KTM 125 SX 2011 Handbuch

SETUP INSTRUCTIONS 2011

125 SX

150 SX

250 SX

150 XC USA

250 XC EU/USA

300 XC EU/USA

Art. no. 3211692en

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 inter-

est 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 specifica-

tions, 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 spe-

cial equipment that does not belong to the regular scope of delivery.

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

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®Identifies a protected name.

Brand™ Identifies a brand in merchandise traffic.

SET‑UP 3

2.1Unpacking and setting up the vehicle

601257-10

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.

–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.

601258-10

Package 12

–Remove the box and the plastic packaging.

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.

601259-10

–Remove the cardboard from around the shock absorber.

–Install the shock absorber. ( p. 6)

600814-01

–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.

SET‑UP 4

B00375-10

–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

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar supports evenly.

600824-10

–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

(14.8 lbf ft)

Info

The markings on the handlebar should be at the center of the handlebar

clamps.

Keep the gap widths equal when tightening.

B00092-01

–Position the controls on the right half of the handlebar.

Info

The routing of the cables can be seen in the figure.

B00093-01

–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.

B00539-01

–Secure the handlebar cushion with two cable binders.

–Install the start number plate. ( p. 7)

SET‑UP 5

800042-10

–Mount the footrests with the springs and bolts. Secure the bolts using the washers

and pins.

Plier for footrest spring (58429083000)

800035-10

(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.

–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.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 8)

–Install the battery. ( p. 9)

B00097-01

–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.

WORK 6

3.1Installing the shock absorber

601191-11

(All 125/150 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)

Loctite®2701

–Mount and tighten screw .

Guideline

Screw, bottom shock

absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

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. Lubri-

cants dissolve the Teflon coating, thereby drastically reducing the ser-

vice life.

303501-11

(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)

Loctite®2701

–Mount and tighten screw .

Guideline

Screw, bottom shock

absorber

M12 80 Nm

(59 lbf ft)

Loctite®2701

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. Lubri-

cants dissolve the Teflon coating, thereby drastically reducing the ser-

vice 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.

B00304-11

–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)

–Insert the spacers.

WORK 7

B00302-11

–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.

–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)

3.3Installing the front fender

B00307-10

–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)

Info

Make sure the holding lugs engage in the start number plate.

3.4Installing the start number plate

303504-11

–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 .

3.5Removing the seat

601192-10

–Remove screw . Lift up the seat at the rear, pull it back and then remove from

above.

WORK 8

3.6Mounting the seat

B00318-01

–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.

601192-10

–Mount and tighten screw of the seat fixation.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

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.

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