KTM 250 SX Owner'S Manual Download

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SERVICE WORK ON THE CHASSIS

M01164-10

–

Remove screw



with the rubber bushing.

–

Pull the hose off the fuel tank breather on the tank lid.

M01182-01

–

Pull both spoilers off of the sides of the radiator bracket and lift off the fuel
tank.

M01185-10

(All 250/300 models)

–

Pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

–

Remove screws



with the collar bushings.

L00951-11

–

Remove screw



with the rubber bushing.

–

Pull the hose off the fuel tank breather on the tank lid.

M01186-01

–

Pull both spoilers off of the sides of the radiator bracket and lift off the fuel
tank.

11.33

Installing the fuel tank

Danger

Fire hazard

Fuel is highly flammable.

–

Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

–

The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.

Summary of Contents for 250 SX

Page 1: ...OWNER S MANUAL 2016 125 SX 150 SX 250 SX 250 XC 300 XC Art no 3213330en ...

Page 2: ......

Page 3: ...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 devi ations from illustrations and descriptions misprints and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of supply 2015 KTM Sportmotorcycle GmbH Mattighofen Aust...

Page 4: ... 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 TUNING THE CHASSIS 30 10 1 Checking the basic chassis setting with the rider s weight 30 10 2 Air suspension AER 48 125 150 SX EU 30 10 3 Compression damping of the shock absorber 31 10 4 Adjusting the low speed compression dampi...

Page 5: ...the battery All XC models 89 14 3 Recharging the battery All XC models 90 14 4 Change the main fuse All XC models 91 15 COOLING SYSTEM 92 15 1 Cooling system 92 15 2 Radiator cover All 125 150 models 92 15 3 Installing the radiator cover All 125 150 models 92 15 4 Removing the radiator cover All 125 150 models 93 15 5 Checking the antifreeze and coolant level 93 15 6 Checking the coolant level 94 ...

Page 6: ...0 SX EU 128 21 8 2 125 150 SX US 128 21 8 3 250 SX EU 128 21 8 4 250 SX US 129 21 8 5 All XC models 129 21 9 Shock absorber 130 21 9 1 125 150 SX EU 130 21 9 2 125 150 SX US 130 21 9 3 250 SX EU 131 21 9 4 250 SX US 131 21 9 5 All XC models 132 21 10 Chassis tightening torques 132 22 SUBSTANCES 134 23 AUXILIARY SUBSTANCES 136 24 STANDARDS 138 25 LIST OF ABBREVIATIONS 139 INDEX 140 ...

Page 7: ...e your motorcycle will be opti mally cared for by specially trained experts using the specialist 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 1 2 Formats used The typographical formats used in this document are explained below Specific name Identifies a proprietary...

Page 8: ...l or serious permanent injury if the appropriate measures are not taken Warning Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measur...

Page 9: ...dered 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 by new parts In some instances a thread locker e g Loctite is required The manufacturer instructions for use must be followed After disassembly clean the parts that are to be reused and check them f...

Page 10: ...M 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 service care and tuning work on the engine and chassis is properly carried out as described in the Owner s Manual Incorrect adjustment and tuning of the engine and chassis can lead to damage and breaka...

Page 11: ... OF VEHICLE 9 4 1 View of vehicle front left example H00044 10 1 Hand brake lever p 12 2 Kill switch p 12 3 Clutch lever p 12 4 Air filter box cover 5 Plug in stand 6 Shift lever p 15 7 Choke p 15 8 Fuel tap ...

Page 12: ... vehicle rear right example H00043 10 1 Seat 2 Filler cap 3 Throttle grip p 12 4 Kick starter p 15 5 Foot brake lever p 16 6 Shock absorber compression adjustment 7 Level viewer for brake fluid rear 8 Shock absorber rebound adjustment ...

Page 13: ...ng 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 side of the fork stub 5 5 Shock absorber article number 0 0 1 1 401948 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring towards the engine side ...

Page 14: ...ll switch M01122 10 The kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start 6 5 Electric starter button All XC models L01200 10 The ele...

Page 15: ...d areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that has been contaminated with fuel Store fuel properly in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system M01123 10 All SX m...

Page 16: ...0 SX 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 Fuel tap All XC models L00904 10 Fuel tap is on the left of the fuel tank 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 ...

Page 17: ...n deactivated The choke lever is pushed in to the stop 6 11 Shift lever 401950 10 Shift lever is mounted on the left of the engine 401950 11 All 125 150 models All XC models The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 401950 13 250 SX The gear positions can be seen in the photograph The neutral or idle position is between the ...

Page 18: ...001 10 The holder for plug in stand is on the left side of the wheel spindle The plug in stand is used to park the motorcycle Info Remove the plug in stand before riding 6 15 Side stand All XC models 401943 10 Side stand is located on the left side of the vehicle 401944 10 The side stand is used for parking the motorcycle Info When you are riding side stand must be folded up and secured with rubbe...

Page 19: ... your foot off the foot brake lever when you are not braking Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may...

