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1. Ground clearance unloaded 390 mm 15 3 in 390 mm 15 3 in 385 mm 15 2 in Weight without fuel 90 8 kg 200 4 Ibs 90 8 kg 200 4 Ibs 95 4 kg 210 3 Ibs STANDARD ADJUSTMENT FORK 125 150 SX 250 SX WP 4860 MXMA CC WP 4860 MXMA CC 14 18 7E 01 14 18 7E 03 Compression adjuster 15 clicks 12 clicks Rebound adjuster 21 clicks 20 clicks Spring 432 485 00 042W 432 485 00 044W STANDARD ADJUSTMENT SHOCK ABSORBER 125 150 SX 250 SX WP 5018 PDS DCC WP 5018 PDS DCC 12 18 7E 01 12 18 7E 03 Compression adjuster Low speed 15 clicks 15 clicks High speed l turn 1 5 turns Rebound adjuster 23 clicks 22 clicks Spring 63 250 69 250 Spring preload 5 mm 0 19 in 6 mm 0 19 in TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 45 Nm Colear screws front brake caliper Collar screws brake disks Clamping screws upper fork bridge M8 10 9 M6 10 9 M8 10 9 Loctite 243 25 Nm 14 Nm 17 Nm Clamping screws lower fork bridge M8 10 9 12 Nm Clamping screws upper steering stem Collar screw top steering stem M8x25 10 9 M20x1 5 Loctite 243 17 Nm 10 Nm Collar screw bottom steering stem M20x1 5 Loctite 243 60 Nm Clamping screws fork stubs Collar nut rear wheel spindle Hexagon nut swing arm bolt M8 M20x1 5 M16x1 5 15 Nm 100 Nm Collar screws handlebar clamp M8 10 9 20 Nm A
2. Never have the throttle wide open when changing down to a lower gear The engine will overrev damaging the valves In addi tion the rear wheel will block so that the motorcycle can eas ily get out of control If the engine runs without throttle during longer downhill travel the engine should be accelerated occasionally to ensure that it is supplied with sufficient lubricant which is mixed in the fuel In the event that while riding on your motorcycle you notice any unusual operation related noise stop immediately turn the engine off and contact an authorized KTM dealer Braking Turn off the gas and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depend ing on your speed AN WARNING LL LLUTTTTOT T TUN Incase of rain after washing the motorcycle after rides through water and in case of rides on wet off road tracks humid or dirty brake discs can delay the braking effect The brakes must be pulled until they are dry or clean Rides on salt strewed or dirty roads can also delay the braking effect The brakes must be pulled until they are clean Dirty brake discs cause increased tear of brake pads and brake discs When you brake the brake discs brake pads brake caliper and brake fluid heat up The hot
3. The adjusting screw 5 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size The clutch lever moves closer to the handlebar if the adjusting screw is tur ned in a counterclockwise direction The clutch lever moves away from the handlebar if the adjusting screw is turned in a clockwise direction CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force Checking the oil level of the hydraulic clutch 125 150 To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 6 and cover 7 together with the rubber boot 8 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add SAE 10 biodegradable hydraulic oil Motorex clutch fluid 75 available from your authorized KTM shop i CAUTION KTM uses biodegradable hydraulic mineral oil to actuate the hydraulic clutch in 125 150 models Do not mix this oil with any other hydraulic oil Always use original KTM hydraulic oil available from your authorized KTM workshop to make sure your clutch operates smoothly Never refill with brake fluid Checking the oil level of the hydraulic clutch 250 To check the oil level in the master cylinder of the clutch remove the cover For th
4. 432 485 00 046W AND ENGIN Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for vari ous reasons Similar to the shock absorber smaller deviations in your weight can be compensated by adjusting the spring preload However if your tele scopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Changing the spring preload on the telescopic fork The telescopic forks for these models must be partly disassembled to adjust the spring preload Pretension spacers are available in heights of 1 5 2 5 5 and 10 mm see spare parts catalog The fork springs may not be preten sioned by more than 20 mm 0 8 in NOTE WP precisely adjusts the spring pressure by Inserting pretension spacers Fluctuations in production are compensated with pretension spacers in vari ous heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and pretension spacers should always stay together Replacing fork springs If you weigh less than 75 kg or more than 85 kg you should install the respec tive fork springs The correct spring rate is shown in the illustrations The stan dard spring is shown in bold print The type number of the telescopic fork is embossed on the inside of the fork leg axle passage If you are uncertain which spring to us
5. N lt L d lt L WNER gt lt N LO N gt on LO gt lt 72 LO N 3211347en IMPORTANT gt We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance 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 and b the use of the vehicle after such device or element of design has been removed or rendered inopera tive by any person All information contained is without obligation KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving
6. Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 493 mm RIdINE RSS CP bbe ew a ee See ee dee 107 mm The riding sag should lie between 102 and 112 mm If the riding sag is less than 102 mm the spring is too hard the spring rate is too high If the riding sag is more than 112 mm the spring is too soft the Spring rate is too low The spring rate is written on the outside of the spring e g 69 250 The type number of the shock absorber is embossed on the front of the shock absorber The illustrations show which spring should be installed The standard spring is Shown in bold print After installing a different spring readjust the static sag to 33 mm 2 mm According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder Spring Spring rate 4 2 N mm 65 70 75 Bo 80 85 90 95 Riders weight inclusive gears in kilogram MODELL 12187E01 125 150 SX 12187E03 250 SX SOFTER STANDARD HARDER 432 485 00 040W 432 485 00 042W 432 485 00 044W 432 485 00 042W 432 485 00 044W
7. mulated To clean lift the filter box cover see illustration and pull off towards the front Detach the bottom of the filter retaining bracket 2 tilt aside and remove the air filter 3 and filter support 4 from the filter box CAUTION Do not clean foam filter with fuel or petroleum since these damage the foam KTM recommends the products of the company Motorex for air fil ter maintenance Dirt Bio Remover and Liquid Bio Power Never start your motorcycle without any air filters otherwise dust and dirt may penetrate and cause damage and increased wear Dust and dirt can accumulate and damage the engine if the air filter is not mounted correctly Thoroughly wash the air filter in special cleaning fluid Motorex Twin Air Dirt Bio Remover and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Motorex Twin Air Liquid Bio Power Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Place the air filter on the filter support and insert both in the center of the filter box Hold in place with the filter retaining clip 4 ARE E Las E gt u AND ENGIN Exhaust system If the end cap 1 can be removed the silencer is filled with glass fiber yarn Have the filling checked regularly by an authorized KTM workshop see Lubrication and Service Chart The i
8. POS MJ ASO lJ NEEDLE POS MJ 1500 m 5000 ft t 751m 2501 ft 750 m 2500 ft t 301 m 1001 ft ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 300 m 1000 ft t Meeresniveau Sea level ASO IJ NEEDLE POS MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se gi 2 IJ Idling jet POS Nadel Clip Position von oben A POS Needle clip position from top HD Hauptd se MJ Main jet NICHT F R STRASSENBETRIEB NICHT F R SANDSTRECKEN Schieber 6 5 mit Ausschnitt Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE AND SAND TRACKS Throttle 6 5 with cut Fuel unleaded fuel with at least RON 95 USA Premium PON 91 VERGASER GRUNDEINSTELLUNG F R SANDSTRECKEN 250 SX CARBURETOR BASIC SETTING FOR SAND TRACKS Keihin PWK 36 S AG Vergasertype Carburetor type Luftregulierschraube offen Umdrehungen l Air screw open from fully seated turns Leerlaufd se D sennadel 45 Idling jet Needle Nadelposition von oben 4 Needle clip position from top Hauptd se l 75 Wenn der Motor unrund l uft ist eine kleinere Hauptd se einzusetzen Main jet If the engine is hezitating applay a smaller main jet 1AA IVI MV 4 D stop button black brown ignition coil ellow black blue white e 5 lt 3 Oj TT oj 2 green red
9. is measured Chains do not always wear off evenly therefore repeat the measurement at different places on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets CAUTION Secure the screws of the chain wheel by applying Loctite and fasten them in a crosswise order d Tightening torque for nuts 35 Nm max 272 mm Tightening torque for screws 50 Nm 16 17 18 AND ENGIN General information about KTM disc brakes BRAKE CALIPERS The brake calipers of this series use a floating mount This means that the brake calipers are not solidly attached to the caliper support which enables them to float for maximum braking contact Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701HHEB sintered lining at the front and TOYO B 143 FF sintered lining at the back These linings provide an optimal combination of dosing brake performance and life cycle BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases The brake disk must be at least 2 50 mm front 3 50 mm rear thick at the thinnest point A Check the thickness of the brake disk at several points 7N WARNING gt A brake disk worn down to less than 2 50 mm Front 3 50 mm Rear is a safety risk Have t
10. 1 Turn the screw clockwise to increase damping turn it counterclockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as It will go turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 1418 E01 15 clicks Typ WP Suspension 1418 E03 12 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound Remove the protecting cap 2 By turning the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 1418 E01 21 clicks Typ WP Suspension 1418 E03 20 clicks Damping action during compression of shock absorber The shock absorber on the SX models can synchronize the compression damp ing in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during com pression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compression rates The high speed setting is effective at fast compression r
