KTM 250 SX (2015) manual

OWNER'S MANUAL 2015 125 SX EU 125 SX US 150 SX EU 150 SX US 250 SX EU 250 SX US 250 XC EU/US 300 XC EU/US Art. no. 3213173en[...]

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DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Ch[...]

TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 5 1.1 Symbols used ....................................... ............ 5 1.2 Formats used ................................ .................... 5 2 SAFETY ADVICE ...................................... ..................... 6 2.1 Use definition -[...]

TABLE OF CONTENTS 3 11.24 Removing the air filter x ................................ 49 11.25 Cleaning the air filter and air filter box x ......... 49 11.26 Installing the air filter x ................................. 50 11.27 Securing the air filter box lid x ....................... 50 11.28 Sealing the air filter box x ........................ [...]

TABLE OF CONTENTS 4 21.4 Capacities .................................................. .. 112 21.4.1 Gear oil ........................... ......................... 112 21.4.2 Coolant .................................................... 112 21.4.3 Fuel .............................................. .......... 112 21.5 Chassis .......................[...]

1 MEANS OF REPRESENTATIO N 5 1.1 Symbols used The meaning of specific symbols is described below. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of you[...]

2 SAFETY ADVICE 6 2.1 Use definition - intended use (All SX models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle may only be used in closed off[...]

2 SAFETY ADVICE 7 2.5 Safe operation Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result [...]

3 IMPORTA NT INFORMATION 8 3.1 Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net ; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting[...]

4 VIEW OF VEHICLE 9 4.1 View of the vehicle from the left front (example) B02068-10 1 Hand brake lever ( p. 12) 2 Kill switch ( p. 12) 3 Clutch lever ( p. 12) 4 Air filter box lid 5 Fuel tap 6 Choke ( p. 15) 7 Shift lever ( p. 15) 8 Chain guide[...]

4 VIEW OF VEHICLE 10 4.2 View of vehicle, rear right (example) B02069-10 1 Seat 2 Filler cap 3 Throttle grip ( p. 12) 4 Shock absorber rebound adjustment 5 Level viewer for brake fluid, rear 6 Shock absorber compression adjustment 7 Foot brake lever ( p. 16) 8 Kick starter ( p. 16)[...]

5 SERIAL NUMBERS 11 5.1 Chassis number 401945-10 The chassis number  is stamped on the right side of the steering head. 5.2 Type label 401946-10 The type label  is fixed to the front of the steering head. 5.3 Engine number 401949-10 The engine number  is stamped on the left side of the engine under the engine sprocket. 5.4 Fork part number[...]

6 CONTROL S 12 6.1 Clutch lever 101655-10 (125/150 SX) The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. L01224-11 (All 250/300 models) The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 6.2 Hand brake lev[...]

6 CONTROL S 13 6.5 Electric starter button (All XC models) L01200-10 The electric starter button  is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position • Electric starter button pressed – In this position, the electric starter is actuated. 6.6 Opening the filler cap Danger Fire hazard  [...]

6 CONTROL S 14 6.7 Closing the filler cap B02071-11 (All SX models) – Mount filler cap  and turn it clockwise until the fuel tank is tightly closed. Info Run the fuel tank breather hose  without kinks. B02073-11 (All XC models) – Mount filler cap  and turn it clockwise until the release button engages. Info Run the fuel tank breather h[...]

6 CONTROL S 15 6.9 Fuel tap (All XC models) L00904-10 The fuel tap is on the left side of the fuel tank. Tap handle  on the fuel tap is used to open or close the supply of fuel to the carbu- retor. Possible states • Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor. • Fuel supply open ON – Fuel can flow from [...]

6 CONTROL S 16 401950-13 (250 SX EU, 250 SX US) The gear positions can be seen in the photograph . The neutral or idle position is between the first and second gears. 6.12 Kick starter 0 0 1 1 401954-10 The kick starter  is fitted on the right side of the engine. The top part can be swiveled. 6.13 Foot brake lever 401956-10 Foot brake lever  [...]