Page 20: ... to inspect or replace parts before the next scheduled service Seal the air filter box p 61 Secure the air filter box cover p 60 Clean the air filter and air filter box p 59 Info Check the air filter approx every 30 minutes Additionally secure the rubber grip p 73 Check the electrical connector for humidity and corrosion and to ensure it is firmly seated If humidity corrosion or damage is found Cl...

Page 21: ...dust cover on the air filter Dust cover for air filter 59006019000 Info See the KTM PowerParts fitting instructions M01102 01 Fit a sand cover on the air filter Sand cover for air filter 59006022000 Info See the KTM PowerParts fitting instructions M01107 01 Adjust the carburetor jetting and setting Info Your authorized KTM workshop can recommend the right carburetor tuning 600868 01 Clean the chai...

Page 22: ...with lukewarm water Change the radiator cap M01106 01 All 125 150 models Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the KTM PowerParts fitting instructions M01103 01 All 250 300 models Fit a waterproofing device on the air filter Rain cover for air filter 59006021000 Info See the KTM PowerParts fitting instructions M01107 01 Adjust the car...

Page 23: ...workshop can recommend the right carburetor tuning 600868 01 Fit the steel sprocket Clean the motorcycle p 107 Straighten bent radiator fins carefully 7 7 Preparations for riding at high temperatures and low speeds M01129 01 Check the radiator cap Value on the radiator cap 1 8 bar 26 psi If the displayed value does not equal the setpoint value Warning Danger of scalding During motorcycle operation...

Page 24: ...94 7 8 Preparing for rides at low temperature or in snow M01106 01 All 125 150 models Fit a waterproofing device on the air filter Waterproofing device for air filter 79006921000 Info See the KTM PowerParts fitting instructions M01103 01 All 250 300 models Fit a waterproofing device on the air filter Rain cover for air filter 59006021000 Info See the KTM PowerParts fitting instructions M01107 01 A...

Page 25: ...oisoning 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 or run the engine in an enclosed space without an effective exhaust extraction system Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the...

Page 26: ...ly switch off the engine and contact an authorized KTM workshop First gear is used for starting off or 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 was activated deactivate it after ...

Page 27: ...nger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such as exhaust system radiator engine shock absorber and the brake system Allow these components to cool down before starting work on them Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances ...

Page 28: ...arning 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 occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swallowed contact a physician immediately Change clothing that is contami...

Page 29: ... play of the steering head bearing p 50 Change the piston and check the cylinder and Z dimension All 125 150 models Change the piston and check the cylinder 250 SX Change the piston and check the cylinder and Z dimension under difficult operating conditions All 125 150 mod els Change the piston and check the cylinder under difficult operating conditions 250 SX Change the spark plug and spark plug ...

Page 30: ...dule Every 40 operating hours after every race Every 20 operating hours Check and charge the battery Change the gear oil Check the front brake linings p 77 Check the rear brake linings p 82 Check the brake discs p 75 Check the brake lines for damage and leakage Check the rear brake fluid level p 80 Check the free travel of the foot brake lever p 79 Check the frame and swingarm Check the swingarm b...

Page 31: ...eck the screws and nuts for tightness Check idle Final check Check the vehicle for safe operation and take a test ride Make the service entry in the KTM Dealer net and in the Service and Warranty Booklet Periodic interval 9 2 2 Service work as additional order Annually Every 80 operating hours every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours...

Page 32: ...t 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 signifi cantly 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 ...

Page 33: ...accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The effect of the low speed setting can be seen in slow to normal compression of the shock absorber M01130 10 All 125 150 models Turn adjusting screw clockwise with a screwdriver up to the las...

Page 34: ...ead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The effect of the high speed setting can be seen in fast compression of the shock absorber M01131 10 All 125 150 models Turn adjusting screw all the way clockwise with a socket wrench Info Do not loosen fitting Turn counterclockwise by the ...

Page 35: ...turns Compression damping high speed All XC models Comfort 2 5 turns Standard 2 turns Sport 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 Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description...

Page 36: ...Standard 15 clicks Sport 13 clicks Rebound damping All XC models Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing 10 7 Measuring the rear wheel sag unloaded Preparatory work Raise the motorcycle with a lift stand p 44 402415 10 Main work All 125 150 models Position the sag gauge in the rear axle and measure the di...

Page 37: ...static sag is the difference between measurements and Check the static sag Static sag 125 150 SX EU 35 mm 1 38 in Static sag 125 150 SX US 40 mm 1 57 in If the static sag is less or more than the specified value Adjust the spring preload of the shock absorber p 36 400989 10 All 250 300 models Measure distance of rear wheel unloaded p 34 Hold the motorcycle upright with the aid of an assistant Meas...

Page 38: ...er 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 now measures the distance between the rear axle and the fixed point Note down the value as dimension Info The riding sag is the difference between measurements and Check the riding sag Guideline Riding sag 250 SX...

Page 39: ...w 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 to measurement Guideline Spring preload 250 SX EU 8 mm 0 31 in Spring preload 250 SX US 8 mm 0 31 in Spring preload All XC models 8 mm 0 31 in Info Depending on the static sag and or the riding sag i...

