KTM 125SX 2012, 150SX 2012, 250SX 2012, 300XC 2012 Owner's manual

OWNER'S MANUAL 2012

125 SX 150 SX 250 SX

150 XC USA 250 XC EU/USA 300 XC EU/USA

Art. no. 3211714en

DEAR KTM CUSTOMER 1

DEARKTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art 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.

Chassis number ( p. 9) Dealer's stamp

Engine number ( p. 9)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service

KTM-Sportmotorcycle AG 5230 Mattighofen, Austria

TABLE OF CONTENTS 2

TABLEOF CONTENTS

MEANS OF REPRESENTATION ............................................ 4

IMPORTANT INFORMATION ................................................ 5

VIEW OF VEHICLE............................................................... 7

View of the vehicle from the left front (example) ................. 7

View of the vehicle from the right rear (example) ................ 8

SERIAL NUMBERS.............................................................. 9

Chassis number............................................................... 9

Type label....................................................................... 9

Engine number................................................................ 9

Fork part number............................................................. 9

Shock absorber part number ............................................. 9

CONTROLS....................................................................... 10

Clutch lever .................................................................. 10

Hand brake lever ........................................................... 10

Throttle grip.................................................................. 10

Kill switch .................................................................... 10

Electric starter button (250/300 XC) ............................... 11

Opening the filler cap .................................................... 11

Closing the filler cap...................................................... 11

Fuel tap (All XC models)................................................. 12

Fuel tap (All SX models)................................................. 12

Choke........................................................................... 12

Shift lever..................................................................... 13

Kickstarter.................................................................... 13

Foot brake lever............................................................. 13

Side stand (All XC models) ............................................. 14

Plug-in stand (All SX models) ......................................... 14

PREPARING FOR USE ....................................................... 15

Advice on first use ......................................................... 15

Running in the engine.................................................... 16

Preparing the vehicle for difficult operating conditions...... 16

Preparations for riding on dry sand.................................. 16

Preparations for riding on wet sand ................................. 17

Preparations for riding on wet and muddy surfaces ........... 18

Preparations for riding at high temperatures and low

speeds.......................................................................... 18

Preparing for rides at low temperatures or in snow ............ 19

RIDING INSTRUCTIONS .................................................... 20

Checks and maintenance work when preparing for use ...... 20

Starting ........................................................................ 20

Starting off ................................................................... 21

Shifting, riding.............................................................. 21

Braking ........................................................................ 21

Stopping, parking .......................................................... 22

Refueling...................................................................... 22

SERVICE SCHEDULE (SX).................................................. 24

Service schedule ........................................................... 24

Maintenance work (as an additional order) ....................... 25

SERVICE SCHEDULE (XC).................................................. 26

Service schedule ........................................................... 26

Service work (as additional order).................................... 27

TUNING THE CHASSIS...................................................... 28

Checking the basic chassis setting with the rider's

weight .......................................................................... 28