6 CONTROL S 17 401944-10 The side stand is used to park the motorcycle. Info When you are riding, side stand  must be folded up and secured with rubber band  .[...]

7 PREPARIN G FOR USE 18 7.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Missing or poor protective clothing presents a[...]

7 PREPARIN G FOR USE 19 – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) – Check the spoke tension. ( p. 74) Info The spoke tension must be checked after h[...]

7 PREPARIN G FOR USE 20 – Change the radiator cap. B00435-01 – Mount the dust cover for the air filter. Dust cover for air filter (59006019000) Info Read the KTM PowerParts installation instructions. B00436-01 – Mount the dust cover for the air filter for sand. Sand cover for air filter (59006022000) Info Read the KTM PowerParts installation [...]

7 PREPARIN G FOR USE 21 600868-01 – Clean the chain. Chain cleaner ( p. 121) – Mount the steel sprocket. Tip Do not grease the chain. – Clean the radiator fins. – Carefully align bent radiator fins. – If used in sand regularly, replace the piston every 10 operating hours. 7.6 Preparations for riding on wet and muddy surfaces B00437-01 –[...]

7 PREPARIN G FOR USE 22 7.8 Preparing for riding at low temperatures or in snow B00437-01 – Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Follow the KTM PowerParts mounting instructions. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tunin[...]

8 RIDING INSTRUCTIO NS 23 8.1 Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 89) – Check the front brake fluid level. ( p. 64) – Check the rear brake fluid level. ([...]

8 RIDING INSTRUCTIO NS 24 (All SX models) – Press the kick starter forcefully through its full range. Info Do not open the throttle. (All XC models) – Press the electric starter button or press the kick starter robustly through its full range. Info Do not open the throttle. 8.3 Starting off Info The plug-in stand must be removed before riding. [...]

8 RIDING INSTRUCTIO NS 25 – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but do [...]

8 RIDING INSTRUCTIO NS 26 8.8 Refueling Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – The fuel in the fuel tank expands when war[...]

9 SERVICE SCHEDUL E 27 9.1 All SX models 9.1.1 Service schedule Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal) Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race Change the gear oil. x (125/150 SX) ● ● Change the gear oil. x (250 SX EU, 250 SX US) ● Check the fron[...]

9 SERVICE SCHEDUL E 28 9.1.2 Service work (as additional order) Annually Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal) Once after 20 operating hours Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after[...]

9 SERVICE SCHEDUL E 29 Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) / after every race Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal) Check the intake diaphragm. x ● ● Check the exhaust control for functioning and smooth operation. x ● Check the clutch. x ● Check all hoses (e[...]

10 TUNING THE CHASSIS 30 10.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. 401030-01 – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspe[...]

10 TUNING THE CHASSIS 31 Guideline Compression damping, low-speed (125/150 SX) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, low-speed (250 SX EU) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, low-speed (250 SX US) Comfort 17 clicks Standard 15 clicks Sport 13 clicks Compression damping, low-s[...]

10 TUNING THE CHASSIS 32 Guideline Compression damping, high-speed (125/150 SX) Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Compression damping, high-speed (250 SX EU) Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Compression damping, high-speed (250 SX US) Comfort 2.5 turns Standard 2 turns Sport 1.5 turns Compression damping, high-spe[...]

10 TUNING THE CHASSIS 33 10.6 Measuring the sag of the unloaded rear wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 39) 400988-10 Main work – Measure the distance – as vertically as possible – between the rear axle and a fixed point such as a mark on the side cover. – Note down the value as dimension  . Finishi[...]

10 TUNING THE CHASSIS 34 » If the riding sag differs from the specified measurement: – Adjust the riding sag. x ( p. 34) 10.9 Adjusting the spring preload of the shock absorber x Caution Danger of accidents   Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the descript[...]

