
(99 …
120 °F)
1.5
27.5
43-71
2
450
2
30
43-71
2
460
2
32.5
43-71
2
460
2
32.5
43-71
2
460
130
Info
Do not use on sandy terrain.
21.3.6
Basic carburetor setting for sandy surfaces (150 SX)
Idle air adjusting screw
Open
Idling jet
Jet needle
Needle position
Main jet
2 turns
37.5
6BFY42 ‑ 71
3rd position from top
540
Info
If the engine is not running smoothly, use a smaller main jet.
TECHNICAL DATA 21
131
21 TECHNICAL DATA
21.3.7
125 XC US
Carburetor type
Carburetor identification number
Needle position
Jet needle
Main jet
Idling jet
Choke nozzle
Needle jet
Idle air adjusting screw open
MIKUNI TMX 38
TMX 38 77
2nd position from top
6BFY43 ‑ 75 (6BFY42 ‑ 71 / 6BFY43 ‑ 71)
470 (480, 490, 500, 520, 540)
32.5 (30 / 35 / 37.5 / 40)
80
S ‑ 7
2 turns
21.3.8
Carburetor tuning (125 XC US)
For normal cross country circuits
MIKUNI TMX 38
ASL
2,301 …
3,000 m
(7,549 …
9,843 ft)
1,501 …
2,300 m
(4,925 …
7,546 ft)
751 …
1,500 m
(2,464 …
4,921 ft)
301 …
750 m
(988 …
2,461 ft)
0 …
300 m (0
… 984 ft)
TEMP
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
− 20 … − 7 °C
( − 4 … 19 °F)
2
32.5
42-75
3
480
2
32.5
42-75
3
490
2
32.5
42-75
3
490
2
32.5
43-75
2
470
2
35
43-75
2
480
− 6 … 5 °C
(21 …
41 °F)
2
30
43-75
2
460
2
32.5
43-75
2
470
2
35
43-75
2
480
2
35
43-75
2
490
2
35
43-75
2
490
ASL
TEMP
ASO
IJ
NDL
POS
6 … 15 °C
(43 …
59 °F)
2
32.5
42-75
2
470
2
30
43-75
2
460
2
32.5
43-75
2
470
2
32.5
43-75
3
470
2
32.5
43-75
2
480
Sea level
Temperature
Idle air adjusting screw open
Idling jet
Needle
Needle position from top
16 … 24 °C
(61 …
75 °F)
2
32.5
42-75
2
460
2
32.5
42-75
2
470
2
30
43-75
2
470
2
32.5
43-75
2
470
2
32,5
43 ‑ 75
2
470
25 … 36 °C
(77 …
97 °F)
2
30
42-75
2
450
1.5
30
42-75
2
460
2
30
43-75
2
460
2
30
43-75
2
470
2
30
43-75
2
470
37 … 49 °C
(99 …
120 °F)
2
30
42-75
2
450
1.5
30
42-75
2
460
2
30
43-75
2
460
2
30
43-75
2
460
132
TECHNICAL DATA 21
MJ Main jet
Info
Do not use on sandy terrain.
ASL
TEMP
ASO
IJ
NDL
POS
MJ
For fast circuits with a large portion of high-load riding
MIKUNI TMX 38
ASL
2,301 …
3,000 m
(7,549 …
9,843 ft)
1,501 …
2,300 m
(4,925 …
7,546 ft)
751 …
1,500 m
(2,464 …
4,921 ft)
301 …
750 m
(988 …
2,461 ft)
0 …
300 m (0
… 984 ft)
TEMP
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
(
−
−
20 …
1.5
35
43-71
2
500
2
37.5
43-71
2
520
1.5
35
42-71
3
540
1.5
37.5
42-71
3
540
1.5
37.5
42-71
3
560
− 7 °C
4 … 19 °F)
1.5
35
42-71
3
520
1.5
35
42-71
3
540
− 6 … 5 °C
(21 …
41 °F)
2
32.5
43-71
2
500
1.5
35
43-71
2
500
2
37.5
43-71
2
520
2
37.5
43-71
2
520
2
37.5
43-71
2
540
6 … 15 °C
(43 …
59 °F)
2
30
43-71
2
490
2
32.5
43-71
2
500
1.5
35
43-71
2
500
Sea level
Temperature
Idle air adjusting screw open
Idling jet
Needle
Needle position from top
Main jet
1.5
35
43-71
2
500
1.5
35
43-71
2
520
16 … 24 °C
(61 …
75 °F)
2
30
43-71
2
480
2
30
43-71
2
490
2
32.5
43-71
2
500
2
32.5
43-71
2
500
2
32.5
43-71
2
500
25 … 36 °C
(77 …
97 °F)
1.5
30
42-71
2
480
2
30
43-71
2
480
2
30
43-71
2
490
37 … 49 °C
(99 …
120 °F)
2
30
43-71
2
490
2
30
43-71
2
490
1.5
30
42-71
2
480
2
30
43-71
2
480
Info
Do not use on sandy terrain.