11. a perfect technical condition For safety reasons you should make it a habit to perform an overall check of your motorcycle before each start The following checks should be performed 1 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks CHAIN A loose chain was fall off the chain wheels an extremely worn chain may tear and insufficient lubrication may result in unnecessary wear of the chain and chain wheels TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance BRAKES Check correct functioning of the braking system Verify that there is suf ficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by an author ized KTM dealer as complete failure of the braking system can be expected Also check the state of the brake h
12. children Incase coolant is ingested consult a doctor immediately If coolant gets into your eyes rinse them out with water immediately and go see a doctor Use a mixture of 50 antifreeze and 50 distilled water for the cooling liquid The antifreeze should be designed for temperatures of at least 25 C 13 F This mixture offers frost protection as well as good corrosion protec tion and should not be replaced by water alone i CAUTION For the cooling system use only with high grade antifreeze e g Motorex Anti Freeze Using lower grade antifreeze agents can cause corrosion and coolant foaming Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system AN WARNING OOOO If possible always check the level of cooling liquid when the engine is cold If you have to open the radiator cap when the engine is hot use a rag to cover the cap and open slowly to release pressure AND ENGIN Bleeding the cooling system By removing the screw 1 at the water pump cover you can drain the coolant To bleed the cooling system add coolant up to approx 10 mm 0 4 in above the radiator fins when the engine Is cold After a short ride check the coolant level once more Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accu
13. destroying the brake disc AND ENGIN Replacing the front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the Sliding metal sheet 3 in the caliper support and of the leaf spring 41 a WARNING OOOO It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correctly after working on the braking system always actuate the hand brake lever or foot brake lever respectively to ensure that the brake pads will lie against the brake disk and the pressure point is established Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motor cycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked in a vertical position A re If the brake fluid level drops below the minimum either the br
14. grey black gre ignition curve selector 125 150 250 SX 2009 ENGLISH CDI harness 548 39 032 300 D LA ENGLISH CABLE COLOURS bl black br brown bu blue en green gr grey or orange pi pink pu purple re red wh white ye yellow ENGLISH rw WIAGKAIMIV DEUTSCH KABELFARBEN bl schwarz br braun bu blau gn gr n gr grau or orange Pi rosa pu violett re rot wh wei ye gelb FRANCAIS ITALIANO CAVO COLORATO bl nero br marrone bu blu en verde gr grigio or arancione pi rosa pu violetto re rosso wh bianco ye giallo ESPANOL CABLE COLOURS bl black br brown bu blue gn green gr grey or orange pi pink pu purple re red wh white ye yellow COULEUR DE CABLE bl noir br brun bu bleu gn vert gr gris or orange Pi rose pu violet re rouge wh blanc ye jaune COLOR DE CABLE bl negro br marron bu azul gn verde gr gris or naranja pi rosado pu violeta re rojo wh blanco ye amarillo Adapting the chain guide 20 Adjusting the engine characteristic via the ignition curve 34 Adjusting the engine characteristic via the auxiliary spring 34 Adjusting the free travel at the hand brake lever 23 Basic suspension setup for the weight of the driver 16 Bleeding the cooling system 29 Bleeding the hydraulic clutch 31 BEE RR REN
15. own safety always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified skilled staff CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear When transporting your KTM ensure that it is held upright with restraining straps or other mechanical fastening devices and that the fuel tap is in the OFF position if the motorcycle should fall over no fuel can leak from the carburetor or fuel tank Only use special screws with an appropriate thread length supplied by KTM to fix the spoilers on the tank Using other screws or longer screws can cause leaks in the tank through which fuel can flow out Do not use toothed washers or spring rings with the engine fastening screws as these work into the frame parts and keep working loose Instead use self locking nuts If you unscrewed any screwed connections with self locking nuts they must be replaced when mounting If no self locking nuts are available apply Loctite 243 to the thread The screws and nuts must be replaced if the thread is damaged All screws and nuts must be tightened to the specified torque figures using a torque wrench If screws or nuts are not adequately tightened they can become loose
16. reasons KTM may stop manufactur ing certain models without previous notice KTM shall not be held liable for any deviations of availabil ity and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2008 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only In accordance with the international quality management ISO 9001 standard KTM uses MANAGEMENT SERGE quality assurance processes that lead to the highest possible product quality INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading interna tional motorcycle associations THE SX MODELS ARE PROHIBITED ON PUBLIC ROADS OWNER S MANUAL Please read this manual carefully and completely before going on your first ride It contains a great deal of information and advice which will help you use and handle your bike properly Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance In your own Interest please pay particular attention to
17. the plug 2 and top up with oil e g Motorex Top Speed AT 15W50 i CAUTION Transmission and clutch will be subjected to excessive wear and tear if you use too little or low grade oil Use only high grade oil e g Motorex Top Speed 4T 15W50 US Changing the transmission oil 125 150 SX AL EE To change the gear oil warm up the engine and park the motorcycle on a hor a T izontal surface Remove oil drain plugs 3 and 4 and drain the used oil into an appropriate container Clean the magnets of the oil drain plugs and mount them together with the appropriate gaskets M12x1 5 20 Nm M10x1 15 Nm Fill in O 7 litres 0 18 USgal oil e g Motorex Top Speed 4T 15W50 mount the plug 2 and check the engine for leaks CAUTION Transmission and clutch will be subjected to excessive wear and tear if you use too little or low grade oil Use only high grade oil e g Motorex Top Speed 4T 15W50 Check transmission oil level 250 SX In order to check the transmission oil level the control screw 5 on the clutch cover is to be removed Oil should just barely escape from the inspection open ing when the motorcycle is in an upright position If necessary remove the plug 6 and top up with oil e g Motorex Top Speed 4T 15W50 CAUTION Transmission and clutch will be subjected to excessive wear and tear if you use too little or low grade oil Use only high grade oil e g Motorex Top Speed 4T 15W50 Changing the trans
18. 09 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY aw S gt io N od n q Before each every 20 hours every 40 hours at least once Check gear box oil level Change gear box oil Check spark plugs adjust distance between electrodes ENGINE Renew spark plug Clean the spark plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Check the carburetor connection boot and intake flange for cracks or leaks Check idle speed setting CARBURETOR Check that vent hoses are not damaged or bent Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation bends adjust and lubricate Check the fluid level in the master cylinder of the hydraulic clutch Clean air filter and filter box Check electric wires for damage and bends ADD ON PARTS Check headlamp setting Check function of electric systems low beam high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake lining Check brake lines for damage and leaks BRAKES Check adjust the function smooth operation and free travel of the hand foot brake lever Check the screws and guide bolts on the brake system for a tight fit Check shock absorber and fork for leaks and functio
19. 50 SX 1 60 Fuel and engine oil should only be mixed immediately before use KTM recommends Motorex Cross Power 2T AN WARNING Gasoline is highly flammable and poisonous Extreme caution should be used when handling gasoline Do not refuel the motorcycle near open flames or burning cigarettes Always switch off the engine before refueling Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot Wipe up spills promptly If gasoline is swallowed or splashed in the eyes seek a doctor s advice immediately The tank cap s locking mechanism always has to snap into place when it is mounted CAUTION Only use premium grade gasoline ROZ 95 mixed with high grade two stroke engine oil Other types of gasoline can cause engine failure Do not use premixed two stroke oils oils for outboard engines or normal engine oil to prepare the mixture Do not use gasoline and oil mixtures that are older than one week The lubrication properties of some two stroke oils can deteriorate very rapidly Only use known brands of high grade 2 stroke engine oil i e Motorex Cross Power 2T Never mix synthetic oils and mineral oils Not enough oil or low grade oil can cause erosion of the pis ton when Using too much oil the engine may start smoking and foul the spark plug Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig 125 150 250 SX 20
20. CONSERVATION FOR WINTER OPERATION STORAGE su wr 22 2 BU 1 eee see ri TECHNICAL SPECIFICATIONS CHASSIS TECHNICAL SPECIFICATIONS ENGINE Carburetor rable 129 2 teh tae Eike Carburetor table 150 Carburetor table 250 4 066694 us Berl WIRUNG DIAGRAMM 30 30 30 31 32 33 33 34 Chassis number The chassis number is stamped on the right side of the steering head tube Enter this number in the field on page no 1 Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 Clutch lever The clutch lever 1 is located on the left side of the handlebars The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand brake lever The hand brake lever 2 is mounted on the handlebars on the right and actu ates the front wheel brake The adjusting screw B can be used to change the basic position of the hand brake lever see maintenance work on chassis and engine TE RER xy r AAN RATA NES WSO APARA NAMA N SPA TR MER gees h N a SERENE SNC NESE SA YI N KRIEGEN The short circuit button 1 turns off the engine When pressing this button the ignition circuit is short circuited Short c