Page 40: ... 54 N mm 308 lb in Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Spring rate 250 SX US 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 rate All XC models 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...

Page 41: ... Ride slowly to start with after making adjustments to get the feel of the new handling characteristic Info Check or adjust the air pressure 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 44 S00861 10 Main work Remo...

Page 42: ... M01187 10 250 SX EU Turn adjusting screws clockwise all the way Info Adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 14 clicks Standard 12 clicks Sport 10 clicks Info Turn clockwise to increase damping turn counterclockwise to r...

Page 43: ...on cap Turn adjusting screw clockwise all the way Info The adjusting screw is located at the lower end of the right fork leg Turn counterclockwise by the number of clicks corresponding to the fork type Guideline Rebound damping Comfort 20 clicks Standard 17 clicks Sport 12 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping Mount protection cap 402496 10 250 SX E...

Page 44: ...ks Sport 13 clicks Rebound damping 250 SX US Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping All XC models Comfort 17 clicks Standard 15 clicks Sport 13 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce damping 10 16 Handlebar position 102144 10 The holes on the handlebar support are placed at a distance of from the center Hole distance A 3 5 mm 0 ...

Page 45: ... nuts from below Place the handlebar support in the required position Mount and tighten screws Guideline Screw handlebar support M10 40 Nm 29 5 lbf ft Loctite 243 Position the handlebar Info Make sure the cables and wiring are positioned correctly Position the handlebar clamps Mount screws but do not tighten yet Screw the handlebar clamps so that both parts touch at the front and tighten all of th...

Page 46: ...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 0 0 1 1 402001 10 All SX mod...

Page 47: ...a lift stand p 44 Remove the fork protector p 47 M01134 10 Main work Push dust boots 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 Warning Danger of accidents Reduced braking efficiency due to oil or grease on the b...

Page 48: ... side of the upper end of the fork legs The second milled groove from the top must be flush with the top 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 402556 10 250 SX EU Position the fork legs Bleeder screws are positioned toward the front Info Grooves are milled into the side of the upper end of...

Page 49: ...e screws Take off the left fork protector Remove screws Take off the right fork protector 11 8 Installing the fork protector M01116 11 Position the fork protection on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screws Position the fork protector on the right fork leg Mount and tighten screws G...

Page 50: ...p 136 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Check whether the upper steering head seal is correctly positioned Slide on protective ring and O ring M01137 10 Position the upper triple clamp with the handlebar Mount screw but do not tighten yet 0 0 0 A A 0 0 5 5 0 0 A A 0 0 5 5 S00867 11 125 150 SX EU Position the fork legs The air release screw o...

Page 51: ...ting screw The rebound damping is located in the right fork leg REB red adjusting screw 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 top edge of the upper triple clamp M01138 10 Tighten screws Guideline Screw bottom triple clamp M8 12 Nm 8 9 lbf ft M01139 10 Tighten screw Guideline Screw top steering head M20x1 5 12...

Page 52: ...will be glad to help Info If the bike is ridden with play in the steering head bearing the bearing and the bearing seats in the frame can become dam aged over time Preparatory work Raise the motorcycle with a lift stand p 44 400738 11 Main work Move the handlebar to the straight ahead position Move the fork legs to and fro in the direction of travel No play should be noticeable in the steering hea...

Page 53: ...ite 243 Screw top steering stem All XC models M8 17 Nm 12 5 lbf ft Loctite 243 Finishing work Check the play of the steering head bearing p 50 Remove the motorcycle from the lift stand p 44 Mount the handlebar cushion 11 13 Greasing the steering head bearing 800010 10 Remove the lower triple clamp p 47 Install the lower triple clamp p 48 11 14 Removing the start number plate M01142 10 All 125 150 ...

Page 54: ...hten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and clamp Mount and tighten screw 11 16 Removing the front fender Preparatory work Remove the start number plate p 51 M01144 10 Main work Remove screws and Remove the front fender 11 17 Installing the front fender M01144 10 Main work Position the front fender Mount and tighten screws and Guideline Remaining s...

Page 55: ...01146 10 Remove screw Remove fitting Info Raise the wheel slightly to be able to remove the screws more easily M01147 10 Press angle lever toward the rear Press linkage lever downward M01148 10 Remove screws M01149 01 Remove the connecting link of the chain Take off the chain M01150 10 Remove nut and pull out the swingarm pivot Push the swingarm back and secure it against falling over ...

Page 56: ...98 10 All 250 300 models Remove screw Remove fitting B02099 10 Press angle lever toward the rear Press linkage lever downward B02100 10 Remove screw Raise the swingarm slightly and remove the shock absorber in upward direction 11 19 Installing the shock absorber M01152 02 Main work All 125 150 models Carefully position the shock absorber into the vehicle from the bottom ...

