KTM 125 SX EU 2015 Owner'S Manual Download

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BRAKE SYSTEM

L00956-11

–

Correct the brake fluid quantity to level



Guideline

Dimension



(brake fluid level below

top edge of container)

5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 (

p. 119)

–

Position the cover with the membrane. Mount and tighten the screws.

Info

Wash off overflowed or spilled brake fluid immediately with water.

12.8

Checking the free travel of foot brake lever

Warning

Danger of accidents

Brake system failure.

–

If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust the free travel on foot brake lever according to specifications.

402026-10

–

Disconnect spring



–

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



Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the foot brake lever.

(

p. 67)

–

Reconnect spring



12.9

Adjusting the basic position of the foot brake lever

Warning

Danger of accidents

Brake system failure.

–

402026-10

–

Disconnect spring



B02113-10

–

Loosen nut



and, with push rod



, turn it back until you have maximum free

travel.

–

To adjust the basic position of the foot brake lever individually, loosen nut



and

turn screw



accordingly.

Info

The range of adjustment is limited.

–

Turn push rod



accordingly until you have free travel



. If necessary, adjust

the basic position of the foot brake lever.
Guideline

Free travel at foot brake lever

3… 5 mm (0.12… 0.2 in)

Summary of Contents for 125 SX EU 2015

Page 1: ...OWNER S MANUAL 2015 125 SX EU 125 SX US 150 SX EU 150 SX US 250 SX EU 250 SX US 250 XC EU US 300 XC EU US Art no 3213173en...

Page 2: ......

Page 3: ...s 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 witho...

Page 4: ...VICE SCHEDULE 27 9 1 All SX models 27 9 1 1 Service schedule 27 9 1 2 Service work as additional order 28 9 2 All XC models 28 9 2 1 Service schedule 28 9 2 2 Service work as additional order 29 10 TU...

Page 5: ...echarging the battery x All XC models 77 14 4 Changing the main fuse All XC models 78 15 COOLING SYSTEM 79 15 1 Cooling system 79 15 2 Radiator cover All SX models 79 15 3 Installing the radiator cove...

Page 6: ...ork 113 21 8 1 125 SX EU 150 SX EU 113 21 8 2 125 SX US 150 SX US 114 21 8 3 250 SX EU 114 21 8 4 250 SX US 114 21 8 5 All XC models 115 21 9 Shock absorber 115 21 9 1 125 150 SX 115 21 9 2 250 SX EU...

Page 7: ...tanding In the interest of your own safety have these jobs performed by an authorized KTM workshop There your motorcycle will be opti mally cared for by specially trained experts using the specialist...

Page 8: ...r 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 Ide...

Page 9: ...ered under the number in paren theses E g bearing puller 15112017000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings pins lock washers must be replaced...

Page 10: ...KTM PowerParts for your vehicle can be found on the KTM website International KTM Website http www ktm com 3 4 Service A prerequisite for perfect operation and prevention of premature wear is that the...

Page 11: ...EHICLE 9 4 1 View of the vehicle from the left front example B02068 10 1 Hand brake lever p 12 2 Kill switch p 12 3 Clutch lever p 12 4 Air filter box lid 5 Fuel tap 6 Choke p 15 7 Shift lever p 15 8...

Page 12: ...vehicle rear right example B02069 10 1 Seat 2 Filler cap 3 Throttle grip p 12 4 Shock absorber rebound adjustment 5 Level viewer for brake fluid rear 6 Shock absorber compression adjustment 7 Foot bra...

Page 13: ...ering head 5 3 Engine number 401949 10 The engine number is stamped on the left side of the engine under the engine sprocket 5 4 Fork part number 401947 10 The fork part number is stamped on the inner...

Page 14: ...brake lever is located on the right side of the handlebar The hand brake lever is used to activate the front brake 6 3 Throttle grip L00932 11 Throttle grip is fitted on the right side of the handleb...

Page 15: ...uctions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If contact occur...

Page 16: ...until the release button engages Info Run the fuel tank breather hose without kinks 6 8 Fuel tap All SX models B02072 10 The fuel tap is on the left side of the fuel tank With tap handle on the fuel...

