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KTM
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125 SX 2010
KTM 125 SX 2010 User Manual
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Disassembly & Assembling
Workshop manual
4860 MXMA
31
Frontfork 4860 MXMA 2003
05/2002
Assemble the spring and shims check-
valve.
12_157
Assemble the piston rebound.
Pay attention to the assembling
direction!!!
12_158
Replace the shims.
Pay attention to the position of the
triangular shims on the piston!!!
12_159
Assembling tap rebound
709
711
Table of Contents
Owner's Manual 2010
4
Table of Contents
4
Means of Representation
6
Important Information
7
View of Vehicle
9
View of the Vehicle from the Left Front (Example)
9
View of the Vehicle from the Right Rear (Example)
10
Location of Serial Numbers
11
Chassis Number
11
Type Label
11
Engine Number
11
Fork Part Number
11
Shock Absorber Part Number
11
Controls
12
Clutch Lever
12
Hand Brake Lever
12
Short Circuit Button
12
Throttle Grip
12
Fuel Tap
13
Opening the Filler Cap
13
Closing the Filler Cap
13
Choke
13
Shift Lever
14
Kickstarter
14
Foot Brake Lever
14
Plug-In Stand
15
Operation
16
General Tips and Hints on Putting into Operation
17
Running in the Engine
17
Preparing the Vehicle for Difficult Operating Conditions
17
Preparations for Riding on Dry Sand
17
Preparations for Riding on Wet Sand
18
Preparations for Riding on Wet and Muddy Surfaces
19
Preparations for Riding at High Temperatures and Riding Slowly
20
Preparations for Riding at Low Temperatures and in Snow
20
Riding Instructions
21
Checks before Putting into Operation
21
Starting
21
Starting up
22
Shifting, Riding
22
Braking
22
Stopping, Parking
23
Refueling
23
Service Schedule
25
Important Maintenance Work that Must be Done in an Authorized KTM Workshop
25
Important Maintenance Work to be Carried out by an Authorized KTM Workshop (as Additional Order)
26
Important Checks and Maintenance Work to be Carried out by the Rider
26
Maintenance Work on Chassis and Engine
28
Jacking up the Motorcycle
28
Removing the Motorcycle from the Work Stand
28
Checking the Basic Chassis Setting with the Rider's Weight
28
Compression Damping of Shock Absorber
28
Adjusting the High-Speed Compression Damping of the Shock Absorber
28
Adjusting the Low-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
30
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
31
Adjusting the Riding Sag
32
Removing the Shock Absorber
32
Installing the Shock Absorber
33
Checking the Basic Setting of the Fork
33
Adjusting the Compression Damping of the Fork
33
Adjusting the Rebound Damping of the Fork
34
Bleeding the Fork Legs
34
Cleaning the Dust Boots of the Fork Legs
34
Loosening the Fork Protection
35
Positioning the Fork Protection
35
Checking the Play of the Steering Head Bearing
35
Adjusting the Play of the Steering Head Bearing
36
Removing the Fork Legs
36
Installing the Fork Legs
37
Removing the Fork Protector
37
Installing the Fork Protector
37
Removing the Lower Triple Clamp
38
Installing the Lower Triple Clamp
38
Greasing the Steering Head Bearing
39
Removing the Front Fender
39
Installing the Front Fender
39
Removing the Start Number Plate
39
Installing the Start Number Plate
40
Handlebar Position
40
Adjusting the Handlebar Position
40
Checking the Play in the Throttle Cable
41
Adjusting the Play in the Throttle Cable
41
Checking the Chain for Dirt
41
Cleaning the Chain
41
Checking the Chain Tension
42