21. For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer AN WARNING Oe Spokes can tear if you continue to ride with them loose This may lead to an unstable handling of your motorcycle Excessively tensioned spokes may rupture due to local overloading The spokes must be tensioned to 5 Nm Cooling system The water pump 1 in the engine circulates the cooling liquid The cooling liquid is cooled by the air stream This means that the cooling effect decreases with the traveling speed Dirty radiators additionally reduce the cooling effect Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 2 a water temperature rising up to 120 C 248 F is admissible without fear of problems AN WARNING 5 If possible always check level of cooling liquid when engine is cold If you have to open the radiator cap 2 when the engine is hot use a rag to cover the cap and open slowly to release pressure Caution scalding hazard Do not detach any radiator hoses while the engine is hot The escaping hot coolant and the steam may cause serious burns In case you get burnt hold the affected part of your body under running cold water right away Coolant is toxic Keep the coolant out of the reach of
22. Joker 440 or engine oil Press the dust boots into the outer tubes by hand Position the fork protectors mount the screws and torque to 10 Nm AN WARNING OOOO No oil may reach the front tire or the brake disks since this would consider ably reduce the tire s road grip and the braking effect of the front brake 1 Lo AND ENGIN Changing the fork offset caster The fork offset A in the SX models center fork legs center steering head angle can be set to either 18 or 20 mm 0 7 or 0 8 in This allows you to optimize the handling to match the race course Remove the blind screw 1 to see which offset is set If the mark B is in front the offset is 18 mm This setting will deliver more directional stability on fast race courses If the mark B is in the rear as illustrated the offset is 20 mm 0 8 in This setting will deliver better handling in curves The offset is set to 20 mm 0 8 in in the condition at delivery To adjust the offset dismount the front wheel and remove the front wheel fender Remove the screw on the starting number plate Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the blind scre
23. Refilling the front brake fluid reservoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reser voir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off Spilled or overflowing brake fluid with water AN WARNING OOOO Never use DOT5 brake fluid It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes rinse with plenty of water and consult a doctor CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid taken from a tightly sealed container Checking the front brake pads The brake pads can be inspected from the rear The linings must be at least 1 mm 0 04 in thick A re At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and
24. SO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se E IJ Idling jet POS Nadel Clip Position von oben mo 4 ae POS Needle clip position from top HD Hauptdise y MJ Main jet NICHT F R STRASSENBETRIEB NICHT F R SANDSTRECKEN Schieber 6 5 mit Ausschnitt Kraftstoff Super Bleifrei ROZ 95 NOT FOR HIGHWAY USE AND SAND TRACKS Throttle 6 5 with cut Fuel unleaded fuel with at least RON 95 USA Premium PON 91 VERGASER GRUNDEINSTELLUNG F R SANDSTRECKEN 150 SX CARBURETOR BASIC SETTING FOR SAND TRACKS Vergasertype Keihin PWK S 38 AG Carburetor type Luftregulierschraube offen Umdrehungen 1 5 Air screw open from fully seated turns Leerlaufd se 45 D sennadel Idling jet Needle Nadelposition von oben Needle clip position from top Hauptd se Wenn der Motor unrund l uft ist eine kleinere Hauptd se einzusetzen Main jet If the engine is hezitating applay a smaller main jet VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 36 S AG MEERESHOHE ALTITUDE TEMPERATUR TEMPERATURE SSS 20 C bis 7 C 2 F to 20 F 250 SX 2009 6 C bis 5 C 19 F to 41 F 6 C bis 15 C 42 F to 60 F 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C 61 F to 78 F 79 F to 98 F 99 F to 120 F 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft ASO IJ NEEDLE
25. TE OA 12 Breather plug front fork 17 Carburetor adjustment 32 Carburetor table I2 5 4 45 4h ace ata eae a e A 41 Carburetor table 150 2 uns sa 2 222 Sen 288 42 Carburetor table 250 ua yA ee tte 43 CHOKE KDE Sd Re anne 6 Blu tch lever 24 28 22 3 ANS Rad er 5 Chain maintenance 21 Chan WEA En dou Shee Oe et Fa ee Ae ee cs eo 21 Changing the spring preloading of the shock absorber 15 Changing the transmission oil 250 35 Changing the transmission oil 125 150 35 Changing the original position of the clutch lever 30 Changing the oil level of hydraulic clutch 125 150 SX 30 Changing the oil level of hydraulic clutch 250 SX 30 Changing the spring preload on the telescopic fork 17 Changing the fork offset caster 18 Changing the basic position of the foot brake pedal 25 Chassis number usa erde 5 CINE ee ee ee ne GO eae 36 Checking the shock absorber and spring 16 Checking the basic setup of the telescopic fork 17 Checking the brake fluid level front brake 23 Checking the front brake pads 23 Checking the rear brake fluid level 24 Checking the rear brake pads 25 Checking spoke tension 28 Checking the float level 33 Checking the coolant level 28 Checking and adjusting
26. Too much slack in the chain on the other hand can result in the chain jumping off the chain wheels If this happens the chain could also block the rear wheel or damage the engine In either case the operator is likely to lose control of the motorcycle Adapting the chain guide to the number of rear sprocket teeth NOTE The position of the chain guide must be adjusted due to the large number of rear sprockets available Up to 44 teeth insert the retaining screw on the chain guide in the lower hole C from 45 teeth in the upper hole DI Loosen the screw 5 and remove screw 6 Tilt the chain guide down and insert the collard bush 7 in the respective hole Tighten the screws to 10 Nm AND ENGIN Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks B Tighten the counter nut of the adjusting screws Before tightening the collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm AN WARNING If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose
27. USE AND SAND TRACKS NICHT F R SANDSTRECKEN Throttle 7 with cut Schieber 7 mit Ausschnitt Fuel unleaded fuel with at least RON 95 Kraftstoff Super Bleifrei ROZ 95 USA Premium PON 91 VERGASER GRUNDEINSTELLUNG F R SANDSTRECKEN 125SX CARBURETOR BASIC SETTING FOR SAND TRACKS Vergasertype Keihin PWK S 38 AG Carburetor type Luftregulierschraube offen Umdrehungen 1 5 Air screw open from fully seated turns Leerlaufd se 45 Idling jet D sennadel Needle Nadelposition von oben 4 Needle clip position from top Hauptd se 208 Main jet Wenn der Motor unrund l uft ist eine kleinere If the engine is hezitating applay a Hauptd se einzusetzen smaller main jet VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK S 38 AG 150 SX 2009 MEERESHOHE ALTITUDE TEMPERATUR TEMPERATURE m Ze 20 C bis 7 C 6 C bis 5 C 6 C bis 15 C 2 F to 20 F 19 F to 41 F 42 F to 60 F 16 C bis 24 C 61 F to 78 F 25 C bis 36 C 37 C bis 49 C 79 F to 98 F 99 F to 120 F 3000 m 10000 ft t 2301 m 7501 ft 2300 m 7500 ft t 1501 m 5001 ft ASO IJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 1 9 42 NOZI 2 182 2 9 40 NOZJ 1500 m 5000 ft t 751m 2501 ft 750m 2500 ft t 301 m 1001 ft ASO lJ NEEDLE POS MJ ASO IJ NEEDLE POS MJ 300 m 1000 ft t Meeresniveau Sea level ASO IJ NEEDLE POS MJ L
28. ake system has a leak or the brake pads are completely worn In this case consult an author ized KTM dealer immediately Refilling the rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 5 Fill DOT5 1 brake fluid e g Motorex Brake Fluid 5 1 up to the mark B on the inside of the reservoir and remount the screw Spilled brake fluid must be rinsed off with water AN WARNING OO Never use DOT5 brake fluid It is based on silicone oil and of a purple color Seals and brake hoses must be especially adapted to it Store brake fluid out of reach of children Brake fluid can cause skin irritation Avoid contact with skin and eyes If you get brake fluid in your eyes rinse with plenty of water and consult a doctor CAUTION Don t let brake fluid get in contact with paint it is an effective paint remover Use only clean brake fluid taken from a tightly sealed container UN A i gt LA My amp f AND ENGIN Changing the basic position of the foot brake pedal To change the basic position of the foot brake lever loosen the counternut 1 and turn the stop screw 2 as needed Be sure to adjust the free travel of the foot brake lever Measured on the outside the foot brake lever should have 3 5 mm free travel before the piston rod moves the piston in the foot brake cylinder you will feel the stronger resistan
29. and cause the motorcycle to go out of control while you drive Tightening the screws and nuts too tightly can damage the thread and components Let your motorcycle cool down before beginning any maintenance work in order to avoid getting burned Dispose of oils fatty matters filters fuels washing detergents etc properly Under no circumstances may used oil be disposed of in the sewage system or in the open countryside 1 liter of used oil contam inates 1 000 000 liters of water Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring 1 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 1 changes the spring pretension by approximately 1 00 mm 0 04 in Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm 6 ft lb ADJUSTMENT VALUES SPRING PRELOAD A Typ WP Suspension 1218 7EO1 5 mm 0 19 tn Typ WP Suspension 1218 E03 6 mm 0 23 in Pivot bearing The pivot bearing 3 for PDS suspension st
30. ate a round and stable engine speed using the air control screw basic position of the air control screw see technical data engine Then adjust to the normal jet needle idling speed by means of the idle adjusting screw Opening up B gt EE TT 45 aA Engine behavior when the throttle opens The idle jet and the shape of the throttle valve influences this range If despite good idling speed and part throttle valve throttle setting the engine sputters and smokes when the throttle is fully opened air control screw and develops its full power not smoothly but suddenly at high engine speeds idle adjusting screw the mixture to the carburetor will be too rich the fuel level too high or the float needle is leaking idle jet II W N RAR AU D Part throttle range C Operation with partly open throttle valve This range is only influenced by the jet needle shape and position The optimum part throt tle setting is controlled by the idling setting in the lower range and by the main jet in the upper range If the engine runs on a four stroke cycle or with reduced power when it is accelerated with the throttle partly open the jet needle must be lowered by one notch If then the engine pings especially when accelerating under full power at maximum engine revs the jet needle should be raised If these faults should occur at the lower end of the part throttle range at a four stroke running make the idling range leaner if the
