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KTM 125 SX manual

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  • Page 1

    KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 6/2006 FOTO: MITTERBAUER 125 SX 250 SX OWNER’S MANUAL 2007 ART. NR. 3.211.174 EN ENGLISH[...]

  • Page 2

    ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer 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,[...]

  • Page 3

    ENGLISH 2 INTRODUCTION » 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?[...]

  • Page 4

    ENGLISH 3 INTRODUCTION » 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. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications m[...]

  • Page 5

    ENGLISH 4 TABLE OF CONTENTS » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5 Clutch lever . . . . . . . . . . . . . . [...]

  • Page 6

    ENGLISH 5 SERIAL NUMBER LOCATIONS » 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[...]

  • Page 7

    ENGLISH 6 OPERATION INSTRUMENTS » ON OFF 3 1 2 Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap T o open it: turn filler cap counter-clockwise. T o close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather[...]

  • Page 8

    ENGLISH 7 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 . OPERATION INSTRUMENTS » 1 N 2,3,4,5, (6) Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivell[...]

  • Page 9

    ENGLISH 8 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 at the bottom of the fork legs. T urn the screw [3] clockwise to increase damping, turn it counterclockwise to reduce damping during compression. ST ANDARD ADJUSTM[...]

  • Page 10

    ENGLISH 9 OPERATION INSTRUMENTS » 1 2 Rebound damping of shock absorber By using the adjusting screw [4] , the degree of damping of the rebound can be adjusted. T urn the knob to the right side to increase damping, turn it to the left side to reduce damping during rebounding. ST ANDARD ADJUSTMENT : – T urn the adjusting screw clockwise to the st[...]

  • Page 11

    ENGLISH 10 DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in 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 T oo little [...]

  • Page 12

    ENGLISH 11 DRIVING INSTRUCTIONS » 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 . – For starting always put on your motorcycle boots to avoid injuries. Y ou could slip off the ki[...]

  • Page 13

    ENGLISH 12 DRIVING INSTRUCTIONS » Shifting/Riding Y ou 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 . T urn 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 th[...]

  • Page 14

    ENGLISH 13 PERIODIC MAINTENANCE SCHEDULE » 125/250 SX 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Before each race 1st service after 10 hours every 20 hours every 40 hours at least once a year ENGINE Check gear box oil level z Change gear box oil z z z z Check spark plugs, adjust distance between electrodes z z Renew spar[...]

  • Page 15

    ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE » 125/250 SX 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Every 20 hours Every 40 hours Every 60 hours Every 80 hours At least once a year Every 2 years Clean and adjust carburetor z Replace the throttle slide, jet needle, float needle valve, needle[...]

  • Page 16

    ENGLISH 15 MAINTENANCE WORK ON CHASSIS AND ENGINE » Maintenance and adjusting work marked with an asterisk * requires expert skills and technical know-how . For your own safety , always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified, skilled staff. – If using a pow[...]

  • Page 17

    ENGLISH 16 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o 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 motorcycle[...]

  • Page 18

    ENGLISH 17 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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[...]

  • Page 19

    ENGLISH 18 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. This allows you to optimize the han- dling 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 [...]

  • Page 20

    ENGLISH 19 MAINTENANCE WORK ON CHASSIS AND ENGINE » 2 1 1 A 3 Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw . T ighten 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. Adj[...]

  • Page 21

    ENGLISH 20 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 b[...]

  • Page 22

    ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » 15 KG 33 lbs max. 272 mm 1 2 3 16 17 18 B 1 2 3 4 B 2 4 3 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 trea- ted with hot grease or chain spray (e.g. Motorex Chainlube 622).. No [...]

  • Page 23

    ENGLISH 22 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 [...]

  • Page 24

    ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » 5 mm min. 3 mm 1 2 3 4 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[...]

  • Page 25

    ENGLISH 24 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[...]

  • Page 26

    ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » min. 1 mm 1 3 2 2 4 5 7 6 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). At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure. For your[...]

  • Page 27

    ENGLISH 26 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. 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 [4] , remove the chain ten[...]

  • Page 28

    ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » TIRES - AIR PRESSURE front rear Offroad 1,0 bar 1,0 bar Tires, air pressure T ire 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. – T ire size can be found in the [...]

  • Page 29

    ENGLISH 28 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 [...]

  • Page 30

    ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accu- mulated. T o clean, lift the filter box cover (see illustration) and pull off towards the front. Detach the bottom of the filter retaining bracket [1] , tilt aside and remove the air filter [2] [...]