Page 57: ... of travel M01153 10 Position the foot brake cylinder Push rod engages in the foot brake cylinder The dust boot is correctly positioned Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft M01154 10 Position the angle lever and linkage lever Mount and tighten screw cap Guideline Nut linkage lever to angle lever M14x1 5 80 Nm 59 lbf ft Info Pay attention to the flat area ...

Page 58: ...screw Guideline Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Finishing work Install the main silencer p 62 Remove the motorcycle from the lift stand p 44 11 20 Removing the seat M01156 10 All 125 150 models Remove screws Raise the rear of the seat pull the seat back and lift it off M01188 10 All 250 300 models Remove screw Raise the rear of the seat pull the seat back and lift it...

Page 59: ...ush it forward Make sure that the seat is correctly locked in M01188 10 Mount and tighten screw Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 22 Removing the air filter box cover M01158 10 All 125 150 models Condition The air filter box cover is secured Remove screw M01158 11 Pull off the air filter box cover in area sideways and remove it toward the front B02101 10 All 250 300 models ...

Page 60: ...into area M01158 10 Condition The air filter box cover is secured Mount and tighten screw Guideline Screw air filter box cover EJOT PT K60x20 Z 3 Nm 2 2 lbf ft EJOT PT screw 0017060204 B02101 12 All 250 300 models Insert the air filter box cover in area and clip it into area B02101 10 Condition The air filter box cover is secured Mount and tighten screws Guideline Screw air filter box cover EJOT P...

Page 61: ...Remove the air filter with the air filter support Remove the air filter from the air filter support 11 25 Cleaning the air filter and air filter box Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since t...

Page 62: ...ter the engine and result in damage L00943 10 All 250 300 models Mount the clean air filter on the air filter support Grease the air filter in area Long life grease p 136 B02102 11 Insert both parts together position them and fasten them using air filter holder The arrow on the marking UP faces up Info If the air filter is not mounted correctly dust and dirt may enter the engine and result in dama...

Page 63: ...25 150 models Seal the air filter box in the marked area 401527 10 All 250 300 models Seal the air filter box in the marked area Finishing work Install the air filter box cover p 58 11 29 Disassembling the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components M01161 10 All 125 150 models R...

Page 64: ...50 300 models Position the main silencer with rubber sleeve Mount and tighten screws with the washers Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 11 31 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 Do not touch hot components Info Over time the fibers of...

Page 65: ...s 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 clothing Do not breathe in the fuel vapors If contact occurs with the eyes rinse with water immediately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fu...

Page 66: ... 11 Remove screw with the rubber bushing Pull the hose off the fuel tank breather on the tank lid M01186 01 Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank 11 33 Installing the fuel tank Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is ...

Page 67: ... 02 All 125 150 models Position the fuel tank and fit the two spoilers to the sides of the radiator bracket Make sure that no cables are trapped or damaged M01164 11 Mount the fuel tank breather Mount and tighten screw with the rubber bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft M01163 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Connect the ...

Page 68: ...g Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life o...

Page 69: ... chain tension does not meet the specification Adjust the chain tension p 67 B02103 10 All 250 300 models Pull the chain at the end of the chain sliding piece upward to measure chain tension Guideline The lower chain section 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 doe...

Page 70: ...8 Checking the chain rear sprocket engine sprocket and chain guide Preparatory work Raise the motorcycle with a lift stand p 44 400227 01 Main work Shift the transmission to idle Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the drivetrain kit Info The engine sprocket rear sprocket and chain should always be replaced together 400987 1...

Page 71: ...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 the screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the...

Page 72: ... 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 the screw on the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft 401760 01 Check the chain guide for wear Info Wear can be seen on the front of the chain guide If the light part of the chain guide ...

Page 73: ...ngarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm Info A damaged swingarm must always be changed Repair of the swingarm is not authorized by KTM 11 41 Checking the routing of the throttle cable Preparatory work Remove the seat p 56 All 125 150 models Turn handle of the fuel tap to the OFF position Figure M01127 10 p 14 250 S...

Page 74: ...s Check the throttle cable routing The throttle cable must be routed along the back of the handlebar to the right of the frame below the fuel tank bracket and to the carburetor The throttle cable must be fixed on the fuel tank bracket with a rubber band If the throttle cable is not routed as specified Correct the throttle cable routing Finishing work Install the fuel tank p 64 Mount the seat p 56 ...

Page 75: ...rn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 11 45 Checking correcting the fluid level of the hydraulic clutch Info The fluid level rises with increasing wear of the clutch facing discs L01222 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level ...

Page 76: ...deline Fluid level below container rim 4 mm 0 16 in Position the cover with the membrane Mount and tighten the screws L01222 10 All 250 300 models Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi tion Remove screws Remove cover with membrane B02111 10 Fill bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 134 On...

Page 77: ...hand 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 adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 12 3 Checking the brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s...

Page 78: ...e 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 to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If...

Page 79: ...brake linings for damage and cracking If damage or cracking is visible Change the front brake linings p 77 12 7 Changing the front brake linings Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with s...

Page 80: ...for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container L00956 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Manually press the brake caliper toward the brake disc to push back the brake pis tons Ensure that brake fluid does n...