31. ates Turning in a clockwise direction will increase the damping turning coun terclockwise will decrease the damping STANDARD LOW SPEED SETTING Turn the adjusting screw 1 to the limit in a clockwise direction using a screwdriver Unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ WP Suspension 1218 E01 15 clicks Typ WP Suspension 1218 E03 15 clicks AN WARNING The damping unit of the shock absorber is filled with high compression nitro gen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the black screw 2 connection 24mm STANDARD HIGH SPEED SETTING Turn the adjusting screw 3 to the limit in a counterclockwise direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber in a clockwise direction Typ WP Suspension 12187E01 1 turn Typ WP Suspension 1218 7E03 1 5 turns Rebound damping of shock absorber By using the adjusting screw 4 the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respecti
32. axle may lead to an unstable driving behavior of your motorcycle Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle NOTE The large adjusting range of the chain adjusters 32mm 1 25 in allows you to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 CAUTION Always mount the chain tensioner equally aligned Chain maintenance For a long chain life good maintenance is very important Chains without X rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray e g Motorex Chainlube 622 A re No lubrication is allowed to reach the rear tire or the brake disk eitherwise the road adherence and the rear wheel braking effects would be strongly reduced and the motorcycle could easily get out of control CAUTION When mounting the chain joint the closed side of the safety device must point in running direction Also check sprockets and chain guides for wear and replace if necessary Chain wear A To check the chain wear observe the following indications A Shift the gear into idling and pull the upper chain strand with approx 10 15 IA kilograms 33 Ib upwards see figure Now one can measure a space of AR N 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in
33. ce of the foot brake lever Loosen the counternut 3 and turn the pushrod 4 as needed AN WARNING eee The brake system will build up pressure if there is no free travel on the foot brake lever This will cause the brake pads to grind The brake system will overheat and can break down entirely in extreme cases Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in AD a At their most worn point brake pad linings should not be thinner than 1 mm otherwise they could lead to brake failure For your own safety don t put off having your brake pads changed i CAUTION If the brake pads are replaced too late so that the lining is partly or entirely worn the steel components of the brake pad will rub against the brake disc thereby imparing the braking effect and destroying the brake disc Replacing the rear brake pads Press the brake caliper 5 in the direction of the chain wheel for the brake piston to reach its basic position Remove the safety device 6 knock out the guide pin 7 from the brake caliper with a drift towards the chain wheel and remove the brake pads Carefully clean the brake caliper with compressed air and check the sleeves of the guide pins for damage Slide the left brake pad into the brake caliper and fix it with the pin Slide in the right brake pad and knock the bolt 7 in as far as it will go Mount the safety
34. cover see above VIAIN NAN NURA UN CHA AND ENGIN Carburetor adjustment Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx 500 meters 1600 ft above sea level and the ambient temperature of approx 20 C 68 F mainly for off road use and central European premium grade fuel 95 ROZ Mixing ratio 2 stroke motor oil super fuel 1 40 125 150 SX 1 60 250 SX Basic information on changing the carburetor setting Always start with the original carburetor setting the provided factory setting is meant for break in operation after the break in period the carburetor needs to be adjusted according to the carburetor datasheet see appendix Essential requirements are a clean air fil ter system air tight exhaust system and an intact carburetor Experience has shown that adjusting the main jet the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance RULE OF THUMB high altitude or high temperatures gt choose leaner carburetor adjustment low altitude or low temperatures gt choose richer carburetor adjustment A Only use premium grade gasoline ROZ 95 USA Premium PON 91 mixed with high grade two stroke engine oil Other types of gasoline can cause engine failure and will void your warranty Only use high grade 2 stroke engine oil of known brands e g Motorex Cr
35. device 6 A re It is very important to keep the brake disk free from oil and fatty matters Otherwise the braking effect would be strongly reduced After assembly check if circlips have been fitted correctly After working on the braking system one must always actuate the hand brake lever or foot brake lever respectively so as to ensure that the brake pads will lie against the brake disk and the pressure point is established y gE u SUN B L AS X i J i 2 u N C y K AND ENGIN Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the collar screw 1 and the clamping screws 2 on both fork leg axle passages Unscrew the collar screw approx 8 turns press on the collar screw with your hand to push the wheel spindle out of the fork leg axle passage and remove the collar screw Hold the front wheel while you pull out the wheel spindle Lift the front wheel off the fork S CAUTION Do not operate the hand brake when the front wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be damaged Before remounting the front wheel clean and grease the shaft seal rings A and the bearing surface B of the distance bushings and mount the distance bushing To install the front wheel lift it into t
36. e contact your KTM workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder Spring Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on the road it will suffice to have this job performed in the course of the periodical maintenance service CAUTION Excessive pressure in the interior of the fork can cause leaks in the fork If your fork is leaking it is recommended to open the breather plugs before hav ing the seals replaced Cleaning the dust sleeves of the telescopic fork The dust protection bellows 2 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Remove the screws 3 from the fork protector and allow the fork protector to hang down Pry the dust boot out of the outer tubes and push down Thoroughly clean the dust boots slide rings outer tubes and fork tubes and oil generously with Universal oil spray Motorex
37. e a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil old engine oil contains aggressive contaminants Check antifreeze and amount of cooling liquid Let the engine warm up again close fuel cock and wait until the engine dies off by itself In this way the carburetor jets are pre vented from becoming resin clogged by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate bearing points of the control levers footrests etc as well as the chain The storage place should be dry and not be subjected to too big temperature fluctuations Cover the motorcycle with an air permeated tarp or blanket Do not use non airtight materials as a possible humidity might not be able to escape and thereby cause corrosion i CAUTION It would be very bad to let the engine run for a short time during the storage period The engine would not get warmed up enough and the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust USE AFTER A PERIOD OF STORAGE Fill up the tank with fresh fuel Check the motorcycl
38. e affa le Complete maintenance of shocka U le Clean and grease steering head bearings and gasket elements le Replace the sealing cup for te foot brake cylinder ee Replace the glassfiber yar filingin the silence CCC Treat electric contacts and switches with contact grease Change break fluid Change the hydraulic clutch oil Note lf the inspection establishes that permissible tolerances are exceeded the respective components must be replaced 125 150 250 SX 2009 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER before each after every cleaning for cross country use Check gear box oil level Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean dust bellows regularly Check cooling liquid level Remove clean and oil the throttle slide 6 Check brake performance Treat blank metal parts with the exception of brake and exhaust systems with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Clean and lubricate chain check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check tightness of screws nuts and hose clamps regularly Maintenance and adjusting work marked with an asterisk requires expert skills and technical know how For your
39. e as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your shop at the beginning of the next biking season CHASSIS Frame Central chrome moly steel frame Fork WP Up Side Down 4860 MXMA CC Multi Adjuster Closed Cartridge Wheel travel front rear 300 335 mm 11 8 13 2 in Rear suspension WP PDS 5018 DCC Progressive Damping System Front brake Disc brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Front tires Bridgestone M59 80 100 21 Bridgestone M59 80 100 21 Bridgestone M59 80 100 21 Air pressure offroad 1 0 bar 14 psi Rear tires Bridgestone M O 100 90 19 Bridgestone M70 100 90 19 Bridgestone M7O 110 90 19 Air pressure offroad 1 0 bar 14 psi Final drive ratio Available final sprockets 38t 40t 42t 45t 48t 49t 50t 51t 52t Chain 5 8 x 1 4 Steering head angle 63 63 63 5 Wheel base 1471 10 mm 57 9 in 0 4 in 1471 10 mm 57 9 in 0 4 in 1475 10 mm 58 1 in 0 4 in Seat height unloaded 985 mm 38 8 in
40. e dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all the gliding bearing parts Treat the chain with a chain spray To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch the short circuit button the light switch and the socket connectors with contact spray JN KVALIUN FUR WIN X UPERALIUN In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent NN LT LT TUT LT TU U U Keep the anti corrosion agent from getting into contact with the brake discs otherwise this will significantly reduce the braking power CAUTION After rides on salted roads clean motorcycle thoroughly with cold water and let it dry well Should you wish to mak