10 TUNING THE CHASSIS 35 B00292-10 Main work – Choose and mount a suitable spring. Guideline Spring rate (125/150 SX) Weight of rider: 65… 75 kg (143… 165 lb.) 45 N/mm (257 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 48 N/mm (274 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 51 N/mm (291 lb/in) Spring rate (250 SX EU) Weight o[...]

10 TUNING THE CHASSIS 36 10.12 Adjusting the compression damping of the fork Info The hydraulic compressio n damping determines the fork suspension behavior. B02081-10 (125 SX EU, 150 SX EU, 250 SX EU) – Turn adjusting screws  clockwise all the way. Info Adjusting screws  are located at the top end of the fork legs. Make the same adjustment[...]

10 TUNING THE CHASSIS 37 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. B02083-10 (125 SX EU, 150 SX EU, 250 SX EU) – Remove protection caps  . – Turn adjusting screws  clockwise all the way. Info Adjusting screws  are located at the bottom end of the fork leg[...]

10 TUNING THE CHASSIS 38 10.14 Handlebar position B00025-11 On the upper triple clamp, there are two holes a distance of  apart. Hole distance A 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of  from the center. Hole distance B 3.5 mm (0.138 in) The handlebar can be mounted in four different positions. In this wa[...]

11 SERVICE WORK ON THE CHASSIS 39 11.1 Raising the motorcycle with the lift stand 401942-01 Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels must no longer touch the ground[...]

11 SERVICE WORK ON THE CHASSIS 40 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 39) – Remove the fork protector. ( p. 41) M00033-10 Main work – Push dust boots  of both fork legs downwards. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes.[...]

11 SERVICE WORK ON THE CHASSIS 41 11.6 Installing the fork legs x B02085-10 Main work – Position the fork legs. Bleeder screws  face forward. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp. B02087-11 – Tighten screws [...]

11 SERVICE WORK ON THE CHASSIS 42 11.9 Removing the lower triple clamp x Preparatory work – Raise the motorcycle with the lift stand. ( p. 39) – Remove the front wheel. x ( p. 71) – Remove the fork legs. x ( p. 40) – Remove the start number plate. ( p. 45) – Remove the front fender. ( p. 46) – Remove the handlebar cushion. B02088-10 Mai[...]

11 SERVICE WORK ON THE CHASSIS 43 B02091-10 (125 SX EU, 150 SX EU, 250 SX EU) – Position the fork legs. Bleeder screws  face toward the front. Info Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the top edge of the upper triple clamp. B02094-10 (All XC models) – [...]

11 SERVICE WORK ON THE CHASSIS 44 M00016-12 – Position the brake caliper. Mount and tighten screws  . Guideline Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite ® 243™ – Position the brake line and clamp. Mount and tighten screws  . Finishing work – Check that the wiring harness, throttle cables and brake and clutch lines[...]

11 SERVICE WORK ON THE CHASSIS 45 11.12 Adjusting the play of the steering head bearing x Preparatory work – Raise the motorcycle with the lift stand. ( p. 39) – Remove the handlebar cushion. B02093-10 Main work – Loosen screws  . Remove screw  . – Loosen and retighten screw  . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 [...]

11 SERVICE WORK ON THE CHASSIS 46 11.15 Installing the start number plate L00948-10 – Position the start number plate. Mount and tighten screw  . Guideline Remaining screws, chassis M 6 10 Nm (7.4 lbf ft) Info Ensure that the holding lugs engage in the fender. – Position the brake line. Position the clamp and mount and tighten screw  . 11[...]

11 SERVICE WORK ON THE CHASSIS 47 11.18 Removing the shock absorber x Preparatory work – Raise the motorcycle with the lift stand. ( p. 39) – Remove the main silencer. ( p. 51) B02098-10 Main work – Remove screw  . – Remove screw cap  . B02099-10 – Press angle lever  toward the rear. – Press linkage lever  downward. B02100-1[...]

11 SERVICE WORK ON THE CHASSIS 48 11.20 Removing the seat 101683-10 – Remove screw  . Lift up the seat at the rear, pull it back and then remove from above. 11.21 Mounting the seat L00950-01 – Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear and simultaneously push forward. – Make sure that the seat i[...]