Page 81: ...e free travel does not meet specifications Adjust the basic position of the foot brake lever p 79 Reconnect spring 12 9 Adjusting the basic position of the 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 le...

Page 82: ... accidents Brake system failure If the brake fluid level drops below the specified marking or the specified value 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 to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Ch...

Page 83: ...be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake...

Page 84: ...to contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease f...

Page 85: ...nts in the rotation direction of the brake disc M01181 10 Insert the new brake linings insert pin and mount cotter pins Info Always change the brake linings in pairs Make sure that decoupling plate 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 M01179 10 All 125 150 models A...

Page 86: ...l withdraw the wheel spindle Take the front wheel out of the fork Info Do not pull the hand brake lever when the front wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged H00003 10 Remove spacers 13 2 Installing the front wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake discs free of ...

Page 87: ...tory work Raise the motorcycle with a lift stand p 44 H00027 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 piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear...

Page 88: ...ly on adjusting screws Check the chain tension p 67 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 26 in enables different secondary ratios with the same chain length Chain adjusters 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 ...

Page 89: ...r and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life 400695 01 Remove the dust cap Check the tire air pressure when the tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap 13 7 Checking the spoke tension Warnin...

Page 90: ...spoke tension varies Correct the spoke tension 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 accessories in set 58429094000 ...

Page 91: ...at p 56 M01119 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 battery up 14 2 Installing the battery All XC models M01120 10 Main work Insert the battery into the battery compartment with the terminals facing to the front Battery YTX4L BS p 127 Attach rubber b...

Page 92: ...rging with a high charging current shortens the service life of the battery If the charging current charging voltage or charging time is exceeded electrolyte escapes through the safety valves This reduces the battery capacity If the battery is depleted by repeated starting the battery must be charged immediately If the battery is left in a discharged state for an extended period it will become ove...

Page 93: ...10 Main work 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 is indicated by a burned out fuse wire A spare fuse is located in the starter relay Install a new main fuse Fuse 58011109110 p 127 Check that the electrical equipment is functioning properly Tip Insert a spare fus...

Page 94: ...or cap This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 15 2 Radiator cover All 125 150 models M01126 01 The radiator cover is mounted in front of the left radiator between the radia...

Page 95: ... screws chassis M6 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 remove the radiator cap radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with lukewarm water War...

Page 96: ... soap and water If fuel is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children Condition The engine is cold 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the coolant level does not matc...

Page 97: ... If contact occurs with the eyes rinse with water imme diately and contact a physician Immediately clean contaminated areas on the skin with soap and water If fuel is swal lowed contact a physician immediately Change clothing that is contaminated with coolant Keep coolant out of reach of children M01171 10 All 125 150 models Make sure that screw is tightened M01172 10 Position the motorcycle uprig...

Page 98: ...ant p 134 Mount radiator cap Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient venti lation and do not start or run the engine in an enclosed space with out an effective exhaust extraction system Allow the engine to warm up and cool down again Check the coolant level p 94 ...

Page 99: ...ering range The idle speed must not change If the idle speed changes Adjust the play in the throttle cable p 97 16 2 Adjusting the play in the throttle cable Preparatory work Remove the seat p 56 All 125 150 models Turn handle of the fuel tap to the OFF position Figure M01127 10 p 14 250 SX Turn handle of the fuel tap to the OFF position Figure B02072 10 p 14 All XC models Turn handle of the fuel ...

Page 100: ... and by the form of the throttle slide If the engine sputters and smokes heavily when it starts despite a good idle and part load setting and if it abruptly reaches full power at a high rpm the carburetor setting is too rich the float level is too high or the float needle valve is leaky Part load range C Operation with the throttle slide partially open This range is influenced by the jet needle fo...

Page 101: ...speed 1 400 1 500 rpm Turn idle air adjusting screw slowly in a clockwise direction until the idle speed begins to fall Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed 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 a...

Page 102: ...igure M01175 10 p 100 Soft better rideability All 250 300 models Disconnect the plug in connector of the ignition timing map Figure B02128 10 p 100 Soft better rideability Switch the ignition timing map from Soft to Performance All 125 150 models Connect the plug in connector of the ignition timing map Figure M01175 10 p 100 Performance better performance All 250 300 models Connect the plug in con...

Page 103: ...t side of the engine below the water pump cover Possible states Auxiliary spring with yellow marking Auxiliary spring mounted at the factory with medium tuning standard for good rideability Auxiliary spring with green marking Auxiliary spring for even softer performance Auxiliary spring with red marking Auxiliary spring for aggressive performance The engine characteristic can be influenced by diff...

Page 104: ...n them together in the clutch cover Auxiliary spring with yellow marking 54637072300 Auxiliary spring with green marking 54837072100 Auxiliary spring with red marking 54837072000 The recess in spring insert engages in the angle lever Info Screw must not be turned as this would worsen the engine characteris tic Check the O ring in the cap Position the cap Mount and tighten the screws Guideline Scre...