41. e rubber band on the air filter box JN gt g JRIVING IN Shifting Riding You are now in first gear referred to as the drive or uphill gear Depending on the conditions hill size etc you can shift to a higher gear Turn down the throttle at the same time pull the clutch lever in and shift to the next higher gear Let the clutch lever go again and open the throttle If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of throttle the gas con sumption will increase When shifting down use the brakes if nec essary and turn down at the same time Pull the clutch lever and shift down to the next lower gear Let the clutch lever go slowly and open the throttle or shift down again ART After falling with the motorcycle check all its functions thor oughly before using it again A twisted handlebar must always be replaced Do not adjust the handlebar it will lose stability i CAUTION High rpm rates when the engine is cold have an adverse effect on the life of your engine We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up After that no further precautions in this respect need to be taken
42. e warranty shall become void The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle WARRANTY The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle AUTOMOTIVE FLUIDS The fuels and lubricants specified in the Owner s Manual or automotive fluids with equivalent specifica tions must be used in accordance with the maintenance schedule SPARE PARTS ACCESSORIES For your own safety use KTM approved parts and accessories only KTM is not liable for damage that arises in connection with the use of other products TRANSPORT When transporting your motorcycle secure it with elastic straps or other mechanical devices in an upright position Be sure that the fuel tap is closed If the motorcycle topples over fuel can flow out of the car buretor or fuel tank ENVIRONMENT Offroad Motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however inv
43. efore vapor pockets may form in old brake fluids even at low temperatures causing the brake system to fail AND ENGIN Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 In this way the position of the point of pressure i e the resis tance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary CAUTION At the hand brake lever free travel must at least be 3 mm 0 1 in Only then may the piston in the hand brake cylinder be moved to be recognized by the greater resistance of the hand brake lever If this free travel is not provided pressure will build up in the braking system and the front wheel brake may fail due to overheating Checking the brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reser voir in a horizontal position the brake fluid level should not drop below the middle of the glass AN WARNING Oe If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn In this case consult an author ized KTM dealer immediately
44. engine pings adjust the idling range richer Full throttle range D Operation with the throttle fully open flat out This range is influenced by the main jet and the jet needle If the porcelain of the new Spark plug is found to have a very bright or white coating or if the engine rings after a short distance of riding flat out a larger main jet is required If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one JET NEEDLE TERE RICHER 125 150 SX RANGE OF ACTION LEANER JET NEEDLE TYPE RICHER 250 SX RANGE OF ACTION LEANER NIEF NIEG NIEH N1EI NIEJ Explanation of table Example Compared to the needle N1EH the jet needle N1EJ is two steps leaner in the range from the closed position of the throttle to 1 4 throttle Otherwise there are no differences CAUTION Pay attention to the correct needle designation when replacing the jet nee dle detailed information on the type of jet needle for the respective models can be found in the carburetor setting table Draining the float chamber of the carburetor Following every wet cleaning procedure the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it Water in the float chamber leads to engine malfunction Make sure you do this while the engine is cold Close the fuel tap and place a cloth under the carburetor which is capable of abso
45. ertificate Tire condition has to be checked every time you want to ride your motor cycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Refer to the specific regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pres Sure ensures optimum driving comfort and extends the life of your tires A re Do not mount tires which have not been approved by KTM Other tires could have adverse effects on the way your motorcycle behaves front and rear wheels may only be fitted with tires having the same tread layout Use homologated tires For your own safety replace damaged tires immediately Worn tires can have a negative effect on how your motorcycle performs especially on wet surfaces If air pressure is too low abnormal wear and overheating of the tire can result ALLIE NUIT LITE WALININIANTANILMNDIINNNMNIDININIIN 10 mm 0 4 in when engine ist cold AND ENGIN Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle at regular intervals
46. g consumed alcohol Only use accessory parts recommended by KTM The front and rear wheel are allowed to be fitted only with tires that have the same profile type Be sure to check the spoke tension after 30 minutes running time The spoke tension will decrease quickly on new wheels If you con tinue to drive with loose spokes the spokes may crack and lead to unstable handling see Checking the spoke tension Adjust your driving speed to the conditions and your driving skills Drive carefully on unknown roads or in unknown territory When driving off road always have a friend on a second motor cycle to keep you company so that you can help each other should difficulties arise Replace the helmet visor or goggle glasses early enough When light shines directly on a scratched visor or goggles you will be practically blind Never leave your motorcycle without supervision as long as the engine is running The Above Models were designed and built for one person only no additional passenger allowed VIU TUR Neither do these models meet the applicable statutory regula tions and safety standards Using them on public roads high ways freeways etc is against the law When riding your motorcycle please bear in mind that other people may feel molested by excessive noise D AR NU E What you should check before each start When you start off the motorcycle must be in
47. he brake disk replaced as soon as it reaches the service limit Have any repairs on the brake system be performed by a KTM dealer BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are completely worn In this case consult an authorized KTM dealer immediately BRAKE FLUID We recommend that you use Motorex DOT 5 1 brake fluid when you refill or change the brake fluid DOT 5 1 brake fluid has a wet boiling point of 180 C 356 F 25 C 45 F higher than DOT 4 and is safer for high performance applications Brake fluid DOT 5 1 is a polyethylene glycol based fluid amber colored and can be mixed with DOT 4 brake fluid Do not in any event use DOT 5 brake fluid It is based on silicone oil and is dyed purple KTM motor cycle gaskets and brake hoses are not designed for DOT 5 brake fluid Brake fluid is exposed to a high thermal load and absorbs moisture from the air which lowers the boiling point The brake fluid should therefore be changed at the prescribed intervals AN WARNING ee Have the brake fluid changed at least once annually If you wash your motor cycle often the brake fluid should be changed even more frequently Brake fluid tends to absorb water Ther
48. he fork position and mount the axle shaft 3 Mount the collar nut 1 tighten the clamping screws 2 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 45 Nm Loosen the clamp screws on the right fork leg Take the motorcycle down from its stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 15 Nm AN WARNING rr If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the front wheel keep operating the hand brake until the pressure point returns It is very important to keep the brake disk free from oil and fatty matters otherwise the braking effect would be strongly reduced TIRES AIR PRESSURE front rear Offroad 1 0 bar 14 psi 1 0 bar 14 psi AND ENGIN Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Remove the collar nut 1 remove the chain tensioner 2 and pull out the wheel spindle 3 until you can push the rear wheel forwards Take the chain off the rear sprocket pull out the wheel spindle and carefully remove the rear
49. ircuit button SX Filler cap To open it Press the release button 2 and turn the tank cap in a coun terclockwise direction To close it Put the tank cap back on and turn in a clockwise direction until the release button snaps into place Install tank breather hose 3 without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor Choke knob When pulling the choke knob 4 fully towards the top a bore is opened in the carburetor Through this bore the engine can take in additional fuel This results in a rich fuel air mixture that is needed for a cold start When pressing the choke knob downward in the carburetor the bore is closed again Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to your seat position see maintenance work Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws
50. is purpose remove screws 9 and cover together with the rubber boot 10 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary add DOT 5 1 brake fluid Motorex Brake Fluid 5 1 CAUTION BREMBO clutch fittings are installed in the 250 300 models and filled with DOT 5 1 brake fluid To make sure the clutch operates smoothly never add hydraulic oil to these systems AND ENGIN Bleeding the hydraulic clutch The clutch control needs to be bled as soon as the resistance in the clutch lever starts to feel unresponsive You will need to use a bleeding syringe spe cial tool Make sure to use Motorex clutch fluid 75 for the 125 150 SX models and Motorex DOT 5 1 brake fluid for the 250 SX models Both are available from your KTM dealer Turn the handlebar until the master cylinder is in a horizontal position remove the screws 1 the cover 2 and the rubber boot 3 Fill the bleeder syringe 4 with a suitable fluid see Technical Specifications Engine Remove the bleeder screw from the slave cylinder 5 and mount the bleeder syringe Press oil into the system until the oil runs out of the hole 6 in the master cylinder without bubbles Occasionally extract the oil from the master cylin der reservoir to keep it from overflowing After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the oil level in the reservoir and mount the
51. lag must be correctly adjusted before the riding sag can be determined Determining the static sag of the shock absorber The static sag should be as close as possible to 33 mm Deviations of more than 2 mm can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the motorcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 567 mm Sees E E E E E eee ee hae oa ee eee ee 33 mm If the static sag is lower the spring preload of the shock absorber must be increased if the static sag Is reduced the spring preload must be higher See chapter Changing the spring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level