Page 17: ...es fully 6 10 Choke L00934 10 The choke is fitted on the left side of the carburetor Activating the choke function frees an opening in the carburetor through which the engine can draw extra fuel This...

Page 18: ...can be swiveled 6 13 Foot brake lever 401956 10 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 6 14 Plug in stand All SX models 0 0...

Page 19: ...6 CONTROLS 17 401944 10 The side stand is used to park the motorcycle Info When you are riding side stand must be folded up and secured with rubber band...

Page 20: ...Take your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misap...

Page 21: ...t or replace parts before the next scheduled service Seal the air filter box x p 51 Secure the air filter box lid x p 50 Clean the air filter and air filter box x p 49 Info Check the air filter approx...

Page 22: ...sand regularly replace the piston every 10 operating hours 7 5 Preparations for riding on wet sand 600872 10 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the displayed value does...

Page 23: ...t radiator fins 7 7 Preparations for riding at high temperatures and low speeds 600872 10 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the displayed value does not equal the setp...

Page 24: ...r in snow B00437 01 Mount the rain cover for the air filter Rain cover for air filter 59006021000 Info Follow the KTM PowerParts mounting instructions Adjust the carburetor jetting and setting Info Yo...

Page 25: ...nger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start...

Page 26: ...f the choke function was activated deactivate it after the engine has warmed up When you reach maximum speed after fully opening the throttle turn back the throttle to about of its range This barely r...

Page 27: ...rk the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Note Material damage Damage to or dest...

Page 28: ...ted areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contaminated with fuel Warning Environmental hazard Improper handling of fuel is...

Page 29: ...correct the fluid level of the hydraulic clutch p 60 Check the front brake fluid level p 64 Check the free travel of the hand brake lever p 63 Check the play of the steering head bearing p 44 Change...

Page 30: ...rvice schedule Every 40 operating hours corresponds to about 280 liters of fuel 74 US gal after every race Every 20 operating hours corresponds to about 140 liters of fuel 37 US gal Check and charge t...

Page 31: ...the idle x Final check Check the vehicle for safe operation and take a test ride Make the service entry in KTM DEALER NET and in the service record x Periodic interval 9 2 2 Service work as additiona...

Page 32: ...peed refer to the compression speed of the rear wheel suspension and not to the vehicle speed The high speed setting for example affects the compression when landing after a jump the rear wheel suspen...

Page 33: ...to increase damping turn counterclockwise to reduce damp ing 10 4 Adjusting the high speed compression damping of the shock absorber Caution Danger of accidents Disassembly of pressurized parts can l...

Page 34: ...nts Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help B02...

Page 35: ...5 150 SX 30 mm 1 18 in Static sag 250 SX EU 30 mm 1 18 in Static sag 250 SX US 30 mm 1 18 in Static sag All XC models 30 mm 1 18 in If the static sag is less or more than the specified value Adjust th...

Page 36: ...Turn adjusting ring until the spring is no longer under tension Hook wrench T106S Measure the overall spring length while the spring is not under tension Tighten the spring by turning adjusting ring...

Page 37: ...ght of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Info The spring rate is shown on the outs...

Page 38: ...ase damping turn counterclockwise to reduce damping Mount protection caps B02082 10 All XC models 125 SX US 150 SX US 250 SX US Turn the white adjusting screw all the way clockwise Info Adjusting scre...

Page 39: ...se to increase damping turn counterclockwise to reduce damping Mount protection caps B02084 10 All XC models 125 SX US 150 SX US 250 SX US Turn the red adjusting screw all the way clockwise Info Adjus...

Page 40: ...material fatigue and the handlebar can break Always replace handle bar B00375 10 Remove screws Remove the handlebar clamp Remove the handlebar and lay it to one side Info Protect the motorcycle and i...

Page 41: ...All SX models Remove the motorcycle from the lift stand Remove the lift stand To park the motorcycle insert plug in stand into the left side of the wheel spindle Info Remove the plug in stand before r...

Page 42: ...grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray p 122 Press the dust boots back into their normal positio...

Page 43: ...s Guideline Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Position the brake line Put the clamp on and mount and tighten screws Finishing work Install the front wheel x p 71 11 7 Removing...