21.3.9
Carburetor - basic setting for sandy surfaces (All 125 models)
Idle air adjusting screw
Open 2 turns
133
21 TECHNICAL DATA
Idling jet
Jet needle
Needle position
Main jet
37.5
6BFY42 ‑ 71
3rd position from top
580
Info
If the engine is not running smoothly, use a smaller main jet.
21.4
Capacities
21.4.1
Gear oil
Gear oil
21.4.2
Coolant
Coolant
21.4.3
Fuel
Total fuel tank capacity, approx.
(All SX models)
Total fuel tank capacity, approx.
(125 XC US)
0.80 l (0.85 qt.)
1.2 l (1.3 qt.)
7.5 l (1.98 US gal)
10 l (2.6 US gal)
21.5
Frame
Chassis
Fork
Suspension travel front rear
Fork offset
Shock absorber
Brake system
Brake discs - diameter front rear
Brake discs - wear limit front rear
Offroad tire pressure front rear
Secondary ratio (All 125 models)
Secondary ratio (150 SX)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Central tube frame made of chrome molybdenum steel tubing
WP XACT 5448
310 mm (12.2 in)
300 mm (11.81 in)
22 mm (0.87 in)
WP XACT 5750
Disc brakes, floating brake calipers
260 mm (10.24 in)
220 mm (8.66 in)
2.5 mm (0.098 in)
3.5 mm (0.138 in)
1.0 bar (15 psi)
1.0 bar (15 psi)
13:51
13:48
134
TECHNICAL DATA 21
Chain
Rear sprockets available
Steering head angle
Wheelbase
Seat height unloaded
Ground clearance unloaded (All SX models)
Ground clearance unloaded (125 XC US)
Weight without fuel, approx. (All SX models)
Weight without fuel, approx. (125 XC US)
Maximum permissible front axle load
Maximum permissible rear axle load
Maximum permissible overall weight
5/8 x 1/4"
48, 50, 52
63.9°
1,485 ± 10 mm (58.46 ± 0.39 in)
950 mm (37.4 in)
375 mm (14.76 in)
370 mm (14.57 in)
87.5 kg (192.9 lb.)
89 kg (196 lb.)
145 kg (320 lb.)
190 kg (419 lb.)
335 kg (739 lb.)
21.6
Electrical system
12-V battery (125 XC US)
Fuse (125 XC US)
HJTZ5S-FP-C
58011109110
Lithium-ion battery
Battery voltage: 12 V
Nominal capacity: 2.0 Ah
Maintenance-free
10 A
21.7
Tires
Validity
(All SX models)
(125 XC US)
Front tire
80/100 - 21 51M TT
Dunlop MX33 F
80/100 - 21 51M M+S TT
Dunlop GEOMAX AT 81 F
Rear tire
100/90 - 19 57M TT
Dunlop MX33
110/100 - 18 64M M+S TT
Dunlop GEOMAX AT 81
The tires specified represent one of the possible series production tires. Additional information is available in the Service section under:
KTM.COM
21.8
Fork
21.8.1
All SX models
Fork article number
Fork
Compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Air pressure
Fork length
34.18.8U.01
WP XACT 5448
17 clicks
12 clicks
7 clicks
17 clicks
12 clicks
7 clicks
8.3 bar (120 psi)
950 mm (37.4 in)
135
21 TECHNICAL DATA
Oil capacity external mechanism left
Oil capacity external mechanism right
Grease capacity, left cartridge
Oil capacity, right cartridge
230 + 10
50 ml (7.78
+ 0.34
1.69
fl. oz.)