52. llan head screws handlebar support Collar screw shock absorber top M10 10 9 M12 10 9 Loctite 243 40 Nm Loctite 243 80 Nm Collar screw shock absorber bottom M12 10 9 Loctite 243 80 Nm Flat head screws subframe Collar nuts rear sprocket screws Collar screw ball joint push rod rear brake cylinder M8 10 9 M8 10 9 M6 10 9 Loctite 243 40 Nm Loctite 243 35 Nm Engine mounting bolts M10 10 9 Engine brace Screw adjusting ring spring preload shock absorber M8 10 9 M6 Spoke nipple M4 5 M5 Other collar screws on chassis M6 M8 Other collar nuts on chassis M6 M8 ENGINE 125 SX 150 SX 250 SX Design Liquid cooled single cylinder two stroke engine with intake and exhaust control Piston displacement 124 8 ccm 143 6 ccm 249 ccm Bore stroke 54 54 5 mm 2 12 2 14 in 54 58 4 mm 2 12 2 30 in 66 4 72 mm 2 61 2 83 in Fuel unleaded fuel with at least RON 95 USA Premium PON 91 mixed with high grade two stroke oil Oil gasoline ratio 1 40 1 40 when using high grade two stroke oil Motorex Cross Power ZT Crankshaft bearing Piston pin bearing 1 deep groove ball bearing 1 cylinder roller bearing Connecting rod bearing needle bearing needle bearing Piston cast aluminum Piston ring 2 half keystone rings 2 half keystone rings tw
53. m 0 9 in Thus you can put the handlebar in the position that is the most convenient for you AND ENGIN The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 2 are offset from the center by 3 5 mm 0 13 in Accordingly you can mount the han 3 dlebar in 4 different positions a For this purpose remove screws 3 of the handlebar clamps and screws 4 MER of the handlebar support Position the handlebar support and tighten screws 12 4 to 40 Nm Mount the handlebar and handlebar clamps and tighten screws 3 to 20 Nm The gap between the handlebar support and the handlebar clamps should be the same size in the front and in the rear A U The screws 4 must be secured with loctite 243 15 mm N BARN Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Press the chain upward at the end of the chain sliding component The dis tance between the chain and the swing arm should be approx 8 10 mm 0 31 0 39 in In the course of this procedure the upper chain portion A must be taut see drawing If necessary correct the chain tension AN WARNING If the chain tension is too great parts within the secondary transmission chain chain wheels and rear wheel bearings will be subjected to unnec essary stress resulting in premature wear and even chain breakage
54. mission oil 250 SX To change the transmission oil run the engine warm and set up the motorcy cle on a horizontal surface Remove the oil drain screw 7 and drain used oll into a container Clean the magnet of the oil drain screw and reinstall oil drain screw with seal M12x1 5 20 Nm Pour in 0 7 litres 0 18 USgal engine oil e g Motorex Top Speed 4T 15W50 replace plug 6 and check engine for leaks CAUTION Transmission and clutch will be subject to excessive wear and tear if you use too little or low grade oil Use only high grade oil e g Motorex Top Speed 4T 15W50 Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet i CAUTION If using a power washer do not point the water jet at the electric components plugs cables bearings carburetor etc The high pres sure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear Before cleaning with water plug the exhaust pipe to prevent water ingress You should use normal brand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush After the motorcycle has been rinsed with a soft water jet it should b
55. n Clean dust bellows Bleed fork legs Check swing arm bearings CHASSIS Check adjust steering head bearings Check tightness of all chassis screws triple clamps fork leg axle passage axle nuts and screws swing arm bearings shock absorber Check spoke tension and rim joint Check tires and air pressure Check chain rear sprockets and chain guides for wear fitment and tension WHEELS Lubricate chain Clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings The kilometer reading for inspection intervals should not exceed 5 hours Maintenance work performed by your authorized KTM workshop is not a substitute for care and maintenance by the driver 125 150 250 SX 2009 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor At least once LETT Ede PET Ey vite Replace the throttle slide jet needle float needle valve needle nozzle Check the reed type intake valve for wear Check the wear on the clutch disks and length of the clutch springs Check the cylinder and piston for wear Check function of exhaust control Check piston pin bearing nder and pi KAKILALA p fel n bear KEKIEHKIEN Replace the crankshaft main bearings Per Replace te conrod bearings el Check the entire transmission he shift mechanism and bearings le Complete maintenanc
56. nance schedule 18 PIVOL Deal NE std sg ey name 15 Rebound damping of fork Refilling the front brake fluid reservoir 23 Refilling the rear brake fluid reservoir 24 Refueling fuel ss to ao aa 12 Replacing fork springs 17 Replacing the front brake pads 24 Replacing the rear brake pads 25 RONE WIN pce ty sek ee ET RE ce dents 9 Serial Number location 5 SMIMICVED 2 ab bse ag Boe Sale SS oe ee 7 SMINERIdINE sickest ace geet at rs Teri rates 12 Shock absorber rebound damping 8 Short circuit DUTLOM u 30s nr nt a 6 SANS Ol ae ae atone uted tec act 11 Starting when the engine is cold 11 Starting when the engine is warm 11 Stopping and parking 12 STOFASRE it ed nee Le An NE Lie an 36 Technical Specifications Chassis 125 150 250 37 Technical Specifications Engine 125 150 250 39 Tires air pressure 4 air aoe hog ah ae Mas 27 What to do when the engine is flooded 11 What you should check before each start 10 Wiring Diagra n 2 EN Oa ee EN eue 44 321134 7en Ae 8002 S vanvayuaLliN 0104 SPensig y7 2 FOR MOTOREX Ales Oil of Switzerland J KTM Group Partner KTM Sportmotorcycle AG A 5230 Mattighofen www ktm com
57. nge the ignition curve via the handlebar switch Power Parts while driving Adjusting the engine characteristic via the auxiliary spring 250 The engine characteristic can be modified through various thicknesses of the auxiliary spring 1 An auxiliary spring designed for good driveability smooth power application is mounted in the condition at delivery One of the auxiliary springs can be mounted if you prefer an even smoother power application or an aggressive engine characteristic Auxiliary spring for good driveability mounted in condition at delivery Spare part number 546 37 072 300 YELLOW color mark Auxiliary spring for an even smoother power application included in scope of Supply Spare part number 548 37 072 100 GREEN color mark Auxiliary spring for aggressive engine characteristic included in scope of sup ply Spare part number 548 37 072 000 RED color mark To mount tilt the motorcycle approx 45 to the left remove both screws 2 lift off the closing cover 3 and remove the springs including the spring insert 4 from the clutch cover Pull both springs off the spring insert mount the auxiliary spring 1 and control spring 5 and slide both into the clutch cover until the recess in the spring insert 4 engages in the rocker arm Check the O ring in the closing cover mount the closing cover ensuring that the dolly screw 6 engages in the auxiliary spring Make sure you do not turn the d
58. notices that are marked as follows AN WARNING Orr Ignoring these instructions can be dangerous to life and limb i CAUTION ignoring these instructions may damage parts of the motorcycle or impair the motorcycle s traffic safety At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it SERVICE Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear An improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached The service work specified in the Lubrication and Maintenance Schedule must be performed by a KTM workshop and recorded in the service manual otherwise claims under th
59. nsulating material fibers escape through the holes in the perforated pipe with time causing the silencer to burn out In addition to causing a higher noise level it will also affect the power char acteristic The insulating material suitable for your exhaust is available from your authorized KTM workshop To replace the glass fiber yarn set 2 remove the end cap and pull off the outer pipe 3 Tape a new glass fiber yarn set to the inner tube and slide on the outer pipe Mount the end cap Make sure the caps are screwed on tightly Mount the muffler stress free before tightening the fixing screws A The exhaust system becomes very hot while the motorcycle is running Do not start work on the exhaust system until it has properly cooled down to avoid burns Changing the original position of the clutch lever 125 150 The adjusting screw 4 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size The clutch lever moves closer to the handlebar if the adjusting screw is tur ned in a clockwise direction The clutch lever moves away from the handle bar if the adjusting screw is turned in a counterclockwise direction CAUTION Adjustment of the clutch lever position is only possible within certain limits Only turn the adjusting screw manually and never apply excessive force Changing the original position of the clutch lever 250
60. nt the hand brake cylinder and tighten the screws to 10 Nm Mount the staring number plate Mount the front wheel see Dismounting and mounting the front wheel Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcy cle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust the 5 clamping screws 1 and 3 loosen the upper triple clamp and turn the end screw 2 until no play is left Don t tighten the steering stem bolt all the way otherwise the bearings will be dam aged With a plastic hammer lightly tap on the triple clamp to release ten sion Hold the middle clamp screw 3 in place with Loctite 243 Retighten the five pinch bolts 17 Nm pinch bolts 1 Loctite 243 17 Nm pinch bolts 3 ADT If the steering head bearing is not adjusted to be free of play the motorcy cle will exhibit unsteady driving characteristics and can get out of control Hold the midddle clamp screw 3 in place with Loctite 243 CAUTION If you drive with play in the steering head bearing for longer periods the bear ings and subsequently the bearing seats in the frame will be destroyed The steering head bearings should be regreased at least once a year e g Motorex Long Term 2000 How to change the handlebar position The handlebar position can be readjusted by 22 m
