KTM 125 Universal 2013 Owner's manual
OWNER'S MANUAL 2013
125 SX EU
125 SX USA
150 SX EU
150 SX USA
250 SX EU
250 SX USA
150 XC USA
250 XC EU/USA
300 XC EU/USA
Art. no. 3211857en
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. 11) Dealer's stamp
Engine number ( p. 11)
The Owner's Manual contained the latest information for this model at the time of going to print. 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.
© 2012 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
1 MEANS OF REPRESENTATION ..................................... 5
1.1 Symbols used ................................................... 5
1.2 Formats used.................................................... 5
2 SAFETY ADVICE........................................................... 6
2.1 Use definition - intended use ............................. 6
2.2 Safety advice.................................................... 6
2.3 Degrees of risk and symbols ............................... 6
2.4 Tampering warning............................................ 6
2.5 Safe operation .................................................. 7
2.6 Protective clothing ............................................ 7
2.7 Work rules........................................................ 7
2.8 Environment..................................................... 7
2.9 Owner's Manual ................................................ 7
3 IMPORTANT NOTES..................................................... 8
3.1 Guarantee, warranty .......................................... 8
3.2 Operating and auxiliary substances ..................... 8
3.3 Spare parts, accessories .................................... 8
3.4 Service ............................................................ 8
3.5 Figures ............................................................ 8
3.6 Customer service............................................... 8
4 VIEW OF VEHICLE ....................................................... 9
4.1 View of vehicle, front left (example) .................... 9
4.2 View of vehicle, rear right (example) ................. 10
5 SERIAL NUMBERS .................................................... 11
5.1 Chassis number .............................................. 11
5.2 Type label ...................................................... 11
5.3 Engine number ............................................... 11
5.4 Fork part number ............................................ 11
5.5 Shock absorber part number ............................ 11
6 CONTROLS................................................................ 12
6.1 Clutch lever.................................................... 12
6.2 Hand brake lever............................................. 12
6.3 Throttle grip ................................................... 12
6.4 Kill switch...................................................... 12
6.5 Electric starter button (250/300 XC)................. 13
6.6 Opening the filler cap...................................... 13
6.7 Closing the filler cap ....................................... 14
6.8 Fuel tap (All SX models) .................................. 14
6.9 Fuel tap (All XC models) .................................. 15
6.10 Choke............................................................ 15
6.11 Shift lever ...................................................... 15
6.12 Kick starter .................................................... 16
6.13 Foot brake lever .............................................. 16
6.14 Plug-in stand (All SX models)........................... 16
6.15 Side stand (All XC models)............................... 16
7 PREPARING FOR USE................................................ 18
7.1 Advice on first use .......................................... 18
7.2 Running in the engine ..................................... 19
7.3 Preparing the vehicle for difficult riding
conditions ...................................................... 19
7.4 Preparations for riding on dry sand ................... 19
7.5 Preparations for riding on wet sand................... 20
7.6 Preparations for riding on wet and muddy
surfaces ......................................................... 21
7.7 Preparations for riding at high temperatures
and low speeds ............................................... 21
7.8 Preparing for riding at low temperatures or in
snow.............................................................. 22
8 RIDING INSTRUCTIONS............................................. 23
8.1 Checks and maintenance work when preparing
for use ........................................................... 23
8.2 Starting.......................................................... 23
8.3 Starting off..................................................... 24
8.4 Shifting, riding ............................................... 24
8.5 Braking.......................................................... 24
8.6 Stopping, parking............................................ 25
8.7 Transport ....................................................... 25
8.8 Refueling ....................................................... 26
9 SERVICE SCHEDULE ................................................. 27
9.1 All SX models ................................................. 27
9.1.1 Service schedule......................................... 27
9.1.2 Service work (as additional order) ................. 28
9.2 All XC models ................................................. 28
9.2.1 Service schedule......................................... 28
9.2.2 Service work (as additional order) ................. 29