Compression damping of shock absorber.......................... 28

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 28

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 29

Adjusting the rebound damping of the shock absorber....... 30

Measuring the sag of the unloaded rear wheel .................. 31

Checking the static sag of the shock absorber .................. 31

Checking the riding sag of the shock absorber .................. 31

Adjusting the spring preload of the shock absorber x ...... 32

Adjusting the riding sag x............................................. 32

Checking the basic setting of the fork.............................. 33

Adjusting the compression damping of the fork ................ 34

Adjusting the rebound damping of the fork....................... 34

Handlebar position ........................................................ 35

Adjusting the handlebar position x................................ 35

SERVICE WORK ON THE CHASSIS ..................................... 37

Raising the motorcycle with the lift stand ........................ 37

Removing the motorcycle from the lift stand .................... 37

Bleeding the fork legs .................................................... 37

Cleaning the dust boots of the fork legs ........................... 38

Loosening the fork protection.......................................... 38

Positioning the fork protection ........................................ 38

Removing the fork legs x.............................................. 39

Installing the fork legs x............................................... 39

Removing the fork protector x....................................... 40

Installing the fork protector x ....................................... 40

Removing the lower triple clamp x ................................ 40

Installing the lower triple clamp x................................. 41

Checking the play of the steering head bearing................. 42

Adjusting the play of the steering head bearing x............ 43

Greasing the steering head bearing x............................. 43

Removing the start number plate .................................... 43

Installing the start number plate ..................................... 43

Removing the front fender .............................................. 44

Installing the front fender............................................... 44

Removing the shock absorber x..................................... 44

Installing the shock absorber x ..................................... 45

Removing the seat ......................................................... 45

Mounting the seat ......................................................... 45

Removing the air filter box lid......................................... 46

Installing the air filter box lid.......................................... 46

Removing the air filter x............................................... 46

Installing the air filter x ............................................... 46

Cleaning the air filter and air filter box x........................ 47

Removing the main silencer............................................ 47

Installing the main silencer ............................................ 48

Changing the glass fiber yarn filling of the main

silencer x ................................................................... 48

Removing the fuel tank x ............................................. 48

Installing the fuel tank x .............................................. 49

Checking the chain for dirt ............................................. 50

Cleaning the chain......................................................... 50

Checking the chain tension ............................................ 51

Adjusting the chain tension ............................................ 51

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 52

Adjusting the chain guide x.......................................... 53

Checking the frame x................................................... 54

Checking the swingarm x ............................................. 54

Checking the throttle cable routing.................................. 54

Checking the rubber grip ................................................ 56

Additionally securing the rubber grip ............................... 56

Adjusting the basic position of the clutch lever................. 56

Checking the fluid level of the hydraulic clutch ................ 57

Changing the hydraulic clutch fluid x ............................ 57

BRAKES........................................................................... 60

Checking the free travel of the hand brake lever ............... 60

Adjusting the basic position of the hand brake lever.......... 60

TABLE OF CONTENTS 3

Checking the brake discs................................................ 60

Checking the front brake fluid level ................................. 61

Adding front brake fluid x ............................................ 61

Checking the front brake linings...................................... 62

Changing the front brake linings x................................. 62

Checking the free travel of foot brake lever....................... 64

Adjusting the basic position of the foot brake lever x ...... 64

Checking the rear brake fluid level .................................. 65

Adding brake fluid for the rear brake x .......................... 65

Checking the rear brake linings ....................................... 66

Changing the rear brake linings x.................................. 66

WHEELS, TIRES ............................................................... 68

Removing the front wheel x .......................................... 68

Installing the front wheel x........................................... 68

Removing the rear wheel x ........................................... 69

Installing the rear wheel x ............................................ 69

Checking the tire condition............................................. 70

Checking the tire air pressure ......................................... 71

Checking the spoke tension ............................................ 71

ELECTRICAL SYSTEM ....................................................... 72

Removing the battery x (250/300 XC) ........................... 72

Installing the battery x (250/300 XC)............................ 72

Recharging the battery x (250/300 XC) ......................... 72

Removing the main fuse (250/300 XC)............................ 73

Installing the main fuse (250/300 XC) ............................ 74

COOLING SYSTEM ............................................................ 75

Cooling system .............................................................. 75

Radiator cover (All SX models) ........................................ 75

Removing the radiator cover (All SX models) .................... 75

Installing the radiator cover (All SX models) ..................... 76

Checking the antifreeze and coolant level ........................ 76

Checking the coolant level.............................................. 77

Draining the coolant x.................................................. 77

Refilling with coolant x ................................................ 78

TUNING THE ENGINE ....................................................... 79

Checking the play in the throttle cable............................. 79

Adjusting the play in the throttle cable x ....................... 79

Carburetor .................................................................... 79