Checking the Rear Sprocket/Engine Sprocket for Wear
42
Checking Chain Wear
42
Adjusting the Chain Tension
43
Adjusting the Chain Guide
44
Checking the Brake Discs
44
Checking the Free Travel of the Hand Brake Lever
45
Adjusting the Basic Position of the Hand Brake Lever
45
Checking the Front Brake Fluid Level
45
Adding Front Brake Fluid
46
Checking the Front Brake Linings
46
Removing the Front Brake Linings
47
Installing the Front Brake Linings
47
Changing the Front Brake Linings
48
Checking the Free Play of the Foot Brake Lever
48
Adjusting the Basic Position of the Foot Brake Lever
49
Checking the Rear Brake Fluid Level
49
Adding Rear Brake Fluid
50
Checking the Rear Brake Linings
50
Removing the Rear Brake Linings
51
Installing the Rear Brake Linings
51
Changing the Rear Brake Linings
52
Removing the Front Wheel
52
Installing the Front Wheel
53
Removing the Rear Wheel
54
Installing the Rear Wheel
54
Checking the Tire Condition
55
Checking the Tire Air Pressure
56
Checking the Spoke Tension
56
Ignition Curve Plug Connection
56
Changing the Ignition Curve
57
Engine Characteristic - Auxiliary Spring (250 SX)
57
Engine Characteristic - Adjusting the Auxiliary Spring (250 SX)
57
Removing the Seat
58
Mounting the Seat
58
Removing the Fuel Tank
58
Installing the Fuel Tank
59
Cooling System
60
Checking the Antifreeze and Coolant Level
60
Checking the Coolant Level
61
Draining the Coolant
61
Refilling with Coolant
62
Removing the Main Silencer
63
Installing the Main Silencer
63
Glass Fiber Yarn Filling of Main Silencer
63
Changing the Glass Fiber Yarn Filling of the Main Silencer
63
Removing the Glass Fiber Yarn Filling of the Main Silencer
64
Installing the Glass Fiber Yarn Filling of the Main Silencer
64
Removing the Air Filter Box Lid
64
Installing the Air Filter Box Lid
64
Removing the Air Filter
65
Installing the Air Filter
65
Cleaning the Air Filter
65
Adjusting the Basic Position of the Clutch Lever
66
Checking the Fluid Level of the Hydraulic Clutch
66
Changing the Hydraulic Clutch Fluid
67
Checking the Basic Position of the Shift Lever
68
Adjusting the Basic Position of the Shift Lever
68
Carburetor
68
Carburetor - Adjusting the Idle Speed
69
Emptying the Carburetor Float Chamber
70
Checking the Gear Oil Level
70
Changing the Gear Oil
71
Draining the Gear Oil
71
Refilling with Gear Oil
72
Adding Gear Oil
72
Troubleshooting
74
Cleaning
76
Cleaning the Motorcycle
76
Storage
77
Putting into Operation after Storage
77
Technical Data - Engine
78
Capacity - Gear Oil
79
Capacity - Coolant
79
Technical Data - Engine Tightening Torques
80
125 Sx, 150 Sx
80
Technical Data - Engine Tightening Torques
81
Nm (14.8 Lbf Ft)
81
Nm (18.4 Lbf Ft)
81
Technical Data - Carburetor
82
Carburetor - Basic Setting for Sandy Surfaces (125 SX)
82
Carburetor Configuration (125 SX)
83
Carburetor - Basic Setting for Sandy Surfaces (150 SX)
84
Carburetor Configuration (150 SX)
85
Carburetor - Basic Setting for Sandy Surfaces (250 SX)
86
Carburetor Configuration (250 SX)
87
Technical Data - Chassis
88
Tires
88
Capacity - Fuel
88
Technical Data - Fork
89
125 Sx, 150 Sx
89
Technical Data - Shock Absorber
90
125 Sx, 150 Sx
90
Technical Data - Tightening Torques for Chassis
92
Wiring Diagram
94
Substances
97
Auxiliary Substances
98
Standards
100
Index
101
Adjusting the Spring Preload of the Shock Absorber Adjusting the Riding Sag X
105
Adjusting the Basic Position of the Foot Brake Lever Checking the Rear Brake Fluid Level
106
Means of Representation
