Page 1
SETUP INSTRUCTIONS 2011
125 SX
150 SX
250 SX
150 XC USA
250 XC EU/USA
300 XC EU/USA
Art. no. 3211692en
Page 2
Page 3
INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG in particular 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.
© 2010 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
Page 4
MEANS OF REPRESENTATION 2
Symbols used
The symbols used are explained in the following.
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).
Identifies a page reference (more information is provided on the specified page).
Denotes additional information or tips.
Denotes the result of a test step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
Formats used
The typographical and other formats used are explained in the following.
Own name Indicates a proprietary name.
®
Name
Brand™ Identifies a brand in merchandise traffic.
Identifies a protected name.
Page 5
SET‑UP 3
2.1Unpacking and setting up the vehicle
Packaging 2
– Remove the box and the plastic packaging.
Info
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
– Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
601257-10
– Have a lift stand available.
Lift stand (54829055000)
– Carefully loosen and remove the tensioning belt over the link fork.
Info
An assistant prevents the motorcycle from falling over.
– Carefully loosen and remove the tensioning belts around the lower triple clamp.
The vehicle is released at the front.
– Together with an assistant, take the vehicle off of the palette.
– Position the vehicle on a lift stand.
– Check the vehicle for transport damage.
Package 12
– Remove the box and the plastic packaging.
601258-10
601259-10
600814-01
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
– Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
– Have a lift stand available.
Lift stand (54829055000)
– Together with an assistant, take the vehicle off of the palette.
– Position the vehicle on a lift stand.
– Check the vehicle for transport damage.
– Remove the cardboard from around the shock absorber.
– Install the shock absorber. ( p. 6)
– Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
– Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm
(8.9 lbf ft)
Info
The upper milled groove in the fork leg must be flush with the top edge
of the upper triple clamp.
Position bleeder screws toward the front.
Page 6
SET‑UP 4
0022
0
0
11
0
0
22
11
– Remove screws . Remove the handlebar clamp.
– Remove screws . Remove the handlebar support.
– Place the handlebar support in the required position. Mount and tighten screws .
Guideline
B00375-10
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
– Position the handlebar clamps. Mount and tighten the screws.
Guideline
Screw, handlebar clamp M8 20 Nm
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
Loctite®243™
(14.8 lbf ft)
600824-10
B00092-01
B00093-01
– Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
– Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
– Install the front fender. ( p. 7)
– Correctly mount the fuel tank breather.
– Secure the handlebar cushion with two cable binders.
– Install the start number plate. ( p. 7)
B00539-01
Page 7
SET‑UP 5
– Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Plier for footrest spring (58429083000)
800042-10
(250/300 XC)
Warning
Risk of injury Battery acid and battery gases cause serious cauteriza-
tion.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
800035-10
– Keep the battery away from sparks or open fire. Charge only in well
ventilated rooms.
– Flush with copious amounts of water in case of skin contact. If bat-
tery acid comes into contact with the eyes, flush the eyes with water
for at least 15 minutes and consult a physician.
B00097-01
– Fill the battery.
Info
Read the notes in the battery package.
– Recharge the battery. ( p. 8)
– Install the battery. ( p. 9)
– Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts installation instructions.
– Apply the label included in the delivery (optional).
– Refuel. ( p. 10)
– Position all controls exactly on the handlebar. Tighten all screws.
– Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.
Page 8
WORK 6
3.1Installing the shock absorber
(All 125/150 models)
– Push splash protector to the side and position the shock absorber. Mount
and tighten screw .
Guideline
601191-11
Screw, top shock
absorber
– Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
Info
The heim joint for the shock absorber at the swing arm is Teflon coated.
It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.
(All 250/300 models)
– Push splash protector to the side and position the shock absorber. Mount
and tighten screw .
Guideline
Screw, top shock
absorber
M12 80 Nm
(59 lbf ft)
M12 80 Nm
(59 lbf ft)
M12 80 Nm
(59 lbf ft)
Loctite®2701
Loctite®2701
Loctite®2701
– Mount and tighten screw .
Guideline
303501-11
Screw, bottom shock
M12 80 Nm
absorber
Info
The heim joint for the shock absorber at the swing arm is Teflon coated.
It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life.
– Remove the motorcycle from the lift stand.
3.2Installing the front wheel
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the wheel bearing.
– Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 13)
Loctite®2701
(59 lbf ft)
B00304-11
– Insert the spacers.