Page 44: ...gainst damage by covering them Do not bend the cables and lines B02089 10 Remove O ring Remove protective ring Take out the lower triple clamp with the steering stem Take out the upper steering head b...

Page 45: ...the right fork leg red adjusting screw The compression damping is located in the left fork leg white adjusting screw Grooves are milled into the side of the upper end of the fork legs The second mill...

Page 46: ...ad bearing play without delay Your authorized KTM workshop will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can bec...

Page 47: ...p to avoid strains Tighten screws Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check...

Page 48: ...e fender Position the brake line Position the clamp and mount and tighten screw 11 16 Removing the front fender Preparatory work Remove the start number plate p 45 B02097 10 Main work Remove screws an...

Page 49: ...19 Installing the shock absorber x B02100 11 Main work Insert the shock absorber from above Position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M10 60 Nm 44 3 lbf ft...

Page 50: ...bushing of the fuel tank lower at the rear and simultaneously push forward Make sure that the seat is correctly locked in 101683 10 Mount and tighten screw of the seat fixation Guideline Remaining scr...

Page 51: ...rdous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Preparatory work Remove the air filter box li...

Page 52: ...x lid p 49 11 26 Installing the air filter x L00943 10 Main work Mount the clean air filter on the air filter support Grease the air filter in area Long life grease p 121 B02102 11 Insert both parts t...

Page 53: ...the main silencer off of the manifold at the rubber sleeve 11 30 Installing the main silencer L00924 11 Mount the main silencer with rubber sleeve Mount and tighten screws Guideline Remaining screws c...

Page 54: ...ds when warm and may emerge if overfilled Follow the instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or c...

Page 55: ...he instructions on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Fuel must not come into contact with the skin eyes or clothing Do not breathe in the fuel vapors If conta...

Page 56: ...rip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and g...

Page 57: ...work Remove the motorcycle from the lift stand p 39 11 37 Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain is too taut the components of th...

Page 58: ...with the specified weight Guideline Weight chain wear measurement 10 15 kg 22 33 lb Measure the distance of 18 chain links in the lower chain section Info Chain wear is not always even so you should...

Page 59: ...the chain guide If the light part of the chain guide is worn Change the chain guide x B02104 01 Check the chain guide for tightness If the chain guide is loose Tighten the chain guide Guideline Remai...

Page 60: ...x p 52 B02106 01 Main work 125 150 SX Check the routing of the throttle cable The throttle cable must be routed along the back of the handlebar to the right of the frame below the fuel tank bracket a...

Page 61: ...the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 121 11 43 Addition...

Page 62: ...correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining discs L00953 10 125 150 SX Move the clutch fluid reservoir mounted on the handl...

Page 63: ...ringe L00953 11 Inject the liquid into the system until it escapes from bore hole of the mas ter cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoi...

Page 64: ...on the handlebar to a horizontal posi tion Remove screws Remove cover with membrane B02111 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DO...

Page 65: ...and brake lever moves away from the handlebar When the adjusting screw is turned counterclockwise the hand brake lever moves closer to the handlebar The range of adjustment is limited Turn the adjusti...

Page 66: ...ue this is an indication that the brake system is leaking or that the brake linings are completely worn down Check the brake system and do not continue riding Your authorized KTM workshop will be glad...

Page 67: ...ake linings for damage and cracking If damage or cracking is visible Change the front brake linings x p 65 12 7 Changing the front brake linings x Warning Danger of accident Brake system failure Maint...

Page 68: ...or DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container L00956 10 Move the brake fluid reservoir mounted o...

Page 69: ...ton and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 67 Reconnec...

Page 70: ...is below the marking Add brake fluid for the rear brake x p 68 12 11 Adding brake fluid for the rear brake x Warning Danger of accidents Brake system failure If the brake fluid level drops below the...

Page 71: ...rear brake linings x p 69 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings x p 69 12 13 Changing the rear brake linings x Warning Skin ir...

Page 72: ...eck that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc 10174...

Page 73: ...eel withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is...

Page 74: ...se the motorcycle with the lift stand p 39 B02119 10 Main work Press the brake caliper onto the brake disc by hand in order to push back the brake piston Info Make sure when pushing back the brake pis...