108
Important Information
109
View of Vehicle
111
View of the Vehicle from the Left Front (Example)
111
View of the Vehicle from the Right Rear (Example)
112
Location of Serial Numbers
113
Chassis Number
113
Type Label
113
Key Number (EXC, EXC SIX DAYS)
113
Engine Number
113
Fork Part Number
113
Shock Absorber Part Number
114
Controls
115
Clutch Lever
115
Hand Brake Lever
115
Throttle Grip
115
Short Circuit Button (EXC, EXC SIX DAYS)
115
Short Circuit Button (XC-W/XC)
116
Emergency off Switch (200 EXC AUS)
116
Emergency off Switch (250/300 EXC AUS)
116
Electric Starter Button (300 EXC EU, 300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC)
116
Electric Starter Button (250/300 EXC AUS)
116
Light Switch (EXC, EXC SIX DAYS)
117
Light Switch (XC-W)
117
Horn Button (EXC, EXC SIX DAYS)
117
Turn Signal Switch (EXC, EXC SIX DAYS)
117
Overview of Indicator Lamps (EXC, EXC SIX DAYS)
117
Controls (All Exc/XC-W Models)
118
Speedometer
118
Speedometer Activation and Test
118
Tripmaster Switch
118
Setting Kilometers or Miles
118
Setting the Clock
119
Adjusting Speedometer Functions
119
Querying the Lap Time
120
Display Mode SPEED (Speed)
120
Display Mode SPEED/H (Service Hours)
120
Display Mode SPEED/CLK (Clock)
121
Display Mode SPEED/LAP (Lap Time)
121
Display Mode SPEED/ODO (Odometer)
121
Display Mode SPEED/TR1 (Trip Master 1)
121
Display Mode SPEED/TR2 (Trip Master 2)
122
Display Mode SPEED/A1 (Average Speed 1)
122
Display Mode SPEED/A2 (Average Speed 2)
122
Display Mode SPEED/S1 (Stop Watch 1)
123
Display Mode SPEED/S2 (Stop Watch 2)
123
Controls
125
Fuel Tap
125
Opening the Filler Cap
125
Closing the Filler Cap
125
Choke (EXC AUS, XC-W/XC)
125
Choke (EXC EU, EXC SIX DAYS)
126
Shift Lever
126
Kickstarter
126
Foot Brake Lever
127
Side Stand
127
Steering Lock (EXC, EXC SIX DAYS)
127
Locking the Steering (EXC, EXC SIX DAYS)
127
Unlocking the Steering (EXC, EXC SIX DAYS)
128
General Tips and Hints on Putting into Operation
130
Running in the Engine
130
Preparing the Vehicle for Difficult Operating Conditions
130
Preparations for Riding on Dry Sand
130
Preparations for Riding on Wet Sand
131
Preparations for Riding on Wet and Muddy Surfaces
132
Preparations for Riding at High Temperatures and Riding Slowly
133
Preparations for Riding at Low Temperatures and in Snow
133
Riding Instructions
134
Checks before Putting into Operation
134
Starting
134
Starting up
135
Shifting, Riding
135
Braking
135
Stopping, Parking
136
Refueling
136
Service Schedule
138
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
138
Important Maintenance Work to be Carried out by an Authorized KTM Workshop (as Additional Order)
139
Important Checks and Maintenance Work to be Carried out by the Rider
140
Maintenance Work on Chassis and Engine
141
Jacking up the Motorcycle
141
Removing the Motorcycle from the Work Stand
141
Checking the Basic Chassis Setting with the Rider's Weight
141
Compression Damping of Shock Absorber
141
Adjusting the High-Speed Compression Damping of the Shock Absorber
141
Adjusting the Low-Speed Compression Damping of the Shock Absorber
142
Adjusting the Rebound Damping of the Shock Absorber
143
Measuring the Sag of the Unloaded Rear Wheel
144
Checking the Static Sag of the Shock Absorber
144
Checking the Riding Sag of the Shock Absorber
145
Adjusting the Spring Preload of the Shock Absorber
145
Adjusting the Riding Sag
146
Removing the Shock Absorber
146
Installing the Shock Absorber
147