10 TUNING THE CHASSIS .............................................. 30
10.1 Checking the basic chassis setting with the
rider's weight.................................................. 30
10.2 Compression damping of shock absorber ........... 30
10.3 Adjusting the low-speed compression damping
of the shock absorber ...................................... 30
10.4 Adjusting the high-speed compression
damping of the shock absorber ......................... 31
10.5 Adjusting the rebound damping of the shock
absorber......................................................... 32
10.6 Measuring the sag of the unloaded rear wheel.... 33
10.7 Checking the static sag of the shock absorber.... 34
10.8 Checking the riding sag of the shock absorber.... 34
10.9 Adjusting the spring preload of the shock
absorber x.................................................... 34
10.10 Adjusting the riding sag x .............................. 35
10.11 Checking the basic setting of the fork ............... 37
10.12 Adjusting the compression damping of the
fork ............................................................... 37
10.13 Adjusting the rebound damping of the fork ........ 38
10.14 Handlebar position.......................................... 38
10.15 Adjusting the handlebar position x ................. 39
11 SERVICE WORK ON THE CHASSIS.............................. 40
11.1 Raising the motorcycle with the lift stand .......... 40
11.2 Removing the motorcycle from the lift stand ...... 40
11.3 Bleeding the fork legs...................................... 40
11.4 Cleaning the dust boots of the fork legs............. 41
11.5 Loosening the fork protection ........................... 41
11.6 Positioning the fork protection.......................... 42
11.7 Removing the fork legs x ............................... 42
11.8 Installing the fork legs x ................................ 42
11.9 Removing the fork protector x ........................ 43
11.10 Installing the fork protector x......................... 43
11.11 Removing the lower triple clamp x.................. 43
11.12 Installing the lower triple clamp x .................. 44
11.13 Checking the play of the steering head
bearing .......................................................... 46
11.14 Adjusting the play of the steering head
bearing x ..................................................... 46
11.15 Greasing the steering head bearing x .............. 47
11.16 Removing the start number plate ...................... 47
11.17 Installing the start number plate....................... 47
11.18 Removing the front fender ............................... 47
11.19 Installing the front fender ................................ 48
11.20 Removing the shock absorber x ...................... 48
11.21 Installing the shock absorber x....................... 49
11.22 Removing the seat .......................................... 49
11.23 Mounting the seat ........................................... 49
11.24 Removing the air filter box lid .......................... 50
TABLE OF CONTENTS 3
11.25 Installing the air filter box lid ........................... 50
11.26 Removing the air filter x ................................ 50
11.27 Installing the air filter x................................. 51
11.28 Cleaning the air filter and air filter box x ......... 51
11.29 Securing the air filter box lid x....................... 52
11.30 Sealing the air filter box x.............................. 52
11.31 Removing the main silencer ............................. 52
11.32 Installing the main silencer.............................. 53
11.33 Changing the glass fiber yarn filling of the
main silencer x............................................. 53
11.34 Removing the fuel tank x............................... 53
11.35 Installing the fuel tank x................................ 54
11.36 Checking the chain for dirt............................... 55
11.37 Cleaning the chain .......................................... 55
11.38 Checking the chain tension .............................. 56
11.39 Adjusting the chain tension.............................. 56
11.40 Checking the chain, rear sprocket, engine
sprocket and chain guide ................................. 57
11.41 Adjusting the chain guide x ........................... 59
11.42 Checking the frame x .................................... 59
11.43 Checking the swingarm x............................... 59
11.44 Checking the routing of the throttle cable.......... 59
11.45 Checking the rubber grip ................................. 61
11.46 Additionally securing the rubber grip................. 61
11.47 Adjusting the basic position of the clutch
lever .............................................................. 61
11.48 Checking/correcting the fluid level of the
hydraulic clutch.............................................. 62
11.49 Changing the hydraulic clutch fluid x.............. 63
12 BRAKE SYSTEM ........................................................ 65
12.1 Checking the free travel of the hand brake
lever .............................................................. 65
12.2 Adjusting the basic position of the hand brake
lever .............................................................. 65
12.3 Checking the brake discs ................................. 65
12.4 Checking the front brake fluid level .................. 66
12.5 Adding front brake fluid x.............................. 66
12.6 Checking the front brake linings ....................... 67
12.7 Changing the front brake linings x .................. 67
12.8 Checking the free travel of foot brake lever ........ 69