11 SERVICE WORK ON THE CHASSIS 49 11.23 Installing the air filter box lid B02101-12 – Insert the air filter box lid into rear area  and clip it into front area  . B02101-10 Condition The air filter box lid is secured. – Mount and tighten screws  . Guideline Screw, air filter box lid EJOT PT ® K60x20-Z 3 Nm (2.2 lbf ft) EJOT PT screw ([...]

11 SERVICE WORK ON THE CHASSIS 50 L00944-10 Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 121) Info Only squeeze the air filter to dry it; never wring it out. – Oil the dry air filter with a high quality filter oil. Oil for foam air filter ( p. 121) – Clean the air [...]

11 SERVICE WORK ON THE CHASSIS 51 11.28 Sealing the air filter box x Preparatory work – Remove the air filter box lid. ( p. 48) 401527-10 Main work – Seal the air filter box in the marked area  . Finishing work – Install the air filter box lid. ( p. 49) 11.29 Removing the main silencer Warning Danger of burns   The exhaust system gets ve[...]

11 SERVICE WORK ON THE CHASSIS 52 401045-10 Main work – Remove screws  . Pull out inner tube  . – Pull the glass fiber yarn filling  from the inner tube. – Clean the parts that are to be reinstalled. – Mount the new glass fiber yarn filling  on the inner tube. – Slide outer tube  over the inner tube with the new glass fiber[...]

11 SERVICE WORK ON THE CHASSIS 53 L00951-11 – Remove screw  with the rubber bushing. – Remove the tube from the fuel tank vent line. 101689-01 – Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank. 11.33 Installing the fuel tank x Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehi[...]

11 SERVICE WORK ON THE CHASSIS 54 101687-11 – Mount and tighten screws  with the collar bushings. Guideline Remaining screws, chassis M 6 10 Nm (7.4 lbf ft) – Connect the fuel hose. Finishing work – Mount the seat. ( p. 48) 11.34 Checking the chain for dirt 400678-01 – Check the chain for heavy soiling. » If the chain is very dirty: –[...]

11 SERVICE WORK ON THE CHASSIS 55 11.36 Checking the chain tension Warning Danger of accidents   Danger caused by incorrect chain tension. – If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bear- ings in the transmission and in the rear wheel) will be under additional load. In [...]

11 SERVICE WORK ON THE CHASSIS 56 Info The wide adjustment range of the chain adjusters (32 mm) enables different secondary ratios with the same chain length. Chain adjusters  can be turned by 180°. Finishing work – Remove the motorcycle from the lift stand. ( p. 39) 11.38 Checking the chain, rear sprocket , engine sprocket and chain guide Pr[...]

11 SERVICE WORK ON THE CHASSIS 57 800202-10 – Check the chain sliding piece for wear. » If the lower bolt edge of the chain is in line with or below the chain sliding piece: – Change the chain sliding piece. x – Check the chain sliding piece for tightness. » If the chain sliding piece is loose: – Tighten the chain sliding piece. Guideline[...]

11 SERVICE WORK ON THE CHASSIS 58 11.40 Checking the swingarm x 500285-01 – Check the swingarm for damage, cracking, and deformatio n. » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. x Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 11.41 Checking the ro[...]

11 SERVICE WORK ON THE CHASSIS 59 B02108-01 (All XC models) – Check the routing of the throttle cable. The throttle cable must be routed along the back of the handlebar, to the right of the frame, below the fuel tank bracket, and to the carburetor. » If the throttle cable is not routed as specified: – Correct the routing of the throttle cable.[...]

11 SERVICE WORK ON THE CHASSIS 60 Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar. When the adjusting screw is turned clockwise, the clutch lever moves closer to the handlebar. The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force. Do not make a[...]

11 SERVICE WORK ON THE CHASSIS 61 11.46 Changing the hydraulic clutch fluid x Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. L00953-10 (125/150 SX) – Move the clutch fluid reservoir mounted[...]