Checking the Basic Setting of the Fork
147
Adjusting the Compression Damping of the Fork
147
Adjusting the Rebound Damping of the Fork
148
Adjusting the Spring Preload of the Fork (EXC, EXC SIX DAYS, XC-W)
149
Bleeding the Fork Legs
150
Cleaning the Dust Boots of the Fork Legs
150
Loosening the Fork Protection
150
Positioning the Fork Protection
150
Checking the Play of the Steering Head Bearing
151
Adjusting the Play of the Steering Head Bearing
151
Removing the Fork Legs
152
Installing the Fork Legs
153
Removing the Fork Protector
154
Installing the Fork Protector
154
Removing the Front Fender
154
Installing the Front Fender
154
Refitting the Headlight Mask with the Headlight (EXC, EXC SIX DAYS)
155
Removing the Headlight Mask with the Headlight (EXC, EXC SIX DAYS)
155
Removing the Start Number Plate (XC-W/XC)
155
Adjusting the Handlebar Position
156
Handlebar Position
156
Installing the Start Number Plate (XC-W/XC)
156
Adjusting the Play in the Throttle Cable
157
Checking the Chain for Dirt
157
Checking the Play in the Throttle Cable
157
Cleaning the Chain
157
Checking Chain Wear
158
Checking the Chain Tension
158
Checking the Rear Sprocket/Engine Sprocket for Wear
158
Adjusting the Chain Tension
159
Adjusting the Chain Guide
160
Checking the Brake Discs
161
Checking the Free Travel of the Hand Brake Lever
161
Adjusting Free Travel of Hand Brake Lever (EXC, EXC SIX DAYS)
162
Adjusting the Basic Position of the Hand Brake Lever (XC-W/XC)
162
Checking the Front Brake Fluid Level
162
Adding Front Brake Fluid
163
Checking the Front Brake Linings
163
Changing the Front Brake Linings
164
Checking the Free Travel of the Foot Brake Lever
165
Adjusting the Basic Position of the Foot Brake Lever
166
Checking the Rear Brake Fluid Level
166
Adding Rear Brake Fluid
167
Checking the Rear Brake Linings
167
Installing the Rear Brake Linings
168
Removing the Rear Brake Linings
168
Changing the Rear Brake Linings
169
Removing the Front Wheel
169
Installing the Front Wheel
170
Installing the Rear Wheel
171
Removing the Rear Wheel
171
Checking the Tire Condition
172
Checking the Spoke Tension
173
Checking the Tire Air Pressure
173
Engine Characteristic - Adjusting the Auxiliary Spring (All 250/300 Models)
174
Engine Characteristic - Auxiliary Spring (All 250/300 Models)
174
Installing the Battery (250 EXC AUS/XC-W/XC, All 300 Models)
175
Recharging the Battery (250 EXC AUS/XC-W/XC, All 300 Models)
175
Removing the Battery (250 EXC AUS/XC-W/XC, All 300 Models)
175
Removing a Fuse (250 EXC AUS/XC-W/XC, All 300 Models)
176
Replacing the Fuse (250 EXC AUS/XC-W/XC, All 300 Models)
176
Adjusting the Headlight Range (EXC, EXC SIX DAYS)
177
Checking the Headlight Setting (EXC, EXC SIX DAYS)
177
Removing the Seat
177
Mounting the Seat
178
Removing the Fuel Tank
178
Installing the Fuel Tank
179
Cooling System
179
Checking the Antifreeze and Coolant Level
180
Checking the Coolant Level
180
Draining the Coolant
181
Refilling with Coolant
182
Removing the Main Silencer
183
Installing the Main Silencer
183
Glass Fiber Yarn Filling of Main Silencer
183
Removing the Glass Fiber Yarn Filling of the Main Silencer
183
Installing the Glass Fiber Yarn Filling of the Main Silencer
184
Changing the Glass Fiber Yarn Filling of the Main Silencer
184
Removing the Air Filter Box Lid
184
Installing the Air Filter Box Lid
184
Removing the Air Filter
184
Installing the Air Filter
185
Cleaning the Air Filter
185
Adjusting the Basic Position of the Clutch Lever