12.9 Adjusting the basic position of the foot brake
lever x ......................................................... 69
12.10 Checking the rear brake fluid level.................... 70
12.11 Adding brake fluid for the rear brake x............ 70
12.12 Checking the rear brake linings ........................ 71
12.13 Changing the rear brake linings x ................... 71
13 WHEELS, TIRES ........................................................ 73
13.1 Removing the front wheel x ........................... 73
13.2 Installing the front wheel x ............................ 73
13.3 Removing the rear wheel x............................. 74
13.4 Installing the rear wheel x.............................. 74
13.5 Checking the tire condition .............................. 75
13.6 Checking the tire air pressure........................... 76
13.7 Checking the spoke tension.............................. 76
14 ELECTRICAL SYSTEM ................................................ 77
14.1 Removing the battery x (250/300 XC)............. 77
14.2 Installing the battery x (250/300 XC) ............. 77
14.3 Recharging the battery x (250/300 XC)........... 77
14.4 Changing the main fuse (250/300 XC) .............. 78
15 COOLING SYSTEM ..................................................... 80
15.1 Cooling system ............................................... 80
15.2 Radiator cover (All SX models) ......................... 80
15.3 Removing the radiator cover (All SX models) ...... 80
15.4 Installing the radiator cover (All SX models)....... 81
15.5 Checking the antifreeze and coolant level .......... 81
15.6 Checking the coolant level ............................... 82
15.7 Draining the coolant x................................... 82
15.8 Refilling with coolant x.................................. 83
16 TUNING THE ENGINE................................................ 85
16.1 Checking the play in the throttle cable .............. 85
16.2 Adjusting the play in the throttle cable x......... 85
16.3 Carburetor - idle.............................................. 85
16.4 Carburetor - adjusting the idle speed x............ 86
16.5 Emptying the carburetor float chamber x......... 87
16.6 Plug-in connection, ignition timing map ............ 88
16.7 Changing the ignition curve.............................. 88
16.8 Checking the basic position of the shift lever ..... 88
16.9 Adjusting the basic position of the shift
lever x ......................................................... 88
16.10 Engine characteristic - auxiliary spring (All
250/300 models)............................................ 89
16.11 Engine characteristic - setting the auxiliary
spring x (All 250/300 models) ....................... 89
17 SERVICE WORK ON THE ENGINE ............................... 91
17.1 Checking the gear oil level ............................... 91
17.2 Changing the gear oil x.................................. 91
17.3 Draining the gear oil x................................... 92
17.4 Refilling with gear oil x.................................. 92
17.5 Adding gear oil x........................................... 93
18 CLEANING, CARE ...................................................... 95
18.1 Cleaning the motorcycle .................................. 95
19 STORAGE.................................................................. 96
19.1 Storage.......................................................... 96
19.2 Preparing for use after storage.......................... 96
20 TROUBLESHOOTING ................................................. 97
21 TECHNICAL DATA...................................................... 99
21.1 Engine........................................................... 99
21.1.1 125 SX EU, 125 SX USA ............................ 99
21.1.2 150 SX EU, 150 SX USA ............................ 99
21.1.3 250 SX EU, 250 SX USA .......................... 100
21.1.4 150 XC USA ............................................ 100
21.1.5 250 XC EU/USA ....................................... 101
21.1.6 300 XC EU/USA ....................................... 102
21.2 Engine tightening torques .............................. 102
21.2.1 All 125/150 models.................................. 102
21.2.2 250 SX EU, 250 SX USA .......................... 103
21.2.3 250/300 XC ............................................. 104
21.3 Carburetor.................................................... 105
21.3.1 125 SX EU, 125 SX USA .......................... 105
21.3.2 Carburetor - basic setting for sandy
surfaces (125 SX EU, 125 SX USA) ........... 105
21.3.3 Carburetor tuning (125 SX EU,
125 SX USA) ........................................... 106
21.3.4 150 SX EU, 150 SX USA .......................... 107
21.3.5 Carburetor - basic setting for sandy
surfaces (150 SX EU, 150 SX USA) ........... 107
21.3.6 Carburetor tuning (150 SX EU,
150 SX USA) ........................................... 108
21.3.7 250 SX EU, 250 SX USA .......................... 109
21.3.8 Carburetor - basic setting for sandy
surfaces (250 SX EU, 250 SX USA) ........... 109
21.3.9 Carburetor tuning (250 SX EU,
250 SX USA) ........................................... 110
21.3.10 150 XC USA ............................................ 111
TABLE OF CONTENTS 4
21.3.11 Carburetor tuning (150 XC USA) ................ 111
21.3.12 250 XC EU/USA ....................................... 112
21.3.13 Carburetor tuning (250 XC EU/USA) ........... 113
21.3.14 300 XC EU/USA ....................................... 114
21.3.15 Carburetor tuning (300 XC EU/USA) x ...... 114