Carburetor - adjusting the idle speed x .......................... 80

Emptying the carburetor float chamber x ....................... 81

Ignition curve plug connection ........................................ 82

Changing the ignition curve ............................................ 82

Checking the basic position of the shift lever.................... 82

Adjusting the basic position of the shift lever x .............. 82

Engine characteristic - auxiliary spring

(All 250/300 models) .................................................... 83

Engine characteristic - adjust the auxiliary spring x

(All 250/300 models) .................................................... 83

SERVICE WORK ON THE ENGINE ...................................... 84

Checking the gear oil level.............................................. 84

Changing the gear oil x ................................................ 84

Draining the gear oil x ................................................. 85

Refilling with gear oil x ................................................ 85

Adding gear oil x ......................................................... 86

CLEANING, CARE ............................................................. 87

Cleaning the motorcycle ................................................. 87

STORAGE ......................................................................... 88

Storage......................................................................... 88

Preparing for use after storage ........................................ 88

TROUBLESHOOTING......................................................... 89

TECHNICAL DATA - ENGINE .............................................. 91

125 SX......................................................................... 91

150 SX......................................................................... 91

150 XC USA ................................................................. 92

250 SX......................................................................... 92

250 XC EU/USA ............................................................ 93

300 XC EU/USA ............................................................ 94

Capacity - transmission oil.............................................. 94

Capacity - coolant.......................................................... 94

TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 95

All 125/150 models ...................................................... 95

250 SX......................................................................... 95

250/300 XC.................................................................. 96

TECHNICAL DATA - CARBURETOR..................................... 98

125 SX......................................................................... 98

Carburetor - basic setting for sandy surfaces (125 SX) ...... 98

Carburetor configuration (125 SX)................................... 99

150 SX....................................................................... 100

Carburetor - basic setting for sandy surfaces (150 SX) .... 100

Carburetor configuration (150 SX)................................. 101

250 SX....................................................................... 102

Carburetor - basic setting for sandy surfaces (250 SX) .... 102

Carburetor configuration (250 SX)................................. 103

150 XC USA ............................................................... 104

Carburetor configuration (150 XC USA) ......................... 104

250 XC EU/USA .......................................................... 105

Carburetor configuration (250 XC EU/USA) .................... 106

300 XC EU/USA .......................................................... 107

Carburetor configuration (300 XC EU/USA) x ............... 107

TECHNICAL DATA - CHASSIS .......................................... 109

Tires .......................................................................... 110

Capacity - fuel............................................................. 110

TECHNICAL DATA - FORK................................................ 111

125/150 SX................................................................ 111

250 SX....................................................................... 111

150 XC USA ............................................................... 112

250/300 XC................................................................ 112

TECHNICAL DATA - SHOCK ABSORBER ........................... 113

125/150 SX................................................................ 113

250 SX....................................................................... 113

150 XC USA ............................................................... 114

250/300 XC................................................................ 114

TECHNICAL DATA - TIGHTENING TORQUES FOR

CHASSIS ........................................................................ 116

SUBSTANCES................................................................. 117

AUXILIARY SUBSTANCES................................................ 119

STANDARDS................................................................... 121

INDEX ............................................................................ 122

MEANS OF REPRESENTATION 4

Symbols used

The symbols used are explained below.

Indicates an expected reaction (e.g., to a work step or a function).

Indicates an unexpected reaction (e.g., to a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained below.

Specific name Identifies a specific name.

Name

Brand™ Identifies a brand available on the open market.

Identifies a protected name.

IMPORTANT INFORMATION 5

Use definition

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 must be used only in closed off areas remote from public road traffic.

Service

A prerequisite for perfect operation and prevention of wear is that the engine and chassis service, care and adjustment work described in the owner's manual is properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components. Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached. Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss. Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

You will find the current KTM PowerParts for your vehicle on the KTM website. International KTM Website: http://www.ktm.com

Work rules

Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000) When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock washers) must be replaced with new parts. Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. After you complete the repair or maintenance work, check the roadworthiness of the vehicle.

Transport

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from

being run. Always let the vehicle cool first.

– Switch off the engine.

(All SX models)

– Turn handle  of the fuel tap to the OFF position. (Figure 601185-10 p. 12)

(All XC models)

– Turn handle  of the fuel tap to the OFF position. (Figure 601157-11 p. 12)

– Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT INFORMATION 6

Environment

Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

– It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and

tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.