11 SERVICE WORK ON THE CHASSIS 62 L01223-10 – Inject the liquid into the system until it escapes from bore hole  of the mas- ter cylinder without bubbles. – To prevent overflow, drain fluid occasionally from the master cylinder reservoir. – Remove the bleeding syringe. Mount and tighten the bleeder screw. – Correct the fluid level of the[...]

12 BRAKE SYSTEM 63 12.1 Checking the free travel of the hand brake lever Warning Danger of accidents   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. L00[...]

12 BRAKE SYSTEM 64 12.4 Checking the front brake fluid level Warning Danger of accidents   Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not continu[...]

12 BRAKE SYSTEM 65 L00959-10 Main work – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  . – Remove cover  with membrane  . – Add brake fluid to level  . Guideline Dimension  (brake fluid level below top edge of container) 5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 119) ?[...]

12 BRAKE SYSTEM 66 Warning Danger of accidents   Reduced braking efficiency due to use of non-approved brake linings. – Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from[...]

12 BRAKE SYSTEM 67 L00956-11 – Correct the brake fluid quantity to level  . Guideline Dimension  (brake fluid level below top edge of container) 5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p. 119) – Position the cover with the membrane. Mount and tighten the screws. Info Wash off overflowed or spilled brake fluid immediately with water. 1[...]

12 BRAKE SYSTEM 68 – Hold screw  and tighten nut  . Guideline Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) – Hold push rod  and tighten nut  . Guideline Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) – Reconnect spring  . 12.10 Checking the rear brake fluid level Warning Danger of accidents   Brake system failure. – If [...]

12 BRAKE SYSTEM 69 Info Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! Preparatory work – Check the rear brake linings. ( p. 6[...]

12 BRAKE SYSTEM 70 101705-10 – Stand the vehicle upright. – Remove screw cap  with membrane  and the O-ring. 101740-10 – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushin[...]

13 WHEELS, TIRES 71 13.1 Removing the front wheel x Preparatory work – Raise the motorcycle with the lift stand. ( p. 39) B02115-10 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes[...]

13 WHEELS, TIRES 72 B02116-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw  . Guideline Screw, front wheel spindle M20x1.5 35 Nm (25.8 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly aga[...]

13 WHEELS, TIRES 73 13.4 Installing the rear wheel x Warning Danger of accidents   Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. B02120-11 Main work – Check the wheel bearing for damage and wear. » If the wheel bearin[...]

13 WHEELS, TIRES 74 400602-10 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tire exhibits cuts, run-in objects or other damage: – Change the tire. – Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth ≥ 2 mm ( ≥ 0.08 in) » If th[...]

13 WHEELS, TIRES 75 » If the spoke tension varies: – Correct the spoke tension. x – Check the spoke torque. Guideline Spoke nipple, front wheel M4.5 6 Nm (4.4 lbf ft) Spoke nipple, rear wheel M4.5 6 Nm (4.4 lbf ft) Torque wrench with various accessories in set (584290940 00)[...]

14 ELECTRIC AL SYSTEM 76 14.1 Removing the battery x (All XC models) Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep sparks and open flames away f[...]

14 ELECTRIC AL SYSTEM 77 14.3 Recharging the battery x (All XC models) Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep sparks and open flames away[...]

14 ELECTRIC AL SYSTEM 78 14.4 Changing the main fuse (All XC models) Warning Fire hazard   The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing u[...]

15 COOLING SYSTEM 79 15.1 Cooling system B02123-10 (125/150 SX) Water pump  in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap  . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions. 120 ?[...]

15 COOLING SYSTEM 80 L00930-10 – Position the correspondin g radiator cover  and attach the radiator shield at hold- ing lugs  . Attach mounting points  at the radiator. 15.4 Removing the radiator cover (All SX models) L00941-10 – Detach radiator shield  at mounting points  and remove it. Remove radiator cover  . L00942-10 –[...]