61. o plain compression rings tk d iston Dimension A near Ignition timing Spark plug 0 0 mm 1 4 mm 0 055 in BTDC NGK BR9 ECMVX 0 0 mm 1 4 mm 0 055 in BTDC NGK BR9 ECMVX 0 0 0 1 mm 1 9 mm 0 074 in BTDC NGK BR8 ECM Electrode gap 0 60 mm 0 023 in height of the control flap Dimension Z 43 5 mm 1 68 in 43 1 mm 1 69 in 47 5 mm 1 87 in Exhaust control start open 5500 min Exhaust control fully open 7000 7500 7900 min red yellow green spring Primary drive Straight cut spur gears Primary ratio 23 73 26 72 Available chain sprockets 13t 14t for chain 5 8 x 1 4 Clutch multiple disc clutch in oil bath hydraulically operated Motorex Hydraulic Fluid 75 Motorex Hydraulic Fluid 75 Motorex brake fluid DOT 5 1 Transmission 6 speed claw actuated 6 speed claw actuated 5 speed claw actuated Gear ratio lst gear 2nd gear 3rd gear Ath gear 5th gear 6th gear Gear lubrication 13 432 12015 215 30 13917 H 17 28 4S20H 20 28 10919 19 23 6 S22H 22 24 1532 2930 3928H 4528 DS23H 6S24H 13 32 acolo LOC 1391 H 17 28 4S20H 20 28 POSLIH 19 23 OS22H 22 24 18327 2930 3928H 4528 DSZ23H 6524H 0 7 liter 0 18 USgal Motorex Top Speed 4T 15W50 1S14 14 28 2515 15 24 3S18 18 24 4521 21 24
62. olly screw since this will impair the engine characteristic CAUTION Be careful not to turn the spring dolly 6 otherwise the engine characteris tic will deteriorate You can also change the engine characteristic through the interaction between the ignition curve auxiliary spring 250 only and exhaust The following table shows examples of possible combinations Further combinations can be adjusted at random depending on the driving requirements 250 SX 2009 Engine performance Standard setting Driveability Standard setting Ignition curve soft soft performance performance performance Auxiliary spring 250 green yellow yellow yellow red Exhaust 250 SX standard 250 SX standard 250 SX standard 250 SXS 250 SXS Example of application extremely difficult difficult track average track good track conditions special track track conditions conditions conditions nonskid roadway well conditions very selective very selective not much prepared MX special deep sand very fast hard hardly any trac traction tiring Stage track routing very well tion very tiring prepared track AND ENGIN Check transmission oil level 125 150 SX In order to check the transmission oil level the control screw 1 on the clutch cover Is to be removed Oil should just barely escape from the inspection open ing when the motorcycle is in an upright position If necessary remove
63. olve potential problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others Enjoy driving your motorcycle KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine Page SERIAL NUMBER LOCATIONS 5 Chassisihumber ss sep aan OM a aoe AE Re ae OS 5 Engine number engine type 5 OPERATION INSTRUMENTS 5 CHEN IVe Re ee ea wen 5 Hand brake lever essaie ds meute eee Saut 5 Short circuit button serre en 6 PUR Cap see eaaa aeaa a ea 6 PCI TAO are ee een A EESE ETE TE 6 CHOKE KNOD A is AS aie a GS di a ace a ee 6 SHIELJEYEL SR AN nr nn AOR Na ire tre 7 Kieckstarler ss N Eee Compression damping of fork 7 Rebound damping of fork 7 Compression damping of shock absorber 8 Rebound damping of shock absorber 8 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ar eu nn Hoa ol cane eae AAR ace 9 Instructions for your first ride 9 PUM MOMs ESS meer de en Son dm a Ta een ee A 9 DRIVING INSTRUCTIONS 10 What you should check before each start 10 Star
64. ose and the thickness of the brake linings Check free travel of the hand brake lever and foot brake lever AN WARNING ee If the resistance in the hand brake lever or foot brake pedal feels spongy too much give this is an indication that something is wrong with the brake system Don t ride your motorcycle anymore without first having the brake sys tem looked over by a KTM dealer 6 CABLES Check correct adjustment and easy running of all control cables COOLING FLUID Check the level of cooling fluid when the engine is cold Starting when the engine is cold 1 Open fuel tap 2 Put the gear in neutral 3 Activate cold starting aid choke 4 Leave throttle closed or open it no more than 1 3 and kick down kick Starter vigorously all the way AN WARNING For starting always put on your motorcycle boots to avoid injuries You could slip off the kickstarter or the motor could kick back and fling your foot upwards Forcefully kick the kickstarter down the whole way and do not open the throttle A kickstart with too little momentum and an opened throttle increases the kicking back risk Check for power transmission at temperatures below O C 32 F before you actuate the kickstarter If you depress the kickstarter without feeling any resistance power is not being transmitted This could cause injuries Do not start the engine and allow it to idle in a closed area Exhaust fumes are poisonous and can ca
65. oss Power 2T Not enough oil or low grade oil can cause erosion of the piston if you use too much oil the engine can start smoking and foul the spark plug and the exhaust control system In the case of a leaner adjustment of the carburetor proceed cautiously Always reduce the jet size in steps of one number to avoid overheating and piston seizure NOTE If the engine does not run properly despite a changed adjustment look for mechanical faults and check the ignition system General information on carburetor wear Engine vibrations subject the throttle slide jet needle float needle valve and the needle jet to extreme wear Wear leads to malfunc tioning of the carburetor e g over enrichment These parts should be replaced after 100 operating hours The carburetor body main jet holder and the float support should be replaced after 200 operating hours Definitions Mixture too rich Too much fuel in proportion to air Mixture too lean Not enough fuel in proportion to air Idling range A Operation with closed throttle valve This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 Only make adjust ments when the engine is hot Ea To this end slightly increase the idling speed of the engine by means of the main Jet idle adjusting screw Turning it clockwise produces a higher idling speed and jet needle turning the screw counterclockwise produces a lower idling speed Cre
66. poe 22821 1528 2524 3824 4524 woogie Available chain sprockets 137 147 f r Kette 5 8 x 1 4 Coolant Carburetor 1 2 litres 50 anti freeze 50 distilled water at least 25 C 13 F Ignition system KOKUSAN 2K 1 KOKUSAN 2K 1 stator 2K 1 flywheel 2K 2 flat slide carburetor carburetor setting see table Air filter BASIC CARBURETOR SETTING Carburetor wet foam type air filter insert Keihin PWK S 38 AG Keihin PWK S 38 AG Keihin PWK 36 S AG Carburetor setting mark AQ7 AQ8 FKO180 Main jet Idling jet 182 180 185 42 40 45 182 180 185 42 40 45 158 155 160 45 40 Starting jet 85 85 85 Jet needle NOZI NOZH NOZJ NOZI NOZH NOZJ NIEI NIEH Needle position from top Throttle valve 7 6 5 6 5 Air adjustment srew open 1 5 turns 1 5 turns l turn TIGHTENING TORQUES ENGINE Flange bolts cylinder head 125 150 SX Flange bolts cylinder head 250 SX Nuts cylinder base 125 150 SX Nuts cylinder base 250 SX Flywheel collar nut M12x1 60 Nm Nut primary sprocket 125 150 SX Nut primary sprocket 250 SX M16x1 5 links M18x1 5 links Loctite 243 130 Nm Loctite 270 150 Nm Nut inner clutch hub 125 150 SX Nut inner clutch hub 250 SX M18x1 5 M18x1 5 Loctite 243 130 Nm Loctite 270 100 Nm Collar screw clutch springs Oil drain pl
67. rbing the leaking fuel Unscrew the plug 1 and clean it with compressed air Then mount the plug together with the gasket open the fuel tap and check the float chamber for leaks AN WARNING re Fuel is easily flammable and toxic When handling fuel be sure to exercise the utmost caution Never perform any work on the fuel system near open flames or burning cigarettes Always allow the engine to cool off first Immediately clean up any fuel which may have been spilled Materials satu rated with fuel are also easily flammable In case you ingested fuel or fuel splashed into your eyes consult a doctor immediately Dispose of the fuel properly Checking the float level Arrange the carburetor diagonally at about 60 so that the spring in the float needle valve is not pressed together In this position the edge of the float should be parallel with the float chamber sealing surface see illustration AND ENGIN Adjusting the engine characteristic via the ignition curve 125 150 250 2 ignition curves PERFORMANCE and SOFT are stored in the digital box The PERFORMANCE ignition curve is activated in the condition at delivery The SOFT ignition curve can easily be activated by disconnecting the socket connector under the tank To change the ignition curve remove the seat and tank A PERFORMANCE higher engine performance socket connector connected B SOFT better driveability socket connector disconnected You can also cha
68. ruts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubricants Grease and other lubricants cause the Teflon coat to dissolve whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing for example 250 SX Spring rate 70 75 80 72 250 85 90 95 Riders weight inclusive gears in kilogram MODELL SOFTER STANDARD 12187E01 125 150 SX 12187E03 250 SX 60 250 66 250 63 250 69 250 HARDER 66 250 72 250 AND ENGIN Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork shock absorber swing arm and frame from being damaged the basic setup of the suspension components must be suitable for your weight At delivery KTM s offroad motorcycles are set to accommodate a driver weighing 75 bis 85 kg wearing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accordingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring Is Suitable for your weight by checking the riding sag The static s
69. ted Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other man ufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you it should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and the rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet Pay attention to running in procedure Running in Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time Therefore every engine needs to be broken in For this reason during its first 500 kilometers 300 miles or 5 hours the engine must not be revved up to its perform ance limits Apply low but changing loads for running in i CAUTION Do not drive at full load for the first 500 kilometers 300 miles or 5 hours AN WARNING Wear suitable clothing when driving a motorcycle smart KTM drivers always wear a helmet boots gloves and a jacket regardless of whether driving all day or just go for a short ride Do not drive after havin