Page 105: ...y in a suitable canister and keep away from children Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Info Carry out this work with a cold engine Water in the float chamber results in malfunctioning Preparatory work All 125 150 models Turn handle of the fuel tap to the OFF position F...

Page 106: ...ar oil runs out Add gear oil p 106 Mount and tighten the gear oil monitoring screw Guideline Screw gear oil level check M6 10 Nm 7 4 lbf ft 17 3 Changing the gear oil 400721 01 Drain the gear oil p 104 400722 01 Refill with gear oil p 105 17 4 Draining the gear oil Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden Wear appropriate protective clothing and...

Page 107: ...fully Thoroughly clean the gear oil drain plug with magnet Clean the sealing surface on the engine Mount and tighten gear oil drain plug with magnet and seal ring Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft 17 5 Refilling with gear oil Info Too little gear oil or poor quality oil results in premature wear of the transmission 0 0 1 1 401955 10 Main work Remove filler plug an...

Page 108: ...t emerges from the drilled hole of the gear oil monitoring screw Engine oil 15W 50 p 134 Mount and tighten the gear oil monitoring screw Guideline All 125 150 models Screw gear oil level check M6 8 Nm 5 9 lbf ft All 250 300 models Screw gear oil level check M6 10 Nm 7 4 lbf ft Mount and tighten filler plug Finishing work Danger Danger of poisoning Exhaust gases are toxic and inhaling them may resu...

Page 109: ...rmal motorcycle cleaner and then clean with a soft brush Motorcycle cleaner p 136 Info Use warm water containing normal motorcycle cleaner and a soft sponge Never apply motorcycle cleaner to the dry vehicle always rinse with water first After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber p 103 Remove the plug from the exhaust system ...

Page 110: ... of service add fuel additive Fuel additive p 136 Refuel p 26 Clean the motorcycle p 107 Change the gear oil p 104 Check the antifreeze and coolant level p 93 Empty the carburetor float chamber p 103 Check the tire air pressure p 87 All XC models Remove the battery p 89 All XC models Recharge the battery p 90 Guideline Storage temperature of battery with out direct sunshine 0 35 C 32 95 F Store th...

Page 111: ...m Kill switch cable in wiring harness frayed kill switch defective Check the kill switch The connector or ignition coil is loose or oxidized Clean the connector and treat it with contact spray Water in carburetor or jets blocked Check set the carburetor components Engine has no idle Idling jet blocked Check set the carburetor components Adjusting screws on carburetor dis torted Carburetor adjust t...

Page 112: ... Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level p 94 Too little air stream Switch off engine when stationary Radiator fins very dirty Clean the radiator fins Foam formation in cooling system Drain the coolant p 94 Refill with coolant p 95 Damaged cylinder head or cylinder head gasket Check the cylinder head and cylinder head gas k...

Page 113: ...3 Sixth gear 22 24 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Spark plug NGK BR9 ECMVX Spark plug electrode gap 0 60 mm 0 0236 in Starting aid Kick starter 21 1 2 All 150 models Design 1 cylinder 2 stroke engine water cooled with reed intake and exhaust control Displacement 144 cm 8 79 cu in Stroke 54 5 mm 2 146 in Bore 58 mm 2 28 in Cr...

Page 114: ...pper edge of cylinder 0 0 10 mm 0 0 0039 in Z height of control flap 48 mm 1 89 in Primary transmission 26 72 Clutch Multidisc clutch in oil bath hydraulically activated Gearbox 5 gear claw shifted Transmission ratio First gear 14 28 Second gear 15 24 Third gear 18 24 Fourth gear 21 24 Fifth gear 22 21 Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type...

Page 115: ...aust valve Beginning of adjustment 5 550 rpm Exhaust valve end of adjustment with red auxiliary spring 7 200 rpm Exhaust valve end of adjustment with yellow auxiliary spring 7 900 rpm Exhaust valve end of adjustment with green auxiliary spring 8 400 rpm Crankshaft bearing 1 grooved ball bearing 1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast P...

Page 116: ...m 7 4 lbf ft Screw gear oil level check M6 8 Nm 5 9 lbf ft Screw intake flange reed valve housing M6 10 Nm 7 4 lbf ft Screw kick starter stop plate M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 14 Nm 10 3 lbf ft Loctite 243 Screw stop plate of exhaust control M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft ...

Page 117: ... cylinder base M10 35 Nm 25 8 lbf ft Drain plug water pump cover M10x1 15 Nm 11 1 lbf ft Nut rotor M12x1 60 Nm 44 3 lbf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Spark plug M14x1 25 25 Nm 18 4 lbf ft Nut inner clutch hub M18x1 5 120 Nm 88 5 lbf ft Loctite 648 Nut primary gear M18LHx1 5 150 Nm 110 6 lbf ft Loctite 648 21 2 3 All XC models Screw inner membrane sheets EJOT DELTA PT...