21.4 Capacities.................................................... 115
21.4.1 Gear oil.................................................... 115
21.4.2 coolant .................................................... 115
21.4.3 fuel ......................................................... 115
21.5 Chassis........................................................ 115
21.6 Electrical system........................................... 116
21.7 Tires............................................................ 116
21.8 Fork............................................................. 117
21.8.1 125 SX EU, 150 SX EU ............................ 117
21.8.2 125 SX USA, 150 SX USA ........................ 117
21.8.3 250 SX EU .............................................. 117
21.8.4 250 SX USA ............................................ 118
21.8.5 150 XC USA ............................................ 118
21.8.6 250/300 XC ............................................. 119
21.9 Shock absorber ............................................. 119
21.9.1 125 SX EU, 150 SX EU ............................ 119
21.9.2 125 SX USA, 150 SX USA ........................ 120
21.9.3 250 SX EU .............................................. 120
21.9.4 250 SX USA ............................................ 121
21.9.5 150 XC USA ............................................ 121
21.9.6 250/300 XC ............................................. 122
21.10 Chassis tightening torques ............................. 122
22 SUBSTANCES ......................................................... 124
23 AUXILIARY SUBSTANCES ........................................ 127
24 STANDARDS ........................................................... 129
INDEX ............................................................................ 130
1 MEANS OF REPRESENTATION 5
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
1.2 Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
®
Name
Brand™ Identifies a brand available on the open market.
Identifies a protected name.
2 SAFETY ADVICE 6
2.1 Use definition - intended use
(All SX models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle may only be used in closed off areas remote from public road traffic.
(All XC models)
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles
comply with currently valid regulations and categories of the top international motorsport organizations.
Info
This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.
2.2 Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety
instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If
they are missing, you or others may not recognize dangers and may therefore be injured.
2.3 Degrees of risk and symbols
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.
2.4 Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 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, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
manufacturer.
2 SAFETY ADVICE 7
2.5 Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result 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.
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 the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2.6 Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents 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 that is in good condition and meets the legal requirements.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7 Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
In some instances, a thread locker (e.g. Loctite®) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.8 Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the
respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that
pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2.9 Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains
useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
3 IMPORTANT NOTES 8
3.1 Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service 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.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
3.2 Operating and auxiliary substances
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.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3 Spare parts, accessories
For your own safety, only use spare parts and accessory products that are 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 accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise
you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4 Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and
chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can
lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more rapid wear
of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or
replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a
much longer service life for your motorcycle.
3.5 Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6 Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE 9
4.1 View of vehicle, front left (example)
1 Hand brake lever ( p. 12)
2 Kill switch ( p. 12)
3 Clutch lever ( p. 12)
4 Air filter box lid
5 Fork rebound setting
6 Fuel tap
7 Choke ( p. 15)
8 Shift lever ( p. 15)
9 Chain guide
101649-10
4 VIEW OF VEHICLE 10
4.2 View of vehicle, rear right (example)
1 Seat
2 Filler cap
3 Handlebar cushion
4 Throttle grip ( p. 12)
5 Fork compression adjustment
6 Shock absorber rebound adjustment
7 Level viewer for brake fluid, rear
8 Shock absorber compression adjustment
9 Foot brake lever ( p. 16)
10 Kick starter ( p. 16)
101650-10
5 SERIAL NUMBERS 11
5.1 Chassis number
The chassis number 1 is stamped on the right side of the steering head.