15 COOLING SYSTEM 81 » If the level of the coolant does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 119) Alternative 2 Coolant (mixed ready to use) ( p. 119) – Mount the radiator cap. 15.6 Checking the coolant level Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is[...]

15 COOLING SYSTEM 82 B02123-11 (125/150 SX) – Remove screw  . Take off radiator cap  . – Completely drain the coolant. – Mount and tighten screw  with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) B02124-11 (All 250/300 models) – Remove screw  . Take off radiator cap  . – Completely drain[...]

16 TUNING THE ENGINE 83 16.1 Checking the play in the throttle cable 400192-11 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back and forth slightly to determine the play in throttle cable  . Play in throttle cable 2… 3 mm (0.08… 0.12 in) » If the throttle cab[...]

16 TUNING THE ENGINE 84 16.3 Carburetor - idle L00927-10 The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. This means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. Info The carburetor and its component s are subjec[...]

16 TUNING THE ENGINE 85 Guideline Idle air adjusting screw (125 SX EU, 125 SX US) Open 2 turns Idle air adjusting screw (150 SX EU, 150 SX US) Open 2 turns Idle air adjusting screw (250 SX EU, 250 SX US) Open 2 turns Idle air adjusting screw (250 XC EU/US) Open 2 turns Idle air adjusting screw (300 XC EU/US) Open 2 turns – Run the engine until wa[...]

16 TUNING THE ENGINE 86 Warning Environmental hazard   Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. Info Carry out this work with a cold engine. Water in the float chamber results in malfunctioning. Preparatory work (All SX models) – Turn handle ?[...]

16 TUNING THE ENGINE 87 16.9 Adjusting the basic position of the shift lever x 401950-12 – Remove screw  and take off shift lever  . 401951-10 – Clean gear teeth  of the shift lever and shift shaft. – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The[...]

16 TUNING THE ENGINE 88 B00056-11 – Take cap  , adjusting spring  , auxiliary spring  , and spring insert  out of the clutch cover. – Pull both springs off of the spring insert. B02130-10 – Mount the required auxiliary spring  and adjusting spring  and slide them into the clutch cover together. Auxiliary spring with yellow m[...]

17 SERVICE WORK ON THE ENGINE 89 17.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. B02131-10 Main work (125/150 SX) – Remove screw  from the opening used to check the gear oil level. – Check the gear oil level. A small [...]

17 SERVICE WORK ON THE ENGINE 90 17.3 Draining the gear oil x Warning Danger of scalding   Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediatel y with lukewarm water. Warning Environmental hazard   Hazardous substances cause environment[...]

17 SERVICE WORK ON THE ENGINE 91 0 0 1 1 401955-10 Main work – Remove screw cap  and fill up gear oil. Gear oil (125/150 SX) 0.70 l (0.74 qt.) Engine oil (15W/50) ( p. 119) Gear oil (All 250/300 models) 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 119) – Mount and tighten the screw cap. Danger Danger of poisoning   Exhaust gases are toxic an[...]

17 SERVICE WORK ON THE ENGINE 92 – Mount and tighten screw cap  . Finishing work Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an[...]

18 CLEANING , CARE 93 18.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between t[...]

19 STORAGE 94 19.1 Storage Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap a[...]

20 TROUBLE SHOOTING 95 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) (All XC models) Operating error – Go through the steps of starting the engine. ( p. 23) Battery discharged – Recharge the battery. x ( p. 77) – Check the charging voltage. x – Check the closed current. x – Check the alternator. x Main fus[...]

20 TROUBLE SHOOTING 96 Faults Possible cause Action Engine stalls or is popping into the carburetor Lack of fuel (All SX models) – Turn handle  of the fuel tap to the ON position. (Figure B02072-10 p. 14) (All XC models) – Turn handle  of the fuel tap to the ON position. (Figure L00904-10 p. 15) – Refuel. ( p. 26) Engine takes in bad ai[...]

21 TECHNICA L DATA 97 21.1 Engine 21.1.1 125 SX EU, 125 SX US Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle be[...]