Page 118: ...3 Screw slave cylinder of the clutch M6 10 Nm 7 4 lbf ft Screw starter motor M6 8 Nm 5 9 lbf ft Screw stator M6 8 Nm 5 9 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Screw cylinder head M8 27 Nm 19 9 lbf ft Screw kick starter M8 25 Nm 18 4 lbf ft Loctite 2701 Nut cylinder base M10 35 Nm 25 8 lbf ft Drain plug water pump cover M10x1 15 Nm 11 1 lbf ft Nut rotor M12x1 60 Nm 44 3 lbf ...

Page 119: ...F N1EE N1EG Main jet 182 180 185 Idling jet 50 48 52 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 All 125 models Idle air adjusting screw Open 1 turn Idling jet 52 Jet needle N1EE Needle position 4th position from top Main jet 192 Info If the engine is not running smoothly use a smaller main jet ...

Page 120: ... 3 180 2 45 N1E G 3 178 2 45 N1E G 2 178 1 500 m 5 000 ft 751 m 2 501 ft ASO IJ NDL POS MJ 2 52 N1E F 4 185 2 52 N1E F 3 185 2 50 N1E F 3 182 2 48 N1E F 3 182 2 48 N1E G 3 180 2 45 N1E G 3 178 750 m 2 500 ft 301 m 1 001 ft ASO IJ NDL POS MJ 2 52 N1E E 4 188 2 52 N1E F 4 185 2 52 N1E F 3 185 2 50 N1E F 3 182 2 48 N1E F 3 182 2 48 N1E G 3 180 300 m 1 000 ft 0 m 0 ft ASO IJ NDL POS MJ 1 52 N1E E 4 19...

Page 121: ...N0ZF Main jet 180 182 185 Idling jet 45 48 50 Starting jet 85 Idle air adjusting screw Open 1 turn Throttle slide 7 with cut out 21 3 5 Carburetor basic setting for sandy surfaces All 150 models Idle air adjusting screw Open 1 turn Idling jet 52 Jet needle N0ZE Needle position 4th position from top Main jet 190 Info If the engine is not running smoothly use a smaller main jet ...

Page 122: ...3 180 2 45 N0Z H 3 178 2 45 N0Z H 2 178 1 500 m 5 000 ft 751 m 2 501 ft ASO IJ NDL POS MJ 1 50 N0Z E 4 185 1 5 50 N0Z F 4 182 1 48 N0Z F 3 182 1 45 N0Z G 3 180 2 45 N0Z G 3 180 2 45 N0Z H 3 178 750 m 2 500 ft 301 m 1 001 ft ASO IJ NDL POS MJ 1 52 N0Z E 4 188 1 50 N0Z E 4 185 1 5 50 N0Z F 4 182 1 48 N0Z F 3 182 1 45 N0Z G 3 180 2 45 N0Z G 3 180 300 m 1 000 ft 0 m 0 ft ASO IJ NDL POS MJ 1 52 N0Z E 5...

Page 123: ...EG Main jet 158 160 162 Idling jet 42 45 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 Idle air adjusting screw Open 1 5 turns Idling jet 45 Jet needle N1EF Needle position 5th position from top Main jet 170 Info If the engine is not running smoothly use a smaller main jet ...

Page 124: ...2 40 N1E I 3 155 2 40 N1E I 2 155 1 500 m 5 000 ft 751 m 2 501 ft ASO IJ NDL POS MJ 2 45 N1E F 4 162 2 45 N1E G 4 160 2 42 N1E G 4 158 2 42 N1E H 4 158 2 42 N1E H 3 158 2 40 N1E I 3 155 750 m 2 500 ft 301 m 1 001 ft ASO IJ NDL POS MJ 1 5 48 N1E F 4 165 2 45 N1E F 4 162 2 45 N1E G 4 160 2 42 N1E G 4 158 2 42 N1E H 4 158 2 42 N1E H 3 158 300 m 1 000 ft 0 m 0 ft ASO IJ NDL POS MJ 1 5 48 N1E E 5 168 1...

Page 125: ...A 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 Carburetor tuning 250 XC 402140 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet ...

Page 126: ...21 TECHNICAL DATA 124 NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces ...

Page 127: ...7_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 tuning 300 XC 402141 01 M FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet ...

Page 128: ...ty approx All XC models 10 l 2 6 US gal Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 p 135 Fuel reserve approx All XC models 2 l 2 qt 21 5 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork 125 150 SX EU WP Performance Systems Upside down AER 48 Fork 125 150 SX US WP Performance Systems Up Side Down 4860 MXMA 4CS Fork 250 SX EU WP Performance Systems Upsid...

Page 129: ...300 models 992 mm 39 06 in Ground clearance unloaded All 125 150 models 375 mm 14 76 in Ground clearance unloaded All 250 300 models 385 mm 15 16 in Weight without fuel approx 125 150 SX EU 87 8 kg 193 6 lb Weight without fuel approx 125 150 SX US 89 2 kg 196 7 lb Weight without fuel approx 250 SX 95 9 kg 211 4 lb Weight without fuel approx All XC models 100 7 kg 222 lb Maximum permissible front a...