101652-10
5.2 Type label
The type label 1 is fixed to the front of the steering head.
5.3 Engine number
5.4 Fork part number
101653-10
The engine number 1 is stamped on the left side of the engine under the engine
sprocket.
101651-10
The fork part number 1 is stamped on the inner side of the fork stub.
101654-10
5.5 Shock absorber part number
800194-10
The shock absorber part number 1 is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
6 CONTROLS 12
6.1 Clutch lever
(All 125/150 models)
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
101655-10
(All 250/300 models)
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
101656-10
6.2 Hand brake lever
6.3 Throttle grip
Hand brake lever 1 is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
101657-10
Throttle grip 1 is fitted on the right side of the handlebar.
101658-10
6.4 Kill switch
The kill switch 1 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.
101659-10
6 CONTROLS 13
6.5 Electric starter button (250/300 XC)
The electric starter button 1 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.
101660-10
6.6 Opening 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.
(All SX models)
– Turn filler cap 1 counterclockwise and lift it off.
101661-10
(All XC models)
– Press release button 1, turn the filler cap counterclockwise, and lift it off.
101663-10
6 CONTROLS 14
6.7 Closing the filler cap
(All SX models)
– Mount filler cap 1 and turn it clockwise until the fuel tank is tightly closed.
Info
Run the fuel tank breather hose 2 without kinks.
101662-10
(All XC models)
– Mount filler cap 1 and turn it clockwise until the release button engages.
Info
Run the fuel tank breather hose 2 without kinks.
101664-10
6.8 Fuel tap (All SX models)
601185-10
The fuel tap is on the left side of the fuel tank.
With tap handle 1 on the fuel tap, you can open or close the supply of fuel to the carburetor.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel
tank empties fully.
6 CONTROLS 15
6.9 Fuel tap (All XC models)
The fuel tap is on the left side of the fuel tank.
Tap handle 1 on the fuel tap is used to open or close the supply of fuel to the carburetor.
Possible states
• Fuel supply closed OFF – Fuel cannot flow from the fuel tank to the carburetor.
• Fuel supply open ON – Fuel can flow from the fuel tank to the carburetor. The fuel
tank empties to the point of reserve capacity.
• Open the fuel reserve supply RES – Fuel can flow from the fuel tank to the carburetor. The fuel tank empties fully.
601157-11
6.10 Choke
6.11 Shift lever
B00004-10
101665-10
The choke 1 is fitted on the left side of the carburetor.
Activating the choke function frees an opening in the carburetor through which the
engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a
cold start.
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.
Shift lever 1 is mounted on the left side of the engine.
(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.
101666-10
6 CONTROLS 16
(250 SX EU, 250 SX USA)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
101667-10
6.12 Kick starter
The kick starter 1 is fitted on the right side of the engine. The top part can be
swiveled.
101734-10
6.13 Foot brake lever
B00007-10
6.14 Plug-in stand (All SX models)
101668-10
Foot brake lever 1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
The holder for plug-in stand 1 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.
6.15 Side stand (All XC models)
800211-10
The side stand 1 is on the left side of the vehicle.
6 CONTROLS 17
The side stand is used to park the motorcycle.
Info
When you are riding, side stand 1 must be folded up and secured with rubber
band 2.
800212-10
7 PREPARING FOR USE 18
7.1 Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing presents 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 that is in good condition and meets the 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. 61)
– Adjust the basic position of the hand brake lever. ( p. 65)
–
Adjust the basic position of the foot brake lever. x ( p. 69)
–
Adjust the basic position of the shift lever. x ( p. 88)
– 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.
7 PREPARING FOR USE 19
– Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
– Check the spoke tension. ( p. 76)
Info
The spoke tension must be checked after half an hour of operation.
– Run in the engine. ( p. 19)
7.2 Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours < 70 %
During the first 5 operating hours < 100 %
– Avoid fully opening the throttle!
7.3 Preparing the vehicle for difficult riding conditions
Info
Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to considerably more
rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
–
Seal the air filter box. x ( p. 52)
–
Secure the air filter box lid. x ( p. 52)
–
Clean the air filter and air filter box. x ( p. 51)
Info
Check the air filter approx. every 30 minutes.