Page 75: ...orrectly on adjusting screws Check the chain tension p 55 Tighten nut Guideline Nut rear wheel spindle M25x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm 1 18 in enabl...

Page 76: ...and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Ti...

Page 77: ...oke tension varies Correct the spoke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Torque wrench with various ac...

Page 78: ...t p 48 B02135 10 Main work Disconnect negative cable from the battery Pull back the positive terminal cover and disconnect the positive cable from the battery Detach rubber band at the bottom Lift the...

Page 79: ...e of the battery Rapid recharging with a high charging current shortens the battery s service life If the charging current charging voltage and charging time are exceeded electrolyte escapes through t...

Page 80: ...rk Remove screw L01203 10 Lift rear fairing slightly and pull starter relay out of the holder 101397 10 Remove protection caps Remove the faulty main fuse Info A defective fuse can be identified by th...

Page 81: ...g 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 coo...

Page 82: ...cooling system to cool down In case of scalding rinse immediately with lukewarm water Warning Danger of poisoning Coolant is poisonous and a health hazard Coolant must not come into contact with the...

Page 83: ...motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the level of the coolant does not meet...

Page 84: ...olant must not come into contact with the skin eyes or clothing If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin w...

Page 85: ...action system Start the engine and let it run idle 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...

Page 86: ...ottle slide If the engine sputters and smokes heavily when it starts despite a good idle and part load setting and if it abruptly reaches full power at a high rpm the carburetor setting is too rich or...

Page 87: ...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...

Page 88: ...16 6 Plug in connection ignition timing map B02128 10 Plug in connection is located on the frame under the fuel tank Possible states Soft The plug in connection is disconnected to achieve better ridea...

Page 89: ...with yellow marking Auxiliary spring mounted at the factory with medium tuning standard for good rideability Auxiliary spring with green marking Auxiliary spring contained in the separate enclosure f...

Page 90: ...em into the clutch cover together Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring in...

Page 91: ...gear oil x p 91 Mount and tighten the screw in the opening used to check the gear oil level Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft B02132 10 All 250 300 models Remove screw from the...

Page 92: ...n plug with magnet Remove gear oil drain plug Completely drain the gear oil Clean the gear oil drain plug thoroughly Clean the sealing area on the engine Mount the gear oil drain plug with magnet and...

Page 93: ...nishing work Check the gear oil level p 89 17 5 Adding gear oil x Info Too little gear oil or poor quality gear oil results in premature wear of the transmission The gear oil must be added while the e...

Page 94: ...aust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila tion and do not start or run the engine in an enc...

Page 95: ...al motorcycle cleaner and then clean with a soft brush Motorcycle cleaner p 121 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry veh...

Page 96: ...e add fuel additive Fuel additive p 121 Refuel p 26 Clean the motorcycle p 93 Change the gear oil x p 89 Check the antifreeze and coolant level p 80 Empty the carburetor float chamber x p 85 Check the...

Page 97: ...ystem x Kill switch cable in wiring harness frayed kill switch defective Check the kill switch x The connector or ignition coil is loose or oxidized Clean the connector and treat it with contact spray...

Page 98: ...akage Check the coolant level p 81 Too little air stream Switch off engine when stationary Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant x p 81 Re...

Page 99: ...th gear 22 24 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Ignition point BTDC 1 4 mm 0 055 in Spark plug NGK BR9 ECMVX Spark plug electrode...

Page 100: ...on rings 2 half keystone rings X upper edge of piston to upper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 48 mm 1 89 in Primary transmission 26 72 Clutch Multidisc clutch in oil b...

Page 101: ...ake and exhaust control Displacement 293 cm 17 88 cu in Stroke 72 mm 2 83 in Bore 72 mm 2 83 in Exhaust valve Beginning of adjustment 5 600 rpm Exhaust valve end of adjustment with red auxiliary sprin...

Page 102: ...ylinder M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch spring M6 10 Nm 7 4 lbf ft Screw engine case M6 10 Nm 7 4 lbf ft Screw exhaust control M6 10 Nm 7 4 lbf ft Screw gear oil level check M6 10 Nm 7 4...