230 + 10 ml (7.78
+ 0.34
fl. oz.)
5 g (0.18 oz)
380 ml (12.85 fl. oz.)
Fork oil (SAE 4) (48601166S1)
Fork oil (SAE 4) (48601166S1)
Special grease (00062010053)
Fork oil (SAE 4) (48601166S1)
21.8.2
125 XC US
Fork article number
Fork
Compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Air pressure
Fork length
Oil capacity external mechanism left
Oil capacity external mechanism right
Grease capacity, left cartridge
Oil capacity, right cartridge
34.18.8U.71
WP XACT 5448
17 clicks
12 clicks
7 clicks
30 clicks
25 clicks
20 clicks
8 bar (116 psi)
950 mm (37.4 in)
230 + 10
50 ml (7.78
+ 0.34
1.69
fl. oz.)
230 + 10 ml (7.78
5 g (0.18 oz)
+ 0.34
380 ml (12.85 fl. oz.) fl. oz.)
Fork oil (SAE 4) (48601166S1)
Fork oil (SAE 4) (48601166S1)
Special grease (00062010053)
Fork oil (SAE 4) (48601166S1)
21.9
Shock absorber
21.9.1
All SX models
Shock absorber article number
Shock absorber
Lowspeed compression damping
Comfort
Standard
Sport
Highspeed compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
18.18.7U.01
WP XACT 5750
17 clicks
15 clicks
13 clicks
2 turns
1.5 turns
1 turn
17 clicks
136
Standard
Sport
Spring preload
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
Spring length
Weight of rider: 65 … 75 kg (143 … 165 lb.)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
Gas pressure
Static sag
Riding sag
Fitted length
Shock absorber fluid ( p. 141)
21.9.2
125 XC US
Shock absorber article number
Shock absorber
Lowspeed compression damping
Comfort
Standard
Sport
Highspeed compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
Sport
Spring preload
Spring rate
Weight of rider: 65 … 75 kg (143 … 165 lb.)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
Spring length
Weight of rider: 65 … 75 kg (143 … 165 lb.)
Weight of rider: 75 … 85 kg (165 … 187 lb.)
Weight of rider: 85 … 95 kg (187 … 209 lb.)
Gas pressure
Static sag
Riding sag
Fitted length
15 clicks
13 clicks
7 mm (0.28 in)
36 N/mm (206 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
255 mm (10.04 in)
260 mm (10.24 in)
260 mm (10.24 in)
10 bar (145 psi)
35 mm (1.38 in)
105 mm (4.13 in)
477 mm (18.78 in)
SAE 2.5
18.18.7U.71
WP XACT 5750
17 clicks
15 clicks
13 clicks
2.5 turns
2 turns
1.5 turns
17 clicks
15 clicks
13 clicks
7 mm (0.28 in)
36 N/mm (206 lb/in)
39 N/mm (223 lb/in)
42 N/mm (240 lb/in)
255 mm (10.04 in)
260 mm (10.24 in)
260 mm (10.24 in)
10 bar (145 psi)
35 mm (1.38 in)
105 mm (4.13 in)
477 mm (18.78 in)
TECHNICAL DATA 21
137
21 TECHNICAL DATA
Shock absorber fluid ( p. 141)
SAE 2.5
21.10
Chassis tightening torques
Hose clamp, radiator
Screw, seat fixing
Screw, stop button
Hose clip, inlet sleeve to carburetor
Screw, carburetor cover
Screw, fixed grip
EJOT EJOFORM PT ® K60x23/18
M3
M4
M4
M4
Screw, service hour counter
Spoke nipple, front wheel
Spoke nipple, rear wheel
Remaining nuts, chassis
Remaining screws, chassis
Screw, shock absorber adjusting ring
Screws on main silencer
Nut, carburetor cover on throttle cable wire
M5
M6
Remaining nuts, chassis