– Additionally secure the rubber grip. ( p. 61)
– 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 riding conditions are:
– Riding on dry sand. ( p. 19)
– Riding on wet sand. ( p. 20)
– Riding on wet and muddy surfaces. ( p. 21)
– Riding at high temperatures and low speeds. ( p. 21)
– Riding at low temperatures or in snow. ( p. 22)
7.4 Preparations for riding on dry sand
– Check the radiator cap.
600872-10
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.
7 PREPARING FOR USE 20
– 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
– Clean the chain.
– Mount the steel sprocket.
– Clean the radiator fins.
600868-01
– Carefully align bent radiator fins.
– If used in sand regularly, replace the piston every 10 operating hours.
7.5 Preparations for riding on wet sand
– Check the radiator cap.
600872-10
Info
Your authorized KTM workshop can recommend the right carburetor tuning.
Chain cleaner ( p. 127)
Tip
Do not grease the chain.
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
Your authorized KTM workshop can recommend the right carburetor tuning.
7 PREPARING FOR USE 21
– Clean the chain.
Chain cleaner ( p. 127)
– Mount the steel sprocket.
Tip
Do not grease the chain.
– Clean the radiator fins.
600868-01
7.6 Preparations 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. 95)
– Carefully align bent radiator fins.
600868-01
Your authorized KTM workshop can recommend the right carburetor tuning.
7.7 Preparations for riding at high temperatures and low speeds
– 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
Info
600872-10
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 quickly when the clutch is operated frequently due
to an excessively high secondary drive.
– Clean the chain.
Chain cleaner ( p. 127)
– Clean the radiator fins.
– Carefully align bent radiator fins.
– Check the coolant level. ( p. 82)
7 PREPARING FOR USE 22
7.8 Preparing for riding 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
Your authorized KTM workshop can recommend the right carburetor tuning.
8 RIDING INSTRUCTIONS 23
8.1 Checks and maintenance work when preparing for use
Info
Before riding the vehicle, always check its condition and operating safety.
The vehicle must be in perfect technical condition when used.
– Check the gear oil level. ( p. 91)
– Check the front brake fluid level. ( p. 66)
– Check the rear brake fluid level. ( p. 70)
– Check the front brake linings. ( p. 67)
– Check the rear brake linings. ( p. 71)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 82)
– Check the chain for dirt. ( p. 55)
– Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 57)
– Check the chain tension. ( p. 56)
– Check the tire condition. ( p. 75)
– Check the tire air pressure. ( p. 76)
– Check the spoke tension. ( p. 76)
– Clean the dust boots of the fork legs. ( p. 41)
– Bleed the fork legs. ( p. 40)
– 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.
8.2 Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient 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. 87)
(All SX models)
– Turn handle 1 of the fuel tap to the ON position. (Figure 601185-10 p. 14)
Fuel can flow from the fuel tank to the carburetor.
(All XC models)
– Turn handle 1 of the fuel tap to the ON position. (Figure 601157-11 p. 15)
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.
8 RIDING INSTRUCTIONS 24
(150 XC, all SX models)
– Press the kick starter forcefully through its full range.
Info
Do not open the throttle.
(250/300 XC)
– Press the electric starter button or press the kick starter robustly through its full range.
Info
Do not open the throttle.
8.3 Starting off
Info
The plug-in stand must be removed before riding.
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.
8.4 Shifting, 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.
8.5 Braking
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 a wet or dirty brake system.
– Clean or dry a dirty or wet brake system by riding and braking gently.
8 RIDING INSTRUCTIONS 25
– On sandy, wet or slippery surfaces, use the rear brake.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– Make use of the braking effect of the engine when driving down long downhill stretches. To do so, shift back one or two gears, but
do not overrev the engine. You will need to apply the brakes far less often and the brake system will not overheat.
8.6 Stopping, 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 the brake system. Allow these
components 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 SX models)
– Turn handle 1 of the fuel tap to the OFF position. (Figure 601185-10 p. 14)
(All XC models)
– Turn handle 1 of the fuel tap to the OFF position. (Figure 601157-11 p. 15)
– Park the vehicle on the side stand.