186
Checking the Fluid Level of the Hydraulic Clutch
186
Changing the Hydraulic Clutch Fluid
187
Checking the Basic Position of the Shift Lever
188
Adjusting the Basic Position of the Shift Lever
188
Carburetor
188
Carburetor - Adjusting the Idle Speed
189
Emptying the Carburetor Float Chamber
190
Checking the Gear Oil Level
191
Changing the Gear Oil
191
Draining the Gear Oil
192
Refilling with Gear Oil
192
Adding Gear Oil
193
Troubleshooting
194
Cleaning
196
Cleaning the Motorcycle
196
Storage
197
Putting into Operation after Storage
197
Technical Data - Engine
198
125 Exc Eu, 125 Exc Six Days Eu
198
150 XC Usa
198
All 200 Models
199
All 250 Models
199
All 300 Models
200
Capacity - Gear Oil
201
Capacity - Coolant
201
Nut, Rotor M12X1
202
Technical Data - Engine Tightening Torques
202
All 125/150/200 Models
202
All 250/300 Models
202
Nm (73.8 Lbf Ft) Loctite
203
Nm (110.6 Lbf Ft) Loctite
203
Technical Data - Carburetor
204
125 Exc Eu, 125 Exc Six Days Eu
204
150 XC Usa
204
200 Exc Eu
204
200 Exc aus
204
200 XC-W Usa
205
250 Exc Eu, 250 Exc Six Days Eu
205
250 Exc aus
205
250 XC Eu/Usa
205
250 XC-W Usa
206
300 Exc Eu, 300 Exc Six Days Eu
206
300 Exc aus
206
300 XC Eu/Usa, 300 XC-W Usa
206
Carburetor Configuration (125 EXC EU, 125 EXC SIX DAYS EU)
207
Carburetor Configuration (150 XC USA)
208
Carburetor Configuration (All 200 Models)
209
Carburetor Configuration (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC-W USA)
210
Carburetor Configuration (250 XC EU/USA)
211
Carburetor Configuration (All 300 Models)
212
General Carburetor Configuration
213
Technical Data - Chassis
214
Lighting Equipment
215
Tires
215
Capacity - Fuel
215
Technical Data - Fork
216
All 125/200 Models
216
150 XC Usa
216
All 250/300 EXC/XC-W Models
217
250/300 XC
217
Technical Data - Shock Absorber
218
All 125/200 Models
218
150 XC Usa
218
All 250/300 EXC/XC-W Models
219
250/300 XC
219
Technical Data - Tightening Torques for Chassis
221
Wiring Diagram
223
Wiring Diagram (125 EXC EU, 125 EXC SIX DAYS EU, 200 EXC EU, 200 EXC AUS, 250 EXC EU, 250 EXC SIX DAYS EU)
224
Wiring Diagram (250/300 EXC AUS, 300 EXC EU, 300 EXC SIX DAYS EU)
227
Wiring Diagram (150 XC USA, 200 XC-W USA)
229
Wiring Diagram (250/300 XC-W, 250/300 XC)
231
Substances
234
Auxiliary Substances
235
Standards
237
Index
238
Ignition Coil
294
Table of Contents
340
Compression Adjuster Low Speed
344
Rebound Adjuster
344
Sae
344
Spring
344
Spring Preload
344
Spring
346
Spring Preload
358
Repairmanual2004-2010
446
Exploded View
448
Disassembly MCC
478
Assembling MCC
484
Assembling Tube Side
487
Disassembly Piston-Rod Side
498
Assembling Adaptor Du-Bush
512
Assembling Piston-Rod Side
515
Assembling Shock Absorber
526
On Pressure with Nitrogen
537
4-1 4 Manual for Vacuum-/Filling Device
613
Supplied Parts
614
Technical Features
614
General Handling Information
616
Before / During Transportation
617
General Operation Instructions
620
Using the Filling Adapters
620
Frequent Checks
632
Filling List
639
Short Operation Instruction for Vacuum Filling Unit
640
MX Multi Adjuster
680
Disassembly Forkleg
683
Disassembly Tap Rebound
706
Assembling Tap Rebound
710
Assembling Cartridge
713
Assembling Forkleg
716
Disassembly Screw-Cap
864
Assembling Screw-Cap
866
4
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KTM 125 SX 2010 Specifications
General
Brand
KTM
Model
125 SX 2010
Category
Motorcycle
Language
English
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