Page 103: ...sing M6 10 Nm 7 4 lbf ft Screw intermediate wheel bolt M6 8 Nm 5 9 lbf ft Loctite 648 Screw kick starter spring M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctit...

Page 104: ...lbf ft Loctite 648 Screw kick starter spring M6 10 Nm 7 4 lbf ft Loctite 243 Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Sc...

Page 105: ...NOZG NOZI Main jet 182 180 185 Idling jet 42 40 45 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut out 21 3 2 Carburetor basic setting for sandy surfaces 125 SX EU 125...

Page 106: ...21 3 3 Carburetor tuning 125 SX EU 125 SX US 401762 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info N...

Page 107: ...EK Main jet 180 178 182 Idling jet 40 42 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut out 21 3 5 Carburetor basic setting for sandy surfaces 150 SX EU 150 SX US Idle...

Page 108: ...21 3 6 Carburetor tuning 150 SX EU 150 SX US 401763 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info N...

Page 109: ...I Main jet 158 155 160 Idling jet 42 40 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 6 5 with cut out 21 3 8 Carburetor basic setting for sandy surfaces 250 SX EU 250 SX US Idl...

Page 110: ...21 3 9 Carburetor tuning 250 SX EU 250 SX US 401764 01 M FT ASL Sea level TEMP Temperature ASO Open idle air adjusting screw IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info N...

Page 111: ...Needle position 3rd position from top Jet needle N2ZW N2ZH N2ZJ Main jet 175 172 Idling jet 38 40 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut out 21 3 11 Carbureto...

Page 112: ...21 TECHNICAL DATA 110 NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces...

Page 113: ...A Needle position 3rd position from top Jet needle N8RG N8RH Main jet 172 170 175 Idling jet 35 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut out 21 3 13 Carburetor t...

Page 114: ...erve approx All XC models 2 l 2 qt 21 5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork 125 SX EU 150 SX EU 250 SX EU WP Suspension Up Side Down 4860 MXMA CC Fork All XC m...

Page 115: ...11109110 10 A 21 7 Tires Validity Front tires Rear tires 125 150 SX 80 100 21 51M TT Dunlop GEOMAX MX 52 F 100 90 19 57M TT Dunlop GEOMAX MX 52 250 SX EU 250 SX US 80 100 21 51M TT Dunlop GEOMAX MX 52...

Page 116: ...4 48601166S1 p 119 21 8 3 250 SX EU Fork part number 14 18 7O 03 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Rebound damping C...

Page 117: ...clicks Standard 15 clicks Sport 13 clicks Spring length with preload spacer s 480 mm 18 9 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 2 N mm 24 lb in Weight of rider 75 85 kg 165 187 lb 4 4 N...

Page 118: ...fort 17 clicks Standard 15 clicks Sport 13 clicks Spring preload 8 mm 0 31 in Spring rate Weight of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in We...

Page 119: ...Weight of rider 65 75 kg 143 165 lb 51 N mm 291 lb in Weight of rider 75 85 kg 165 187 lb 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Spring length 260 mm 10 24 in Gas pres...

Page 120: ...1 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 2701 Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine bracket screw M10 60 Nm 44 3 lbf ft Remai...

Page 121: ...res Using inferior antifreeze can result in corrosion and foaming Use only coolant based on ethylene glycol Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 dis...

Page 122: ...91 Standard classification DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10...

Page 123: ...e 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...

Page 124: ...23 AUXILIARY SUBSTANCES 122 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic...

Page 125: ...rom the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performan...

Page 126: ...mber 11 Choke 15 Clutch fluid level checking correcting 60 fluid changing 61 Clutch lever 12 basic position adjusting 59 Compression damping fork adjusting 36 Compression damping high speed shock abso...

Page 127: ...eaning 93 raising with lift stand 39 removing from lift stand 39 O Operating substances 8 Owner s Manual 7 P Plug in stand 16 Preparing for use advice on first use 18 after storage 94 checks and maint...

Page 128: ...rques 117 electrical system 113 engine 97 engine tightening torques 100 fork 113 shock absorber 115 tires 113 Throttle cable play adjusting 83 checking 83 Throttle cable routing checking 58 Throttle g...

Page 129: ...3213173en 3213173en 04 2014 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM...

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