  • Page 31

    ENGLISH 30 Bleeding the hydraulic clutch * The clutch control needs to be bled as soon as the resistance in the clutch lever starts to feel unresponsive. Y ou will need to use a bleeding syringe (spe- cial tool). Please note that Motorex 75 clutch fluid must be used for the 125 models and Motorex DOT . 5.1 brake fluid for the 250 models. Both are a[...]

  • Page 32

    ENGLISH 31 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[...]

  • Page 33

    ENGLISH 32 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. W ater 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 [...]

  • Page 34

    ENGLISH 33 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the engine characteristic via the ignition curve (125-250) 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 conne[...]

  • Page 35

    ENGLISH 34 Check transmission oil level (125 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 the plug [2] and top up with oil (e. g. Motorex T op Speed 4T 15W50[...]

  • Page 36

    ENGLISH 35 CLEANING » CONSERVATION FOR WINTER OPERATION » STORAGE » 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 wa[...]

  • Page 37

    ENGLISH 36 TECHNICAL SPECIFICATIONS – CHASSIS 125/250 SX 2007 » CHASSIS 125 SX 250 SX Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 MXMA CC (Closed Cartridge Multi Adjuster) Wheel travel front/rear 300/335 mm (11.8/13.2 in) Rear suspension WP PDS 5018 DCC B07 Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10[...]

  • Page 38

    ENGLISH 37 TECHNICAL SPECIFICATIONS – CHASSIS 125/250 SX 2007 » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm Brake disks M6 14 Nm Clamping screws, upper fork bridge M8 17 Nm Clamping screws, lower fork bridge M8 12 Nm Clamping screws, upper steering stem M8x25 Loctit[...]

  • Page 39

    ENGLISH 38 TECHNICAL SPECIFICATIONS – ENGINE 125/250 SX 2007 » ENGINE 125 SX 250 SX Design Liquid-cooled, single-cylinder , two-stroke engine with intake and exhaust control Piston displacement 124,8 cm 3 249 cm 3 Bore / stroke 54 / 54,5 mm 66,4 / 72 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91), mixed with high grade two str[...]

  • Page 40

    ENGLISH 39 TECHNICAL SPECIFICATIONS – ENGINE 125/250 SX 2007 » BASIC CARBURETOR SETTING 125 SX 250 SX Carburetor Keihin PWK 39 Keihin PWK 36 S AG Carburetor setting mark 98SA0/98SA1 FK0160 Main jet 188 (185/190) 158 (155, 160) Idling jet 45 (48) 45 (42) Starting jet 85 85 Jet needle R1469D (R1468D) N1EI (N1EH) Needle position from top II III Thr[...]

  • Page 41

    ENGLISH 40 INDEX » Page Adapting the chain guide . . . . . . . . . . . . . . . . . . . . .20 Adjusting the engine characteristic via the ignition curve . .33 Adjusting the engine characteristic via the auxiliary spring .33 Adjusting the free travel at the hand brake lever . . . . .23 Basic suspension setup for the weight of the driver . . .16 Blee[...]

  • Page 42

    ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAMM 7 0 0 2 0 5 2 - 5 2 1 X S 6 0 0 2 . 4 0 . 0 1 l i o c n o i t i n g i n o t t u b p o t s G 3 p u k c i p r o t a r e n e g C D I 0 0 3 . 2 3 0 . 9 3 . 8 4 5 r o t c e l e s e v r u c n o i t i n g i red -whit e red-black e t i h w - e u l b n w o r b k c a l b - w o l l e [...]

  • Page 43

    ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAMM » ENGLISH DEUTSCH IT ALIANO CABLE COLOURS KABELF ARBEN CA VO COLORA TO bl: black bl: schwarz bl: nero ye: yellow ye: gelb ye: giallo bu: blue bu: blau bu: blu gr: green gr: grün gr: verde re: red re: rot re: rosso wh: white wh: weiß wh: bianco br: brown br: braun br: mar[...]

  • Page 44

    VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK-S 39 AG 125 SX 2007 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 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 61 °F to 78°F 25°C bis 36°C 79°F to 98°F 37°C bis 49°C 99°F to 120°F 3000 m 10000 ft 2301 m 7501 ft LSO ASO LD IJ NA[...]

  • Page 45

    VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK-S 36 AG 250 SX 2007 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 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 61 °F to 78°F 25°C bis 36°C 79°F to 98°F 37°C bis 49°C 99°F to 120°F 3000 m 10000 ft 2301 m 7501 ft LSO ASO LD IJ NA[...]

  • Page 46

    KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 6/2006 FOTO: MITTERBAUER 125 SX 250 SX MANUAL DE INSTRUCCIONES 2007 ART. NR. 3.211.174 ES ESPAÑOL[...]