Page 130: ...80 ml 12 85 fl oz Fork oil SAE 4 48601166S1 p 134 21 8 2 125 150 SX US Fork part number 24 18 7P 51 Fork WP Performance Systems Up Side Down 4860 MXMA 4CS Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring length with preload spacer s 475 mm 18 7 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 0 ...

Page 131: ... 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 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6 N mm 26 3 lb in Weight of rider 85 95 kg 187 209 lb 4 8 N mm 27 4 lb in Fork length 940 mm 37 01 in Oil capacity per fork leg 665 ml 22 48 fl oz Fork oil SAE 4 48601166S1 p 134 21 8 5 All XC models Fork part number 24 18 7O 73 For...

Page 132: ... length 247 mm 9 72 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 477 mm 18 78 in Shock absorber fluid p 135 SAE 2 5 21 9 2 125 150 SX US Shock absorber article number 18 18 7P 51 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping high speed Comf...

Page 133: ...n Weight of rider 85 95 kg 187 209 lb 57 N mm 325 lb in Spring length 260 mm 10 24 in Gas pressure 10 bar 145 psi Static sag 30 mm 1 18 in Riding sag 100 mm 3 94 in Fitted length 490 mm 19 29 in Shock absorber fluid p 135 SAE 2 5 21 9 4 250 SX US Shock absorber part number 18 18 7O 53 Shock absorber WP Performance Systems 5018 DCC Link Compression damping low speed Comfort 17 clicks Standard 15 cl...

Page 134: ...g 30 mm 1 18 in Riding sag 100 mm 3 94 in Fitted length 490 mm 19 29 in Shock absorber fluid p 135 SAE 2 5 21 10 Chassis tightening torques Spoke nipple front wheel M4 5 6 Nm 4 4 lbf ft Spoke nipple rear wheel M4 5 6 Nm 4 4 lbf ft Remaining nuts chassis M5 5 Nm 3 7 lbf ft Remaining screws chassis M5 5 Nm 3 7 lbf ft Screw battery terminal All XC models M5 2 5 Nm 1 84 lbf ft Screw shock absorber adj...

Page 135: ...1 Screw top steering stem All SX mod els M8 20 Nm 14 8 lbf ft Loctite 243 Screw top steering stem All XC mod els 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 Remaining nuts chassis M10 45 Nm 33 2 lbf ft Remaining screws chassis M10 45 Nm 33 2 lbf ft Screw bottom shock absorber M10 60 Nm 44 3 lbf ft Loctite 2701 Screw handle...

Page 136: ...49 F anti corrosion antifreeze distilled water Recommended supplier Motorex COOLANT M3 0 Engine oil 15W 50 Standard classification JASO T903 MA p 138 SAE p 138 15W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties Recommended supplier Motorex Top Speed 4T Engine oil 2 stroke Standard classif...

Page 137: ... unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 Super unleaded 95 octane mixed with 2 stroke engine oil 1 60 Standard classification DIN EN 228 JASO FD p 138 1 60 Mixture ratio 1 60 Engine oil 2 stroke...

Page 138: ...mended 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 Special cleaner...

Page 139: ...23 AUXILIARY SUBSTANCES 137 Universal oil spray Recommended supplier Motorex Joker 440 Synthetic ...

Page 140: ...es In most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA 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 vis cosity The viscosity describes only one property of oil and says nothing about quality JASO FD JASO FD is a cl...

Page 141: ...25 LIST OF ABBREVIATIONS 139 Art no Article number ca circa cf compare e g for example etc et cetera i a inter alia no number poss possibly ...

Page 142: ...ng 67 checking 67 Chassis number 11 Choke 15 Clutch fluid level checking correcting 73 fluid changing 73 Clutch lever 12 basic position adjusting 73 Compression damping fork adjusting 40 Compression damping high speed shock absorber adjusting 32 Compression damping low speed shock absorber adjusting 31 Coolant draining 94 refilling 95 Coolant level checking 93 94 Cooling system 92 Customer service...

Page 143: ...62 installing 62 Motorcycle cleaning 107 lift stand raising with 44 lift stand removing from 44 O Operating substances 8 Owner s Manual 7 P Plug in stand 16 Preparing for use advice on first use 17 after storage 108 checks and maintenance work when preparing for use 23 Protective clothing 7 R Radiator cover 92 installing 92 removing 93 Rear sprocket checking 68 Rear wheel installing 86 removing 85...

Page 144: ...tening torques 132 electrical system 127 engine 111 engine tightening torques 114 fork 128 shock absorber 130 tires 127 Throttle cable play adjusting 97 checking 97 Throttle cable routing checking 71 Throttle grip 12 Tire air pressure checking 87 Tire condition checking 86 Transport 26 Troubleshooting 109 110 Type label 11 U Use definition 6 V View of vehicle front left 9 rear right 10 W Warranty ...

Page 145: ... 3213330en 3213330en 07 2015 KTM Sportmotorcycle GmbH 5230 Mattighofen Austria http www ktm com Photo Mitterbauer KTM ...

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KTM 250 SX, Owner'S Manual

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