KTM 125 SX User Manual

125 SX 250 SX

OWNER’S MANUAL 2007

ART. NR. 3.211.174 EN

ENGLISH

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, 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 reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability 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.

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.

In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

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.

ENGLISH

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 international 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 notices that are marked as follows:

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.

– Ignoring these instructions can be dangerous to life and limb!

– ignoring these instructions may damage parts of the motorcycle or impair the motorcycle’s traffic safety!

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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 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 specifications 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 carburetor 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, involve 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 & engine

ENGLISH

TABLE OF CONTENTS

Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . .6

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Choke knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . .8

Compression damping of fork . . . . . . . . . . . . . . . . . . .8

Compression damping of shock absorber . . . . . . . . . . .8

Shock absorber rebound damping . . . . . . . . . . . . . . . .9

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Instructions for your first ride . . . . . . . . . . . . . . . . . . .9

Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .10

What you should check before each start . . . . . . . . . .10

Starting when the engine is cold . . . . . . . . . . . . . . . .10

Starting when the engine is warm . . . . . . . . . . . . . . .10

What to do when the engine is „flooded“ . . . . . . . . . .10

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .11

Refueling, fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . .12

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .15

Changing the spring preloading of the shock absorber

. .15

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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) (XC) . . . . . . . . . . . .18

Checking and adjusting the steering head bearing . . .19

How to change the handlebar position . . . . . . . . . . . .19

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .20

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .20

Adapting the chain guide . . . . . . . . . . . . . . . . . . . . .20

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .21

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .21

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

General information about KTM disc brakes . . . . . . . .22

Adjusting the free travel at the hand brake lever . . . . .23

Checking the brake fluid level - front brake . . . . . . . .23

Refilling the front brake fluid reservoir . . . . . . . . . . .23

Page

Checking the front brake pads . . . . . . . . . . . . . . . . .23

Replacing the front brake pads . . . . . . . . . . . . . . . . .24

Checking the rear brake fluid level . . . . . . . . . . . . . .24

Refilling the rear brake fluid reservoir . . . . . . . . . . . .24

Changing the basic position of the foot brake pedal . .24

Checking the rear brake pads . . . . . . . . . . . . . . . . . .25

Replacing the rear brake pads . . . . . . . . . . . . . . . . .25

Dismounting and mounting the front wheel . . . . . . . .25

Dismounting and mounting the rear wheel . . . . . . . . .26

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .27

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .27

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Checking the coolant level . . . . . . . . . . . . . . . . . . . .28

Bleeding the cooling system . . . . . . . . . . . . . . . . . . .28

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .29

Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Changing the original position of the clutch lever . . . .30

Changing the oil level of hydraulic clutch 125 SX . . . .30

Changing the oil level of hydraulic clutch 250 SX . . . .30

Bleeding the hydraulic clutch . . . . . . . . . . . . . . . . .30

Carburetor adjustment . . . . . . . . . . . . . . . . . . . . . . .31

Draining the float chamber of the carburetor . . . . . . .32

Checking the float level . . . . . . . . . . . . . . . . . . . . . .32

Adjusting the engine characteristic via the ignition curve

. .33

Adjusting the engine characteristic via the auxiliary spring

.33

Check transmission oil level (125) . . . . . . . . . . . . . .34

Changing the transmission oil (125) . . . . . . . . . . . . .34

Check transmission oil level (250) . . . . . . . . . . . . . .34

Changing the transmission oil (250) . . . . . . . . . . . . . . .34

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .35

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

TECHNICAL SPECIFICATIONS – CHASSIS 125 / 250 . . .36

TECHNICAL SPECIFICATIONS – ENGINE 125 / 250 . . .38

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

WIRING DIAGRAM, CARBURETOR TABLE . . . . .APPENDIX

ENGLISH

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

The clutch lever [1] is located on the left side of the handlebars. The adjusting 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 actuates 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).

OPERATION INSTRUMENTS »

ENGLISH

OPERATION INSTRUMENTS

ON OFF

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

To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] 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 [3] 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.

ENGLISH

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

2,3,4,5, (6)

Kickstarter

The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled.

Foot brake pedal

The foot brake pedal is disposed in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work).

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Compression damping of fork

Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. Turn the screw [3] 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 14187C01 . . . . .18 clicks

Typ WP Suspension 14187C03 . . . . .15 clicks

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is rebound. Remove the protecting cap [1]. By turning the adjusting screw [2], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise 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 14187C01 . . . . .21 clicks

Typ WP Suspension 14187C03 . . . . .20 clicks

Damping action during compression of shock absorber

The shock absorber on the SX models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression 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 rates.Turning in a clockwise direction will increase the damping, turning counterclockwise will decrease the damping.