– The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is

sold.

VIEW OF VEHICLE 7

3.1View of the vehicle from the left front (example)

1 Hand brake lever ( p. 10) 2 Kill switch ( p. 10) 3 Clutch lever ( p. 10) 4 Air filter box lid 5 Fuel tap 6 Choke ( p. 12) 7 Shift lever ( p. 13) 8 Chain guide

800192-10

VIEW OF VEHICLE 8

3.2View of the vehicle from the right rear (example)

1 Seat 2 Filler cap 3 Handlebar cushion 4 Throttle grip ( p. 10) 5 Shock absorber, rebound adjustment 6 Level viewer, rear brake fluid 7 Shock absorber, compression adjustment 8 Foot brake lever ( p. 13) 9 Kickstarter ( p. 13)

800193-10

SERIAL NUMBERS 9

4.1Chassis number

The chassis number  is stamped on the right side of the steering head.

601177-10

4.2Type label

The type label  is fixed to the front of the steering head.

4.3Engine number

4.4Fork part number

601177-11

The engine number  is stamped on the left side of the engine under the engine sprocket.

601178-10

The fork part number  is stamped on the inner side of the fork stub.

4.5Shock absorber part number

B00265-01

The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring on the engine side.

800194-10

CONTROLS 10

5.1Clutch lever

(All 125/150 models)

The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

B00001-10

(All 250/300 models)

The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.

B00009-10

5.2Hand brake lever

5.3Throttle grip

Hand brake lever  is located on the right side of the handlebar. The hand brake lever is used to activate the front brake.

400196-10

Throttle grip  is fitted on the right side of the handlebar.

B00060-10

5.4Kill switch

The kill switch  is fitted on the left side of the handlebar.

Possible states

• Kill switch in basic position – In this position, the ignition circuit is closed, and the engine can be started.

• Kill switch pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

B00002-10

CONTROLS 11

5.5Electric starter button (250/300 XC)

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.

B00080-10

5.6Opening the filler cap

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of children.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

– Do not allow fuel to get into the ground water, the ground, or the sewage system.

– Press release button , turn the filler cap counterclockwise and lift it free.

303502-10

5.7Closing the filler cap

– Replace the filler cap and turn clockwise until the release button  locks in place.

Info

Run the fuel tank breather hose  without kinks.

303503-10

CONTROLS 12

5.8Fuel tap (All XC models)

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 carburetor.

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve.

• Reserve fuel supply open RES – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.

601157-11

5.9Fuel tap (All SX models)

5.10Choke

The fuel tap is on the left side of the fuel tank. With tap handle  on the fuel tap, you can open or close the supply of fuel to the carburetor.

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank empties completely.

601185-10

The choke  is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

B00004-10

Info

If the engine is warm, the choke function must be deactivated.

Possible states

• Choke function activated – The choke lever is pulled out to the stop.

• Choke function deactivated – The choke lever is pushed in to the stop.

CONTROLS 13

5.11Shift lever

Shift lever  is mounted on the left side of the engine.

B00005-10

(All 125/150 models, All XC models)

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

B00005-12

(250 SX)

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.

5.12Kickstarter

5.13Foot brake lever

B00005-11

The kickstarter  is fitted on the right side of the engine. The top part can be swiveled.

800195-10

Foot brake lever  is located in front of the right footrest. The foot brake lever is used to activate the rear brake.

B00007-10

CONTROLS 14

5.14Side stand (All XC models)

The side stand  is on the left side of the vehicle.

800211-10

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 .

800212-10

5.15Plug-in stand (All SX models)

The holder for plug-in stand  is on the left side of the wheel spindle. The plug-in stand is used to park the motorcycle.

Info

Remove the plug-in stand before riding.

100950-10

PREPARING FOR USE 15

6.1Advice 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 present an increased safety risk.

– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always

wear protective clothing, which must be undamaged and meet legal requirements.

Warning

Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.

– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

– Adapt your riding speed to the road conditions and your riding ability.

Warning

Danger of accidents Accident risk caused by presence of a passenger.

– Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidents Failure of brake system.

– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take

your foot off the foot brake lever when you are not braking.

Warning

Danger of accidents Unstable riding behavior.

– Do not exceed the maximum permissible weight and axle loads.

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the service record at vehicle handover.

– Before your first trip, read the entire operating instructions carefully. – Get to know the controls. – Adjust the basic position of the clutch lever. ( p. 56) – Adjust the basic position of the hand brake lever. ( p. 60)

–

Adjust the basic position of the foot brake lever. x ( p. 64)

– Become accustomed to the handling of the motorcycle on suitable terrain.

Info

Your motorcycle is not authorized for riding on public roads. Offroad, you should be accompanied by another person on another machine so that you can help each other.

– Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle. – Do not make any offroad trips that over-stress your ability and experience. – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – Do not transport luggage. – Do not exceed the overall maximum permitted weight and the axle loads.

PREPARING FOR USE 16

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. 71)

Info

The spoke tension must be checked after half an hour of operation.

– Run the engine in.

6.2Running in the engine

– During the running-in phase, do not exceed the specified engine performance.

Guideline

Maximum engine performance

During the first 3 service hours < 70 % During the first 5 service hours < 100 %

– Avoid fully opening the throttle!

6.3Preparing the vehicle for difficult operating conditions

Info

Using a motorcycle in difficult conditions can lead to excessive wear of components such as the power train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

–

Seal the air filter box. x

Tip

Seal the air filter box at the edges against dirt.

–

Clean the air filter and air filter box. x ( p. 47)

Info

Check the air filter approx. every 30 minutes.

– Additionally secure the rubber grip. ( p. 56) – Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.

» If humidity, corrosion, or damage is found:

– Clean and dry the connector, or change it if necessary.

Difficult operating conditions are:

– Riding on dry sand. ( p. 16) – Riding on wet sand. ( p. 17) – Riding on wet and muddy surfaces. ( p. 18) – Riding at high temperatures and low speeds. ( p. 18) – Rides at low temperatures or in snow. ( p. 19)

6.4Preparations for riding on dry sand

600872-10

– Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)

» If the displayed value does not equal the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling

system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

PREPARING FOR USE 17

– Change the radiator cap.

– Mount the dust cover for the air filter.

Dust cover for air filter (59006019000)

Info

Read the KTM PowerParts installation instructions.

B00435-01

– Mount the dust cover for the air filter for sand.

Sand cover for air filter (59006022000)

Info

Read the KTM PowerParts installation instructions.

– Adjust the carburetor jetting and setting.

B00436-01

600868-01

6.5Preparations for riding on wet sand

600872-10

Info

Recommendations on the carburetor setting are available from your authorized KTM workshop.

– Clean the chain.

Chain cleaner ( p. 119)

– 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.

– Check the radiator cap.

Value on the radiator cap 1.8 bar (26 psi)

» If the displayed value does not equal the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling

system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

B00437-01

– Change the radiator cap.

– Mount the rain cover for the air filter.

Rain cover for air filter (59006021000)

Info

Read the KTM PowerParts installation instructions.

– Adjust the carburetor jetting and setting.

Info

Recommendations on the carburetor setting are available from your authorized KTM workshop.

PREPARING FOR USE 18

– Clean the chain.

Chain cleaner ( p. 119)

– Mount the steel sprocket.

Tip

Do not grease the chain.

– Clean the radiator fins.

600868-01

6.6Preparations for riding on wet and muddy surfaces

– Carefully align bent radiator fins. – If used in sand regularly, replace the piston every 10 operating hours.

– 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.

B00437-01

– Mount the steel sprocket. – Clean the motorcycle. ( p. 87) – Carefully align bent radiator fins.

600868-01

6.7Preparations for riding at high temperatures and low speeds

– Check the radiator cap.

The recommended carburetor tuning is available from your authorized KTM workshop.