8.7 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.
401475-01
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against acci-
dents or falling over.
8 RIDING INSTRUCTIONS 26
8.8 Refueling
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. 13)
– Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A 35 mm (1.38 in)
400382-10
Total fuel tank
capacity, approx.
Total fuel tank
capacity, approx.
2-stroke engine oil ( p. 124)
– Close the filler cap. ( p. 14)
7.5 l
(1.98 US gal)
10 l (2.6 US gal) Super unleaded gasoline (95 octane),
Super unleaded gasoline (98 octane),
mixed with 2-stroke engine oil (1:40)
( p. 126) (125/150 SX)
Super unleaded gasoline (95 octane),
mixed with 2-stroke engine oil
(1:60) ( p. 125) (250 SX EU,
250 SX USA)
mixed with 2-stroke engine oil (1:40)
( p. 125) (150 XC USA)
Super unleaded gasoline (95 octane),
mixed with 2-stroke engine oil (1:60)
( p. 125) (250/300 XC)
9 SERVICE SCHEDULE 27
9.1 All SX models
9.1.1 Service schedule
S10A S20A S30A
Change the gear oil. x (125/150 SX)
Change the gear oil. x (250 SX EU, 250 SX USA)
Check the front brake linings. ( p. 67) • • •
Check the rear brake linings. ( p. 71) • • •
Check the brake discs. ( p. 65) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. ( p. 70) • • •
Change the foot brake cylinder seals. x
Check the free travel of the foot brake lever. ( p. 69) • • •
Check the frame and swingarm. x
Check the swingarm bearing. x
Check the shock absorber linkage. x
Conduct a minor fork service. x
Conduct a major fork service. x
Check the tire condition. ( p. 75) • • •
Check the tire air pressure. ( p. 76) • • •
Check the wheel bearing for play. x
Check the wheel hubs. x
Check the rim run-out. x
Check the spoke tension. ( p. 76) • • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 57) • • •
Check the chain tension. ( p. 56) • • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x
Check/correct the fluid level of the hydraulic clutch. ( p. 62) • • •
Check the front brake fluid level. ( p. 66) • • •
Check the free travel of the hand brake lever. ( p. 65) • • •
Check the play of the steering head bearing. ( p. 46) • • •
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 EU, 250 SX USA)
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. 81) • • •
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. 51)
Change the glass fiber yarn filling of the main silencer. x ( p. 53)
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 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S30A: Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal)
9 SERVICE SCHEDULE 28
9.1.2 Service work (as additional order)
S20N S40A J1A
Change the front brake fluid. x
Change the rear brake fluid. x
Change the hydraulic clutch fluid. x ( p. 63)
Grease the steering head bearing. x ( p. 47)
Check/set the carburetor components. x
Service the shock absorber. 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 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal)
J1A: Annually
9.2 All XC models
9.2.1 Service schedule
• •
• •
•
•
•
•
•
•
•
S20A S40A
Check and charge the battery. x (250/300 XC)
Change the gear oil. x
Check the front brake linings. ( p. 67) • •
Check the rear brake linings. ( p. 71) • •
Check the brake discs. ( p. 65) • •
Check the brake lines for damage and leakage. • •
Check the rear brake fluid level. ( p. 70) • •
Check the free travel of the foot brake lever. ( p. 69) • •
Check the frame and swingarm. x
Check the swingarm bearing. x
Check the shock absorber linkage. x
Conduct a minor fork service. x
Check the tire condition. ( p. 75) • •
Check the tire air pressure. ( p. 76) • •
Check the wheel bearing for play. x
Check the wheel hub. x
Check the rim run-out. x
Check the spoke tension. ( p. 76) • •
Check the chain, rear sprocket, engine sprocket, and chain guide. ( p. 57) • •
Check the chain tension. ( p. 56) • •
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x
Check/correct the fluid level of the hydraulic clutch. ( p. 62) • •
Check the front brake fluid level. ( p. 66) • •
Check the free travel of the hand brake lever. ( p. 65) • •
Check the play of the steering head bearing. ( p. 46) • •
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. 81) • •
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. • •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
• •
•
•
•
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