STANDARD LOW-SPEED SETTING:

– Turn the adjusting screw [4] 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 12187C01 . . . . .15 clicks

Typ WP Suspension 12187C03 . . . . .15 clicks

The damping unit of the shock absorber is filled with high-compression nitrogen. 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 (24mm).

OPERATION INSTRUMENTS

STANDARD HIGH-SPEED SETTING:

– Turn the adjusting screw [6] 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 12187C01 . . . . .1 turn

Typ WP Suspension 12187C03 . . . . .1 turn

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OPERATION INSTRUMENTS

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 respective type of shock absorber.

Typ WP Suspension 12187C01 . . . . .25 clicks

Typ WP Suspension 12187C03 . . . . .25 clicks

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

Instructions for your first ride

– Make sure the work for the "pre-delivery inspection" was per-

formed by your authorized KTM workshop. The DELIVERY CERTIFICATE 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 overheated. – 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 performance limits. Apply low but changing loads for running-in.

Do not drive at full load for the first 500 kilometers (300 miles) or 5 hours!

– 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 having 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!

– Neither do these models meet the applicable statutory regula-

tions and safety standards. Using them on public roads, highways, freeways, etc. is against the law.

– When riding your motorcycle, please bear in mind that other

people may feel molested by excessive noise.

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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

Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism.

2 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.

3 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.

4 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.

5 BRAKES

Check correct functioning of the braking system. Verify that there is sufficient 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 authorized KTM dealer, as complete failure of the braking system can be expected. Also check the state of the brake hose and the thickness of the brake linings. Check free travel of the hand brake lever and foot brake lever.

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 system looked over by a KTM dealer.

6 CABLES

Check correct adjustment and easy running of all control cables.

7 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

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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. 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 0°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 cause loss of consciousness and death. Always provide adequate ventilation while the engine is running.

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 standing 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.

– 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 the rubber band on the air filter box.

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DRIVING INSTRUCTIONS

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 consumption will increase. When shifting down, use the brakes if necessary 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.

– 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.

– 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.

– Never have the throttle wide open when changing down to a

lower gear. The engine will overrev, damaging the valves. In addition, the rear wheel will block so that the motorcycle can easily 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 depending on your speed.

– In case 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 hotter 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 something is wrong with the brake system. Don’t ride your motorcycle 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 simultaneously. 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.

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 starting the motorcycle, and take care to park it where pedestrians are not likely to touch it and get burned.

– 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 SX: 1:40 Mixture ratio 250 SX: 1:60

Fuel and engine oil should only be mixed immediately before use. KTM recommends Motorex Cross Power 2T.

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.

– Only use premium-grade gasoline ROZ 98 respectively 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. – If your motorcycle is equipped with a catalytic converter, always

keep in mind that leaded fuel will destroy the catalytic converter. – Fuel expands when its temperature rises. Therefore do not fill

the tank to the top. (see fig.)

35 mm

ENGLISH

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

Change gear box oil

z z z z

Check spark plugs, adjust distance between electrodes

z z

Renew spark plugs

z z

Clean the spark-plug connector and check for a tight fit

z z z

Check the screws on the kick starter and shift lever for a tight fit

z z z

CARBURETOR

Check the carburetor connection boot and intake flange for cracks or leaks

z z z

Check idle speed setting

z z z z

Check that vent hoses are not damaged or bent

z z z z

ADD-ON-PARTS

Check cooling system for leaks, check quantity of antifreeze

z z z z

Check exhaust system for leaks and fitment

z z z

Check cables for damage, smooth operation, bends; adjust and lubricate

z z z

Check the fluid level in the master cylinder of the hydraulic clutch

z z z z

Clean air filter and filter box

z z z z z

Check electric wires for damage and bends

z z

Check headlamp setting

z z

Check function of electric systems (low beam, high beam, break light, indicator,

z z z

indicator lamps, speedometer illumination, horn, emergency OFF switch or button

BRAKES

Check brake fluid level, lining thickness, brake lining

z z z

Check brake lines for damage and leaks

z z z

Check/adjust the function, smooth operation and free travel of the hand/foot brake lever

z z z

Check the screws and guide bolts on the brake system for a tight fit

z z z

CHASSIS

Check shock absorber and fork for leaks and function

z z z z

Clean dust bellows

z z z

Bleed fork legs

z z z

Check swing arm bearings

z z

Check/adjust steering head bearings

z z z

Check tightness of all chassis screws (triple clamps, fork leg axle passage

z z z

axle nuts and screws, swing arm bearings, shock absorber)

WHEELS

Check spoke tension and rim joint

z z z z

Check tires and air pressure

z z z z

Check chain, rear sprockets and chain guides for wear, fitment and tension

z z z z

Lubricate chain, Clean and grease the adjusting screws on the chain tensioner

z z z z

Check clearance of wheel bearings

z z z

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!

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