21 TECHNICA L DATA 98 5th gear 19:23 6th gear 22:24 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.4 mm (0.055 in) Spark plug NGK BR9 ECMVX Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter 21.1.3 250 SX EU, 250 SX US Design 1-cylinder 2-stroke [...]

21 TECHNICA L DATA 99 Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48 mm (1.89 in) Primary transmission 26:72 Clutch Multidisc clutch in oil bath/hydrau lically activ[...]

21 TECHNICA L DATA 100 Spark plug NGK BR 7 ES Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 21.2 Engine tightening torques 21.2.1 125/150 SX Screw, inner reed valves EJOT DELTA PT ® 35x25 1 Nm (0.7 lbf ft) – Screw, membrane core plate EJOT DELTA PT ® 30x12 1 Nm (0.7 lbf ft) – Screw, outer reed val[...]

21 TECHNICA L DATA 101 21.2.2 250 SX EU, 250 SX US Screw, inner reed petals EJOT DELTA PT ® 35x25 1 Nm (0.7 lbf ft) – Screw, membrane core plate EJOT DELTA PT ® 30x12 1 Nm (0.7 lbf ft) – Screw, outer reed petals EJOT DELTA PT ® 30x6 1 Nm (0.7 lbf ft) – Screw ,stator M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, alternator cover M5 5 Nm (3.[...]

21 TECHNICA L DATA 102 Screw, retaining bracket of exhaust control M5 7 Nm (5.2 lbf ft) Loctite ® 243™ Screw, water pump wheel M5 6 Nm (4.4 lbf ft) Loctite ® 243™ Screw, alternator cover M6 8 Nm (5.9 lbf ft) – Screw, bearing retainer M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, clutch cover M6 10 Nm (7.4 lbf ft) – Screw, control flap, e[...]

21 TECHNICA L DATA 103 21.3 Carburetor 21.3.1 125 SX EU, 125 SX US Carburetor type KEIHIN PWK 38S AG Carburetor identification number BS5_0 Needle position 4th position from top Jet needle NOZH (NOZG, NOZI) Main jet 182 (180, 185) Idling jet 42 (40, 45) Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut-out 21.3.2 Carbu[...]

21 TECHNICA L DATA 104 21.3.3 Carburetor tuning (125 SX EU, 125 SX US) 401762-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces[...]

21 TECHNICA L DATA 105 21.3.4 150 SX EU, 150 SX US Carburetor type KEIHIN PWK 38S AG Carburetor identification number BS6_0 Needle position 3rd position from top Jet needle N1EJ (N1EI, N1EK) Main jet 180 (178, 182) Idling jet 40 (42) Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut-out 21.3.5 Carburetor - basic settin[...]

21 TECHNICA L DATA 106 21.3.6 Carburetor tuning (150 SX EU, 150 SX US) 401763-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces[...]

21 TECHNICA L DATA 107 21.3.7 250 SX EU, 250 SX US Carburetor type KEIHIN PWK 36S AG Carburetor identification number BS8_0 Needle position 4th position from top Jet needle N1EH (N1EG, N1EI) Main jet 158 (155, 160) Idling jet 42 (40) Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 6.5 with cut-out 21.3.8 Carburetor - basic sett[...]

21 TECHNICA L DATA 108 21.3.9 Carburetor tuning (250 SX EU, 250 SX US) 401764-01 M/FT ASL Sea level TEMP Temperature ASO Open idle air adjusting screw IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces[...]

21 TECHNICA L DATA 109 21.3.10 250 XC EU/US Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ6_A Needle position 3rd position from top Jet needle N2ZW (N2ZH, N2ZJ) Main jet 175 (172) Idling jet 38 (40) Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut-out 21.3.11 Carburetor tuning (250 XC EU/US) 402[...]