Remaining screws, chassis
M6
M6
Screw, absorbing element on frame M6
Screw, absorbing element on manifold
M6
M6 Screw, ball joint of push rod on foot brake cylinder
Screw, brake lever M6
M6 Screw, chain guide on link fork at the rear
Screw, chain sliding guard M6
M4
M4.5
M4.5
M5
M5
M5
Screw, clutch lever
Screw, front brake disc
M6
M6
Screw, fuel tank spoiler on radiator M6
Screw, rear brake disc M6
Screw, throttle grip
Nut, foot brake lever stop
Nut, rear sprocket screw
M6
M8
M8
Nut, rim lock
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom triple clamp
M8
M8
M8
M8
2.4 Nm (1.77 lbf ft)
2.5 Nm (1.84 lbf ft)
0.4 Nm (0.3 lbf ft)
2.8 Nm (2.07 lbf ft)
1.3 Nm (0.96 lbf ft)
5 Nm (3.7 lbf ft)
Loctite ® 243™
0.8 Nm (0.59 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
7 Nm (5.2 lbf ft)
3 Nm (2.2 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
Loctite ® 243™
5 Nm (3.7 lbf ft)
10 Nm (7.4 lbf ft)
Loctite ® 243™
10 Nm (7.4 lbf ft)
Loctite ® 243™
5 Nm (3.7 lbf ft)
14 Nm (10.3 lbf ft)
Loctite ® 243™
6 Nm (4.4 lbf ft)
14 Nm (10.3 lbf ft)
Loctite ® 243™
5 Nm (3.7 lbf ft)
20 Nm (14.8 lbf ft)
35 Nm (25.8 lbf ft)
Loctite ® 2701™
12 Nm (8.9 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
12 Nm (8.9 lbf ft)
138
Screw, chain sliding piece
Screw, engine brace on engine
Screw, engine brace on frame
Screw, engine sprocket cover on frame
Screw, fork stub
Screw, front brake caliper
Screw, handlebar clamp
Screw, manifold
Screw, subframe bottom
Screw, subframe top
Screw, top steering stem
Screw, top triple clamp
Engine bracket screw
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom shock absorber
Screw, handlebar support
Screw, top shock absorber
Nut, angle lever to link fork
Nut, frame on linkage lever
Nut, linkage lever on angle lever
Nut, fork pivot
Screw, front wheel spindle
Screw, top steering head
Screw-in fitting, cooling system
Nut, rear wheel spindle
M8
M8x20
M8x15
M8
M8
M8
M8
M8
M8x18
M8x20
M8
M8
M10
M10
M10
M10
M10
M10
M14x1.5
M14x1.5
M14x1.5
M16x1.5
M20x1.5
M20x1.5
M24x1.5
M25x1.5
TECHNICAL DATA 21
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
Loctite ® 243™
25 Nm (18.4 lbf ft)
Loctite ® 2701™
15 Nm (11.1 lbf ft)
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
Loctite ® 243™
20 Nm (14.8 lbf ft)
15 Nm (11.1 lbf ft)
30 Nm (22.1 lbf ft)
Loctite ® 2701™
35 Nm (25.8 lbf ft)
Loctite ® 2701™
20 Nm (14.8 lbf ft)
Loctite ® 243™
17 Nm (12.5 lbf ft)
60 Nm (44.3 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
60 Nm (44.3 lbf ft)
Loctite ® 2701™
40 Nm (29.5 lbf ft)
Loctite ® 243™
60 Nm (44.3 lbf ft)
60 Nm (44.3 lbf ft)
60 Nm (44.3 lbf ft)
60 Nm (44.3 lbf ft)
100 Nm (73.8 lbf ft)
35 Nm (25.8 lbf ft)
12 Nm (8.9 lbf ft)
18 Nm (13.3 lbf ft)
Loctite ® 2701™
Loctite ® 243™
80 Nm (59 lbf ft)
139
22 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1
Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX ®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that has the relevant properties.