Value on the radiator cap 1.8 bar (26 psi)

» If the displayed value does not equal the setpoint value:

Warning

Danger of scalding During motorcycle operation, the coolant gets

very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling

600872-10

Info

system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.

600868-01

– Change the radiator cap.

– Adjust the secondary ratio to the terrain.

Info

The engine oil heats up rapidly if the clutch needs to be operated too frequently because the secondary ratio is too long.

– Clean the chain.

Chain cleaner ( p. 119)

– Clean the radiator fins. – Carefully align bent radiator fins. – Check the coolant level. ( p. 77)

PREPARING FOR USE 19

6.8Preparing for rides at low temperatures or in snow

– 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.

B00437-01

Info

The recommended carburetor tuning is available from your authorized KTM workshop.

RIDING INSTRUCTIONS 20

7.1Checks 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. 84) – Check the front brake fluid level. ( p. 61) – Check the rear brake fluid level. ( p. 65) – Check the front brake linings. ( p. 62) – Check the rear brake linings. ( p. 66) – Check that the brake system is functioning properly. – Check the coolant level. ( p. 77) – Check the chain for dirt. ( p. 50) – Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 52) – Check the chain tension. ( p. 51) – Check the tire condition. ( p. 70) – Check the tire air pressure. ( p. 71) – Check the spoke tension. ( p. 71) – Clean the dust boots of the fork legs. ( p. 38) – Bleed the fork legs. ( p. 37) – Check the air filter. – Check the settings of all controls and ensure that they can be operated smoothly. – Check all screws, nuts and hose clamps regularly for tightness. – Check the fuel supply.

7.2Starting

Danger

Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.

– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed

space without an effective exhaust extraction system.

Note

Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

– Always warm up the engine at low engine speeds.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately.

Engine has been out of use for more than 1 week

–

Empty the carburetor float chamber. x ( p. 81)

(All SX models)

– Turn handle  of the fuel tap to the ON position. (Figure 601185-10 p. 12)

Fuel can flow from the fuel tank to the carburetor.

(All XC models)

– Turn handle  of the fuel tap to the ON position. (Figure 601157-11 p. 12)

Fuel can flow from the fuel tank to the carburetor.

– Remove the motorcycle from the stand. – Shift gear to neutral.

The engine is cold

– Pull choke lever out as far as possible.

RIDING INSTRUCTIONS 21

(250/300 XC)

– Press the electric starter button or press the kick starter robustly through its full range.

Info

Do not open the throttle.

(150 XC, all SX models)

– Press the kick starter forcefully through its full range.

Info

Do not open the throttle.

7.3Starting off

Info

The plug-in stand must be removed before riding. When you are riding, the side stand must be folded up and secured with the rubber band.

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

7.4Shifting, riding

Warning

Danger of accidents If you change down at high engine speed, the rear wheel can lock up.

– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

– When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-

neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

– If the choke function was activated, deactivate it after the engine has warmed up. – When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces

vehicle speed but lowers fuel consumption considerably.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption. – To shift down, brake and close the throttle at the same time. – Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again. – Switch off the engine if you expect to be standing for a long time.

Guideline

≥ 2 min

– Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system. – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

7.5Braking

Warning

Danger of accidents If you brake too hard, the wheels can lock.

– Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.

– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking efficiency due to wet or dirty brakes.

– Clean or dry dirty or wet brakes by riding and braking gently.

RIDING INSTRUCTIONS 22

– 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. – On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.

In this way, you have to brake far less and the brakes do not overheat.

7.6Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

– Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.

Warning

Danger of burns Some vehicle components become very hot when the vehicle is operated.

– Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-

nents to cool down before starting work on them.

Note

Danger of damage The parked vehicle may roll away or fall over.

– Always place the vehicle on a firm and even surface.

Note

Fire hazard Some vehicle components become very hot when the vehicle is operated.

– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from

being run. Always let the vehicle cool first.

Note

Material damage Damage and destruction of components by excessive load.

– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side

stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

– Brake the motorcycle. – Shift gear to neutral. – Press and hold the kill switch while the engine is idling until the engine stops.

(All XC models)

– Turn handle  of the fuel tap to the OFF position. (Figure 601157-11 p. 12)

(All SX models)

– Turn handle  of the fuel tap to the OFF position. (Figure 601185-10 p. 12)

– Park the vehicle on the side stand.

7.7Refueling

Danger

Fire hazard Fuel is highly flammable.

– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no

fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

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.

– Switch off the engine. – Open the filler cap. ( p. 11)

RIDING INSTRUCTIONS 23

– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

400382-10

Total fuel tank capacity, approx.

2-stroke engine oil ( p. 117)

– Close the filler cap. ( p. 11)

7.5 l (1.98 US gal)

11.5 l (3.04 US gal)

Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) ( p. 118) (125/150 SX)

Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 118) (250 SX)

Super unleaded gasoline, mixed with 2-stroke engine oil (1:40) ( p. 118) (150 XC USA)

Super unleaded gasoline, mixed with 2-stroke engine oil (1:60) ( p. 118) (250/300 XC)

SERVICE SCHEDULE (SX) 24

8.1Service schedule

S10A S20A S30A

Change the gear oil. x (125/150 SX) Change the gear oil. x (250 SX)

Check the front brake linings. ( p. 62) • • • Check the rear brake linings. ( p. 66) • • • Check the brake discs. ( p. 60) • • • Check the brake lines for damage and leakage. • • • Check the rear brake fluid level. ( p. 65) • • •

Change the foot brake cylinder seals. x

Check the free travel of the foot brake lever. ( p. 64) • • •

Check the frame and swingarm. x Check the swingarm bearing. x Check the shock absorber linkage. x Conduct a minor fork service. (All SX models) x Conduct a major fork service. (All SX models) x

Check the tire condition. ( p. 70) • • • Check the tire air pressure. ( p. 71) • • •

Check the wheel bearing for play. x Check the wheel hubs. x Check the rim run-out. x

Check the spoke tension. ( p. 71) • • • Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 52) • • • Check the chain tension. ( p. 51) • • •

Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x

Check the fluid level of the hydraulic clutch. ( p. 57) • • • Check the front brake fluid level. ( p. 61) • • • Check the free travel of the hand brake lever. ( p. 60) • • • Check the play of the steering head bearing. ( p. 42) • • •

Change the piston and check the cylinder. x Change the piston and check the cylinder. (under difficult riding conditions) x Change the spark plug and spark plug connector. x (125/150 SX) Change the spark plug and spark plug connector. x (250 SX) Check the intake diaphragm. x Check the exhaust control for functioning and smooth operation. x Check the clutch. x

Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect

routing. x

Check the antifreeze and coolant level. ( p. 76) • • •

Check the cables for damage and routing without sharp bends. x

Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • • •

Clean the air filter and air filter box. x ( p. 47) Change the glass fiber yarn filling of the main silencer. x ( p. 48) Check the screws and nuts for tightness. x Check the idle. x

Final check: Check the vehicle for safe operation and take a test ride. • • •

Make the service entry in KTM DEALER.NET and in the service record. x

• • •

•

• • •

•

• • •

•

• • •

•

• • •

•

• • •

•

• • •

•

• • •

S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal) S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)

SERVICE SCHEDULE (SX) 25

8.2Maintenance work (as an additional order)

S20N S40A J1A

Change the front brake fluid. x Change the rear brake fluid. x Change the hydraulic clutch fluid. x ( p. 57) Grease the steering head bearing. x ( p. 43) Check/set the carburetor components. x Service the shock absorber. (All SX models) x Change the connecting rod, conrod bearing and crank pin. x Check the transmission and shift mechanism. x Change all engine bearings. x

S20N: Once after 20 service hours - corresponds to about 140 liters of fuel (37 US gal) S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal) J1A: Annually