Page 9
WORK 7
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
– Operate the hand brake lever several times until the brake linings are lying correctly
against on the brake disc.
B00302-11
3.3Installing the front fender
– Remove the motorcycle from the lift stand.
– Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
– Tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
– Ensure that the spacers are mounted in the fender.
– Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
B00307-10
3.4Installing the start number plate
303504-11
3.5Removing the seat
Info
Make sure the holding lugs engage in the start number plate.
– Position the start number plate. Mount and tighten screw .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Ensure that the holding lugs engage in the fender.
– Position the brake line. Position the clamp and mount and tighten screw .
– Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
601192-10
Page 10
WORK 8
3.6Mounting the seat
– Hook in the front of the seat at the collar bushing of the fuel tank, lower at the rear
and simultaneously push forward.
– Make sure that the seat is correctly locked in.
B00318-01
– Mount and tighten screw of the seat fixation.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
601192-10
3.7Recharging the battery (250/300 XC)
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
– Flush with copious amounts of water in case of skin contact. If battery acid comes into contact with the eyes, flush the
eyes with water for at least 15 minutes and consult a physician.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
– Switch off all power consumers and switch off the engine.
– Remove the seat. ( p. 7)
– Disconnect the negative cable of the battery to avoid damage to the motorcycle's
electronics.
Page 11
WORK 9
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the battery.
Info
Never remove lid .
400240-10
– Switch off the charger after charging. Disconnect the battery.
– Mount the seat. ( p. 8)
3.8Installing the battery (250/300 XC)
– Place the battery in the battery holder.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing .
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
3 months
motorcycle is not in use
Battery (YTX4L-BS)
3.9Opening the filler cap
3.10Closing the filler cap
– Reconnect rubber band .
– Attach the positive cable and replace the positive terminal cover .
– Attach negative cable .
– Mount the seat. ( p. 8)
B00361-11
– Press release button , turn the filler cap counterclockwise and lift it free.
303502-10
– 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
Page 12
WORK 10
AA
3.11Refueling
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. 9)
– Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
400382-10
Total fuel tank
capacity, approx.
Total fuel tank
capacity, approx.
2-stroke engine oil ( p. 12)
– Close the filler cap. ( p. 9)
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. 12)
(125/150 SX)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 12)
(250 SX)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:40) ( p. 12)
(150 XC USA)
Super unleaded gasoline, mixed with
2-stroke engine oil (1:60) ( p. 12)
(250/300 XC)
Page 13
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 11
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Screw, frame protector M5 3 Nm (2.2 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Nut, starter motor (250/300 XC) M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft)
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, side stand attachment M8 40 Nm (29.5 lbf ft)
Screw, subframe M8 35 Nm (25.8 lbf ft)
Screw, top steering stem M8 17 Nm (12.5 lbf ft)
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine bracket screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Screw, bottom shock absorber M12 80 Nm (59 lbf ft)
Screw, top shock absorber M12 80 Nm (59 lbf ft)
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft)
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
M6 10 Nm (7.4 lbf ft)
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®243™
Loctite®2701
Loctite®243™
Loctite®2701
Loctite®2701
Loctite®243™
Loctite®243™
Loctite®2701
Loctite®2701
Loctite®243™
Page 14
SUBSTANCES 12
2-stroke engine oil
According to
– JASO FC ( p. 14)
Guideline
–
Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex®products.
Fully synthetic
Supplier
®
Motorex
– Cross Power 2T
Super unleaded gasoline, mixed with 2-stroke engine oil (1:40)
According to
– DIN EN 228
– JASO FC ( p. 14) (1:40)
Mixture ratio
1:40 2-stroke engine oil ( p. 12)
Super unleaded (ROZ 95 / RON 95 / PON 91)
Super unleaded gasoline, mixed with 2-stroke engine oil (1:60)
According to
– DIN EN 228
– JASO FC ( p. 14) (1:60)
Mixture ratio
1:60 2-stroke engine oil ( p. 12)
Super unleaded (ROZ 95 / RON 95 / PON 91)
Page 15
AUXILIARY SUBSTANCES 13
Long-life grease
Guideline
–
KTM recommends Motorex®products.
Supplier
®
Motorex
– Bike Grease 2000
Page 16
STANDARDS 14
JASO FC
JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
Page 17
*3211692en*
3211692en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
08/2010
Photo: Mitterbauer
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