Antifreeze protection to at least − 25 °C ( − 13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.
Recommended supplier
MOTOREX ®
– COOLANT M3.0
Engine oil (15W/50)
Standard/classification
–
–
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
Recommended supplier
MOTOREX ®
– Top Speed 4T
Engine oil, 2-stroke
Standard/classification
–
Guideline
– Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
140
SUBSTANCES 22
Recommended supplier
MOTOREX ®
– Cross Power 2T
Fork oil (SAE 4) (48601166S1)
Standard/classification
–
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
–
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Super unleaded (ROZ 98 / RON 98 / PON 94)
Standard/classification
– DIN EN 228 (ROZ 98 / RON 98 / PON 94)
Super unleaded (98 octane) mixed with 2-stroke engine oil (1:40)
Standard/classification
– DIN EN 228
–
Mixture ratio
1:40
Engine oil, 2-stroke ( p. 140)
Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 141)
Recommended supplier
MOTOREX ®
– Cross Power 2T
141
23 AUXILIARY SUBSTANCES
Air filter cleaner
Recommended supplier
MOTOREX ®
– Racing Bio Dirt Remover
Chain cleaner
Recommended supplier
MOTOREX ®
– Chain Clean
Fuel additive
Recommended supplier
MOTOREX ®
– Fuel Stabilizer
High viscosity grease
Recommended supplier
SKF ®
– LGHB 2
Long-life grease
Recommended supplier
MOTOREX ®
– Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX ®
– Moto Clean
Off-road chain spray
Recommended supplier
MOTOREX ®
– Chainlube Offroad
Oil for foam air filter
Recommended supplier
MOTOREX ®
– Racing Bio Liquid Power
Preserving materials for paints, metal and rubber
Recommended supplier
MOTOREX ®
– Moto Protect
142
AUXILIARY SUBSTANCES 23
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX ®
– Quick Cleaner
Special grease (00062010053)
Recommended supplier
Klüber Lubrication ®
– KLÜBERFOOD NH1 34 ‑ 401
Universal oil spray
Recommended supplier
MOTOREX ®
– Joker 440 Synthetic
143
24 STANDARDS
JASO T903 MA2
Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
144
Art. no.
ca.
cf.
e.g.
etc.
i.a.
no.
poss.
Article number circa compare for example et cetera inter alia number possibly
LIST OF ABBREVIATIONS 25
145
INDEX
INDEX
1
12 V battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 97
12-V battery
charging . . . . . . . . . . . . . . . . . . . . . . . . . . 98
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 63
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 64
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Air filter box
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Air filter box cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 62
preparing for securing . . . . . . . . . . . . . . . . . 64
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Air suspension XACT 5448
. . . . . . . . . . . . . . . . . 37
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . 102
Auxiliary substances
. . . . . . . . . . . . . . . . . . . . . 10
B
Basic chassis setting
checking with rider's weight . . . . . . . . . . . . . 37
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . 81
rear brake, adding . . . . . . . . . . . . . . . . . . . 86
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . 80
rear brake, checking . . . . . . . . . . . . . . . . . . 86
Brake linings
C
Capacity
Carburetor
Adjusting the idle speed . . . . . . . . . . . . . . 112
float chamber, emptying . . . . . . . . . . . . . . 115
idle setting . . . . . . . . . . . . . . . . . . . . . . . 111
Carburetor tuning
. . . . . . . . . . . . . . . . . . . . . . 109
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 70
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Choke
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Clutch
fluid level, checking/correcting . . . . . . . . . . . 76
fluid, changing . . . . . . . . . . . . . . . . . . . . . . 77
Clutch lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
basic position, adjusting . . . . . . . . . . . . . . . 76
Compression damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 45
Coolant
changing . . . . . . . . . . . . . . . . . . . . . . . . . 106
draining . . . . . . . . . . . . . . . . . . . . . . . . . 104
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . 102-103
Cooling system
. . . . . . . . . . . . . . . . . . . . . . . . 101
Customer service
. . . . . . . . . . . . . . . . . . . . . . . 10
D
Defined use
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Difficult operating conditions
. . . . . . . . . . . . . . . . 23
dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . 24
high temperatures . . . . . . . . . . . . . . . . . . . 27
low temperature . . . . . . . . . . . . . . . . . . . . . 28
snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . 25
wet surfaces . . . . . . . . . . . . . . . . . . . . . . . 27
E
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine number
. . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Environment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F
Figures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Filling up
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Foot brake lever
. . . . . . . . . . . . . . . . . . . . . . . . 20
basic position, adjusting . . . . . . . . . . . . . . . 85
146
free travel, checking . . . . . . . . . . . . . . . . . . 85
Fork
air pressure, adjusting . . . . . . . . . . . . . . . . . 44
article number . . . . . . . . . . . . . . . . . . . . . . 13
basic setting, checking . . . . . . . . . . . . . . . . 43
Fork legs
Fork protector
Frame
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Front fender
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 92
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 67
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel tank filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fuel tap
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel, oils, etc.
. . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuse
main fuse, changing . . . . . . . . . . . . . . . . . . 99
G
Gear oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . 117
changing . . . . . . . . . . . . . . . . . . . . . . . . . 116
Gear oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . 116
H
Hand brake lever
. . . . . . . . . . . . . . . . . . . . . . . 15
Handlebar position
High-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 39
I
Ignition timing map
Implied warranty
. . . . . . . . . . . . . . . . . . . . . . . . 10
Intended use
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
K
Kick starter lever
. . . . . . . . . . . . . . . . . . . . . . . 20
L
Link fork
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Lower triple clamp
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Low-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 38
M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Main silencer
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manufacturer warranty
. . . . . . . . . . . . . . . . . . . . 10
Misuse
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 119
O
Owner's Manual
. . . . . . . . . . . . . . . . . . . . . . . . . 9
P
Play in throttle cable
Plug-in stand
. . . . . . . . . . . . . . . . . . . . . . . . . . 20
Preparing for use
advice on preparing for first use . . . . . . . . . . 22
after storage . . . . . . . . . . . . . . . . . . . . . . 122
checks and maintenance measures when
preparing for use . . . . . . . . . . . . . . . . . . . . 29
Protective clothing
. . . . . . . . . . . . . . . . . . . . . . . 8
R
Radiator cover
removing . . . . . . . . . . . . . . . . . . . . . . . . . 102
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 93
147
INDEX
INDEX
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 45
shock absorber, adjusting . . . . . . . . . . . . . . 39
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rubber grip
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 75
S
Safe operation
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seat
Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service hour counter
. . . . . . . . . . . . . . . . . . . . . 21
Shift lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
basic position, adjusting . . . . . . . . . . . . . . 114
basic position, checking . . . . . . . . . . . . . . 113
Shock absorber
article number . . . . . . . . . . . . . . . . . . . . . . 14
compression damping, general . . . . . . . . . . . 38
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 58
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 57
riding sag, checking . . . . . . . . . . . . . . . . . . 41
spring preload, adjusting . . . . . . . . . . . . . . . 42
static sag, checking . . . . . . . . . . . . . . . . . . 41
Side stand
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spare parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Start button
. . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start number plate
Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Steering head bearing
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 55
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 55
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Stop button
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
T
Technical accessories
. . . . . . . . . . . . . . . . . . . . 10
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . 134
carburetor . . . . . . . . . . . . . . . . . . . . . . . . 128
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 134
chassis tightening torques . . . . . . . . . . . . . 138
electrical system . . . . . . . . . . . . . . . . . . . 135
engine . . . . . . . . . . . . . . . . . . . . . . . . . . 125
engine tightening torques . . . . . . . . . . . . . 126
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
shock absorber . . . . . . . . . . . . . . . . . . . . . 136
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Throttle grip
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Transporting
. . . . . . . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting
. . . . . . . . . . . . . . . . . . . . 123-124
Type label
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
V
Vehicle identification number
. . . . . . . . . . . . . . . 13
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . 11
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 12
W
Work rules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
148
*3214411en*
3214411en
05/2021
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
KTM.COM
Photo: Mitterbauer/KISKA/KTM
Shkarko
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