21 TECHNICA L DATA 110 NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces[...]

21 TECHNICA L DATA 111 21.3.12 300 XC EU/US Carburetor type KEIHIN PWK 36S AG Carburetor identification number BZ7_A Needle position 3rd position from top Jet needle N8RG (N8RH) Main jet 172 (170, 175) Idling jet 35 Starting jet 85 Idle air adjusting screw Open 2 turns Throttle slide 7 with cut-out 21.3.13 Carburetor tuning (300 XC EU/US) x 402141-[...]

21 TECHNICA L DATA 112 NDL Needle POS Needle position from above MJ Main jet Info Not for sandy surfaces 21.4 Capacities 21.4.1 Gear oil Gear oil (125/150 SX) 0.70 l (0.74 qt.) Eng ine oil (15W/50) ( p. 119) Gear oil (All 250/300 models) 0.80 l (0.85 qt.) Engine oil (15W/50) ( p. 119) 21.4.2 Coolant Coolant 1.2 l (1.3 qt.) Coolant ( p. 119) Coolant[...]

21 TECHNICA L DATA 113 Chain 5/8 x 1/4" Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52 Steering head angle 63.5° Wheelbase (125/150 SX) 1,480±10 mm (58.27±0.39 in) Wheelbase (All 250/300 models) 1,495±10 mm (58.86±0.39 in) Seat height unloaded 992 mm (39.06 in) Ground clearance unloaded (125/150 SX) 395 mm (15.55 in) Ground c[...]

21 TECHNICA L DATA 114 Oil capacity fork leg without cartridge 370 ml (12.51 fl. oz.) For k oil (SAE 4) (48601166S1) ( p. 119) 21.8.2 125 SX US, 150 SX US Fork part number 24.18.7O.51 Fork WP Suspension Up Side Down 4860 MXMA 4CS Compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Rebound damping Comfort 17 clicks Standard 15 c[...]

21 TECHNICA L DATA 115 Rebound damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Spring length with preload spacer(s) 480 mm (18.9 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.4 N/mm (25.1 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm ([...]

21 TECHNICA L DATA 116 Weight of rider: 75… 85 kg (165… 187 lb.) 48 N/mm (274 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 51 N/mm (291 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) Fitted length 490 mm (19.29 in) Shock absorber fluid ( p. 120) SAE 2.5 21.9.2 [...]

21 TECHNICA L DATA 117 Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 51 N/mm (291 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 54 N/mm (308 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 57 N/mm (325 lb/in) Spring length 260 mm (10.24 in) Gas pressure 10 bar (145 psi) Static sag 30 mm (1.18 in) Riding sag 100 mm (3.94 in) [...]

21 TECHNICA L DATA 118 Screw, front brake disc M 6 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, throttle grip M6 5 Nm (3.7 lbf ft) – Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) – Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite ® 2701™ Nut, rim lock M8 12 Nm (8.9 lb[...]

22 SUBSTAN CES 119 2-stroke engine oil Standard/classific ation – JASO FC ( p. 123) Guideline – Only use high grade 2-stroke engine oil of a reputable brand. Fully synthetic Recommended supplier Motorex ® – Cross Power 2T Brake fluid DOT 4 / DOT 5.1 Standard/classific ation – DOT Guideline – Use only brake fluid that complies with the sp[...]

22 SUBSTAN CES 120 Hydraulic fluid (15) Standard/classific ation – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) St[...]

23 AUXILIAR Y SUBSTANCES 121 Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier SKF ® – LGHB 2 Long-life grease Recommended supplier Motorex ® – [...]

23 AUXILIAR Y SUBSTANCES 122 Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic[...]

24 STANDAR DS 123 JASO FC JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first rate synthetic esters and specially designed additives, superb combustio n is achieved even under extreme operating conditions. JASO T903 MA Different technical development directions req[...]

INDEX 124 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 A[...]

INDEX 125 Fork part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fork protector installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Frame checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fro[...]

INDEX 126 Steering head bearing greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Steering head bearing play adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Storage . . . . . . . . . . . . . . . . . . . . . . . . [...]

*321 317 3en* 3213173en 04/2014 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com Photo: Mitterbauer/KTM[...]