70. ter these parts get the weaker the breaking effect In extreme cases the entire braking system can fail If the resistance in the hand brake lever or foot brake pedal feels spongy too much give this is an indication that some thing is wrong with the brake system Don t ride your motorcy cle anymore without first having the brake system looked over by a KTM dealer Stopping and parking Close the throttle and apply the hand and foot brake simultane ously Be especially careful when you apply the brakes on sandy wet or slick surfaces Always apply the brakes intuitively locked wheels can cause the bike to skid or crash Shift down to a lower gear to match your speed Always apply the brakes before you enter a curve ADT Motorcycle engines produce a great amount of heat while running The engine exhaust pipe muffler brake rotors and shock absorbers can become very hot Do not touch any of these parts after start ing the motorcycle and take care to park it where pedestrians are not likely to touch it and get burned CAUTION Close the fuel tap when leaving your vehicle Otherwise the car buretor may get flooded and fuel will enter the engine Never park your motorcycle in places where there exist fire haz ards due to dry grass or other easily flammable materials Refueling fuel Unleaded premium gasoline RON 95 mixed with high grade two stroke oil Mixture ratio 125 150 SX 1 40 Mixture ratio 2
71. the hand brake lever 23 Checking the brake fluid level front brake 23 Refilling the front brake fluid reservoir 23 Checking the front brake pads 23 Replacing the front brake pads Checking the rear brake fluid level Refilling the rear brake fluid reservoir Changing the basic position of the foot brake pedal Checking the rear brake pads Replacing the rear brake pads Dismounting and mounting the front wheel Dismounting and mounting the rear wheel Tires air pressure Checking spoke tension Cooling system Checking the coolant level Bleeding the cooling system Cleaning the air filter Exhaust system Changing the original position of the clutch lever Changing the oil level of hydraulic clutch 125 150 Changing the oil level of hydraulic clutch 250 Bleeding the hydraulic clutch Carburetor adjustment Draining the float chamber of the carburetor Checking the float level Adjusting the engine characteristic via the ignition curve Adjusting the engine characteristic via the auxiliary spring Check transmission oil level 125 150 Changing the transmission oil 125 150 Check transmission oil level 250 Changing the transmission oil 250 CLEANING vse mens dense yee pa otre ets
72. the steering head bearing 19 Cleaning the dust sleeves of the telescopic fork 17 Cleaning the air filter 29 Check chain tension 20 Check transmission oil level 125 150 35 Check transmission oil level 250 35 Compression damping of fork 7 Compression damping of shock absorber 8 Correct chain tension 20 Conservation for winter operation 36 Cooling system sa 28 Correct chain tension 21 Determining the static sag of the shock absorber 16 Determining the riding sag of the shock absorber 16 Dismounting and mounting the front wheel 26 Dismounting and mounting the rear wheel 27 Draining the float chamber of the carburetor 33 Driving INStrUCtionS ss es ee 10 Engine number engine type 5 FXNause system aan 30 POL CAPE ee 68 oe es ace ee A Be ARE ch Bei 6 MOTS RS CR re ein 6 General information about KTM disc brakes 22 General tips and wanrnings for starting the motorcycle 9 Page Hand brake lever 5 How to change the handlebar position 19 Instructions for your first ride 9 RATE IC IEC PET Wh ea Set At a TR ET wed Bee aa 7 Maintenance work on chassis and engine 15 Operation instruments 5 Periodic mainte
73. ting when the engine is cold 11 Starting when the engine is warm 11 What to do when the engine is flooded 11 Starine ON inks ta ie eo a whee EEE Her 11 SMIRNE RIONE u een rat ane 12 Braking satisfait en 12 Stopping and parking 12 Refueling fuel vs Hate ew ea le 12 PERIODIC MAINTENANCE SCHEDULE 13 MAINTENANCE WORK ON CHASSIS AND ENGINE 15 Changing the spring preloading of the shock absorber 15 Pivot bearing Basic suspension setup for the weight of the driver 16 Checking the shock absorber and spring 16 Determining the static sag of the shock absorber 16 Determining the riding sag of the shock absorber 16 Checking the basic setup of the telescopic fork 17 Changing the spring preload on the telescopic fork 17 Replacing fork springs 17 Breather plug front fork 17 Cleaning the dust sleeves of the telescopic fork 17 Changing the fork offset caster Checking and adjusting the steering head bearing 19 How to change the handlebar position 19 Check chain tension 20 Adapting the chain guide 20 Correct chain tension 21 Chain maintenance mas 21 CHANT Wear Secs sar S08 ne ne UN ic ae Scere Ea 21 General information about KTM disc brakes 22 Adjusting the free travel at
74. ug M6 M12x1 5 10 Nm Oil drain plug 125 150 SX clutch cover M10x1 Drain plug water pump cover Collar screw water pump cover M10x1 M6 Loctite 243 10 Nm Water pump wheel Crankcase and clutch cover bolts M5 M6 Loctite 243 6 Nm 10 Nm Collar screws ignition cover Spark plug M5 M14x1 25 5 Nm 25 Nm Collar screws ignition system Collar screw kickstarter lever M5 M8 Loctite 243 6 Nm Loctite 243 25 Nm Collar screw shifting lever Other screws M6 10 9 Loctite 243 14 Nm VERGASERREGULIERUNG CARBURETOR SETTING 125 SX 2009 KEIHIN PWK S 38 AG MEERESHOHE TEMPERATUR 20 C bis 7 C 6 C bis 5 C 6 C bis 15 C 16 C bis 24 C 25 C bis 36 C 37 C bis 49 C ALTITUDE TEMPERATURE 2F to 20 F 19 F to 41 F 42 F to 60 F 61 F to 78 F 79 F to 98 F 99 F to 120 F 3000 m 1 5 2 5 10000 ft 42 38 A NEEDLE NOZI NOZJ 2301 m POS 3 7501 ft 182 178 2300 m 7500 ft NEEDLE 1501 m POS 5001 ft 1500 m 5000 ft NEEDLE 751m POS 2501 ft 750 m 2500 ft NEEDLE 301m POS 1001 ft 300 m 1000 ft NEEDLE Meeresniveau POS Sea level MJ LSO Luftregulierschraube offen 1 ASO Air screw open from fully seated LD Leerlaufd se 3 IJ Idling jet POS Nadel Clip Position von oben POS Needle clip position from top HD Hauptd se 977 MJ Main jet NICHT F R STRASSENBETRIEB NOT FOR HIGHWAY
75. use loss of consciousness and death Always pro vide adequate ventilation while the engine is running CAUTION Do not ride your motorcycle with full load and do not rev up the engine when cold Since the piston warms up and expands faster than the water cooled cylinder this might cause engine damage Always let engine idle until warm or drive it warm at low r p m speeds NOTE The highly inflammable components in modern fuels volatilize if left stand ing for longer periods of time If the motorcycle has not been used for over 1 week the fuel should be drained from the float chamber The engine will Start up immediately if the float chamber is filled with fresh ignitable fuel Starting when the engine is warm 1 Open fuel tap 2 Put the gear in neutral 3 Open throttle to 1 2 and kick down kickstarter vigorously What to do when the engine is flooded 1 Close fuel tap 2 Start engine with full throttle If necessary unscrew spark plug and dry it 3 Once the engine is running open fuel tap again Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and accelerate at the same time A WARNING OOO Before you start off check that the main or side stand has been swung right up to the top If the stand drags on the floor you may lose control of your motorcycle Before starting for an off road tour it is recommended to additionally secure the side stand with th
76. ve type of shock absorber Typ WP Suspension 12187E01 23 clicks Typ WP Suspension 1218 E03 22 clicks AN WARNING OO The damping unit of the shock absorber is filled with high compression nitro gen Never try to take the shock absorber apart or to do any maintenance work yourself Severe injuries could be the result Never unscrew the black screw 5 connection 15mm NERA gt AND WARNING Instructions for your first ride Make sure the work for the pre delivery inspection was per formed by your authorized KTM workshop The DELIVERY CER TIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle Thoroughly read the whole instruction manual before starting for your first tour Familiarize yourself with the controls Adjust the clutch lever the hand brake lever and the foot brake pedal to the most comfortable position Get used to handling the motorcycle on an empty parking lot Or open space before going for a longer ride Also try to ride as Slowly as possible while standing upright to improve your feeling for the vehicle Do not drive along off road trails which go beyond your ability and experience Hold the handlebar with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system Is overhea
77. w 1 from the upper triple clamp loosen the clamp screw and upper triple clamp on the seat Remove the O ring 3 and the pro tection ring 4 Tap gently on the lower triple clamp with a rubber hammer to loosen the steer ing stem 5 out of the bearing seat Take the lower triple clamp with the steer ing stem out of the steering head Remove the collar screw from the lower triple clamp and pull out the steer ing stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp tighten the collar screw all the way to the stop Grease the steering head bearing and sealing elements AN WARNING OOO Be sure to lock the thread on the collar screw 2 with Loctite 243 Do not confuse the collar screw 2 with the blind screw 1 AND ENGIN Mount the lower triple clamp upper steering head bearing protection ring O ring upper triple clamp and the blind screw Tighten the collar screw on the lower triple clamp to 60 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages Adjust the steering head bearing with zero clearance see section on check ing and adjusting the steering head support Hold the middle clamp screw A in place with Loctite 243 Tighten the clamp screws on the upper triple clamp to 17 Nm in 3 stages i CAUTION Hold the middle clamp screw A in place with Loctite 243 Mount the front wheel fender and tighten the screws to 10 Nm Mou
78. wheel from the swing arm CAUTION Do not operate the rear brake when the rear wheel has been dismounted Make sure the brake disc is always on top when you lay down the wheel otherwise the brake disc can be damaged If the axle is dismounted clean the thread of the wheel spindle and col lar nut thoroughly and apply a new coat of grease to prevent the thread from jamming The rear wheel is remounted in the reverse order Before tightening the col lar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws A re If you don t happen to have a torque wrench at hand make sure you have the tightening torque corrected by a KTM dealer as soon as possible A loose axle may lead to an unstable driving behavior of your motorcycle After mounting the rear wheel keep operating the rear brake until the pres sure point returns It is very important to keep the brake disk free from oil and fatty matters otherwise the braking effects would be strongly reduced Tighten the collar nut with the required torque A loose wheel spindle may lead to an unstable behavior of your motorcycle Tires air pressure Tire type tire condition and air pressure level affect the way your motorcy cle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications and in the homolo gation c

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