OWNER'S MANUAL 2010 125 SX 150 SX 250 SX Art. no. 3211480en DEAR KTM CUSTOMER DEAR KTM CUSTOMER 1 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 great pleasure riding the 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. © 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria All rights reserved Reproduction, even in part, 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 TABLE OF CONTENTS 2 Checking the static sag of the shock absorber .................. Checking the riding sag of the shock absorber .................. Adjusting the spring preload of the shock absorber ...... Adjusting the riding sag Removing the shock absorber Installing the shock absorber Checking the basic setting of the fork.............................. Adjusting the compression damping of the fork ................ Adjusting the rebound damping of the fork....................... Bleeding the fork legs .................................................... Cleaning the dust boots of the fork legs ........................... Loosening the fork protection.......................................... Positioning the fork protection ........................................ Checking the play of the steering head bearing................. Adjusting the play of the steering head bearing Removing the fork legs Installing the fork legs Removing the fork protector Installing the fork protector ....................................... Removing the lower triple clamp Installing the lower triple clamp Greasing the steering head bearing Removing the front fender .............................................. Installing the front fender............................................... Removing the start number plate .................................... Installing the start number plate ..................................... Handlebar position ........................................................ Adjusting the handlebar position Checking the play in the throttle cable............................. Adjusting the play in the throttle cable ....................... Checking the chain for dirt ............................................. Cleaning the chain......................................................... Checking the chain tension ............................................ Checking the rear sprocket/engine sprocket for wear ......... Checking chain wear ...................................................... Adjusting the chain tension ............................................ Adjusting the chain guide Checking the brake discs................................................ Checking the free travel of the hand brake lever ............... Adjusting the basic position of the hand brake lever.......... Checking the front brake fluid level ................................. Adding front brake fluid ............................................ Checking the front brake linings...................................... Removing the front brake linings Installing the front brake linings Changing the front brake linings Checking the free play of the foot brake lever ................... Adjusting the basic position of the foot brake lever ...... Checking the rear brake fluid level .................................. Adding rear brake fluid Checking the rear brake linings ....................................... Removing the rear brake linings Installing the rear brake linings Changing the rear brake linings Removing the front wheel Installing the front wheel Removing the rear wheel ........................................... Installing the rear wheel Checking the tire condition............................................. Checking the tire air pressure ......................................... Checking the spoke tension ............................................ 29 29 29 30 30 31 31 31 32 32 32 33 33 33 34 34 35 35 35 36 36 37 37 37 37 38 38 38 39 39 39 39 40 40 40 41 42 42 43 43 43 44 44 45 45 46 46 47 47 48 48 49 49 50 50 51 52 52 53 54 54 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 LOCATION OF 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 Short circuit button ....................................................... 10 Throttle grip.................................................................. 10 Fuel tap........................................................................ 11 Opening the filler cap .................................................... 11 Closing the filler cap...................................................... 11 Choke........................................................................... 11 Shift lever..................................................................... 12 Kickstarter .................................................................... 12 Foot brake lever............................................................. 12 Plug-in stand ................................................................ 13 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION...................................................................... 14 Advice on first use ......................................................... 14 Running in the engine.................................................... 15 Preparing the vehicle for difficult operating conditions ...... 15 Preparations for riding on dry sand .................................. 15 Preparations for riding on wet sand ................................. 16 Preparations for riding on wet and muddy surfaces ........... 17 Preparations for riding at high temperatures and riding slowly........................................................................... 18 Preparations for riding at low temperatures and in snow .... 18 RIDING INSTRUCTIONS .................................................... 19 Checks before putting into operation ............................... 19 Starting ........................................................................ 19 Starting up ................................................................... 20 Shifting, riding .............................................................. 20 Braking ........................................................................ 20 Stopping, parking .......................................................... 21 Refueling...................................................................... 21 SERVICE SCHEDULE......................................................... 23 Important maintenance work that must be done in an authorized KTM workshop .............................................. 23 Important maintenance work to be carried out by an authorized KTM workshop (as additional order)................. 24 Important checks and maintenance work to be carried out by the rider ............................................................. 24 MAINTENANCE WORK ON CHASSIS AND ENGINE .............. 26 Jacking up the motorcycle .............................................. 26 Removing the motorcycle from the work stand.................. 26 Checking the basic chassis setting with the rider's weight .......................................................................... 26 Compression damping of shock absorber.......................... 26 Adjusting the high-speed compression damping of the shock absorber .............................................................. 26 Adjusting the low-speed compression damping of the shock absorber .............................................................. 27 Adjusting the rebound damping of the shock absorber....... 28 Measuring the sag of the unloaded rear wheel .................. 28 x x............................................. x..................................... x..................................... x............ x.............................................. x............................................... x....................................... x x................................ x................................. x............................. x................................ x x.......................................... x x................................ x................................. x................................. x x.............................................. x................................. x.................................. x.................................. x.......................................... x........................................... x x............................................ TABLE OF CONTENTS Ignition curve plug connection ........................................ Changing the ignition curve ............................................ Engine characteristic - auxiliary spring (250 SX)............... Engine characteristic - adjusting the auxiliary spring (250 SX) ...................................................................... Removing the seat ......................................................... Mounting the seat ......................................................... Removing the fuel tank ............................................. Installing the fuel tank Cooling system .............................................................. Checking the antifreeze and coolant level ........................ Checking the coolant level.............................................. Draining the coolant Refilling with coolant Removing the main silencer............................................ Installing the main silencer ............................................ Glass fiber yarn filling of main silencer ............................ Changing the glass fiber yarn filling of the main silencer ................................................................... Removing the glass fiber yarn filling of the main silencer ................................................................... Installing the glass fiber yarn filling of the main silencer ................................................................... Removing the air filter box lid......................................... Installing the air filter box lid.......................................... Removing the air filter Installing the air filter ............................................... Cleaning the air filter Adjusting the basic position of the clutch lever................. Checking the fluid level of the hydraulic clutch ................ Changing the hydraulic clutch fluid Checking the basic position of the shift lever.................... Adjusting the basic position of the shift lever .............. Carburetor .................................................................... Carburetor - adjusting the idle speed Emptying the carburetor float chamber Checking the gear oil level................ ...