• •

•

SERVICE SCHEDULE (XC) 26

9.1Service schedule

S20A S40A

Check and charge the battery. x (250/300 XC) Change the gear oil. x

Check the front brake linings. ( p. 62) • • Check the rear brake linings. ( p. 66) • • Check the brake discs. ( p. 60) • • Check the brake lines for damage and leakage. • • Check the rear brake fluid level. ( p. 65) • • Check the free travel of the foot brake lever. ( p. 64) • •

Check the frame and swingarm. x Check the swingarm bearing. x Check the shock absorber linkage. x Conduct a minor fork service. (All XC models) x

Check the tire condition. ( p. 70) • • Check the tire air pressure. ( p. 71) • •

Check the wheel bearing for play. x Check the wheel hub. x Check the rim run-out. x

Check the spoke tension. ( p. 71) • • Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 52) • • Check the chain tension. ( p. 51) • •

Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x

Check the fluid level of the hydraulic clutch. ( p. 57) • • Check the front brake fluid level. ( p. 61) • • Check the free travel of the hand brake lever. ( p. 60) • • Check the play of the steering head bearing. ( p. 42) • •

Change the spark plug and spark plug connector. x Check the intake diaphragm. x Check the exhaust control for functioning and smooth operation. x Check the clutch. x Check all hoses (e. g. fuel, cooling, bleeding, drainage) and sleeves for cracking, leaks, and incorrect routing. x

Check the antifreeze and coolant level. ( p. 76) • •

Check the cables for damage and routing without sharp bends. x

Check that the throttle cables are undamaged, routed without sharp bends and set correctly. • •

Clean the air filter and air filter box. x ( p. 47) Change the glass fiber yarn filling of the main silencer. x ( p. 48) Check the screws and nuts for tightness. x Check the idle. x

Final check: Check the vehicle for safe operation and take a test ride. • •

Make the service entry in KTM DEALER.NET and in the service record. x

• •

•

• •

•

• •

S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal) S40A: Every 40 service hours - corresponds to approx. 280 liters of fuel (74 US gal) / after each race

SERVICE SCHEDULE (XC) 27

9.2Service work (as additional order)

S40A S80A J1A

Change the front brake fluid. x Change the rear brake fluid. x Change the hydraulic clutch fluid. x ( p. 57) Grease the steering head bearing. x ( p. 43) Check/set the carburetor components. x Conduct a major fork service. (All XC models) x Service the shock absorber. (All XC models) x Check the starter drive. x (250/300 XC) Change the piston and check the cylinder. x (All 125/150 models) Change the connecting rod, conrod bearing and crank pin. x Check the transmission and shift mechanism. x Change all engine bearings. x

S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal) S80A: Every 80 service hours - corresponds to approx. 560 liters of fuel (148 US gal) / every 40 service hours when used for sporting

purposes - corresponds to approx. 280 liters of fuel (74 US gal) J1A: Annually

• •

•

TUNING THE CHASSIS 28

10.1Checking 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.

– For optimal motorcycle riding characteristics and to avoid damage to forks, shock

absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight.

– As delivered, KTM offroad motorcycles are adjusted for a standard rider weight

(with full protective clothing). Guideline

Standard rider weight 75… 85 kg (165… 187 lb.)

– If the rider's weight is above or below the standard range, the basic setting of the

suspension components must be adjusted accordingly.

– Small weight differences can be compensated by adjusting the spring preload, but

in the case of large weight differences, the springs must be replaced.

401030-01

10.2Compression damping of shock absorber

The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed. High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed. The high-speed setting, for example, affects the compression when landing after a jump: the rear wheel suspension compresses more quickly. The low-speed setting, for example, affects the compression when riding over long ground swells: the rear wheel suspension compresses more slowly. These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa.

10.3Adjusting the low-speed compression damping of the shock absorber

Caution

Danger of accidents Disassembly of pressurized parts can lead to injury.

– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop

will be glad to help.)

Info

The low-speed setting can be seen during the slow to normal compression of the shock absorber.

– Turn adjusting screw  clockwise with a screwdriver to the last click.

B00290-10

Info

Do not loosen nut !

– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.

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