KTM 125 SX EU 2014 Manual

SETUP INSTRUCTIONS 2014

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. 3213126en

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 these setup instructions.

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 specifically 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 supply.

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

1 MEANS OF REPRESENTATION 2

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).

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Denotes a voltage measurement.

Denotes a current measurement.

Denotes a resistance measurement.

1.2 Formats used

The typographical formats used in this document are explained below.

Proprietary name Identifies a proprietary name.

Name®Identifies a protected name.

Brand™ Identifies a trademark.

2 SETUP 3

2.1 Unpacking and setting up the vehicle

B00888-01

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 supply

is complete on the basis of the enclosed packing list.

–Have a lift stand available.

Lift stand (54829055000)

–Carefully loosen and remove the tension belt of the footrest mount.

Info

An assistant prevents the motorcycle from falling over.

–Together with an assistant, take the vehicle off 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 supply

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 the palette.

B00898-01

–Position the vehicle on a lift stand.

–Check the vehicle for transport damage.

101014-10

–Remove the cardboard from around the shock absorber.

–Position the angle lever and linkage lever.

–Mount and tighten screw cap 1.

Guideline

Nut, frame to linkage

lever

M14x1.5 80 Nm

(59 lbf ft)

Loctite®2701™

–Mount and tighten screw 2.

Guideline

Screw, bottom shock

absorber

M10 60 Nm

(44.3 lbf ft)

Loctite®2701™

2 SETUP 4

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

Grooves are milled into the side of the top end of the fork legs. The sec-

ond milled groove (from the top) in the fork leg must be flush with the

upper edge of the upper triple clamp.

Position the bleeder screws toward the front.

B00375-13

–Remove screws 3. Take off the handlebar clamps.

–Remove screws 4. Remove the handlebar holders.

–Place the handlebar holders in the required position. Mount and tighten screws 4.

Guideline

Screw, handlebar support M10 40 Nm

(29.5 lbf ft)

Loctite®243™

Info

Position the left and right handlebar holders evenly.

600824-10

–Position the handlebar.

Info

Make sure the cables and wiring are positioned correctly.

–Position the handlebar clamps. Mount and tighten the screws evenly.

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.

B00899-01

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

2 SETUP 5

B00900-01

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

Info

The routing of the cables is shown in the figure.

–Correctly mount the fuel tank breather.

–Install the front fender. ( p. 8)

–Install the start number plate. ( p. 8)

B00910-01

–Mount the handlebar cushion.

800042-10

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

and cotter pins.

Pliers for footrest spring (58429083000)

800035-10

(250/300 XC)

Warning

Risk of injury Battery acid and battery gases cause serious chemical

burns.

–Keep batteries out of the reach of children.

–Wear suitable protective clothing and goggles.

–Avoid contact with battery acid and battery gases.

–Keep sparks and open flames away from the battery. Only charge in

well-ventilated rooms.

–In the event of skin contact, rinse with large amounts of water. If

battery acid gets in the eyes, rinse with water for at least 15 minutes

and contact a physician.

–Fill the battery.

Info

Read the notes in the battery package.

–Recharge the battery. ( p. 9)

–Install the battery. ( p. 10)

2 SETUP 6

B00901-01

–Unpack and mount the KTM PowerParts included in the delivery (optional).

Info

Read the accompanying KTM PowerParts fitting instructions.

–Apply the label included in the delivery (optional).

–Refuel. ( p. 12)

–Position all controls in their exact positions on the handlebar. Tighten all screws.

–Print out the current PDI form found on KTM DEALER.NET and perform the delivery

inspection.

3 WORK 7

3.1 Raising the motorcycle with the lift stand

L00939-10

(All 125/150 models)

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

–Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

The wheels must no longer touch the ground.

–Secure the motorcycle against falling over.

L01220-10

(All 250/300 models)

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

–Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

The wheels must no longer touch the ground.

–Secure the motorcycle against falling over.

3.2 Removing the motorcycle from the lift stand

Note

Danger of damage The parked vehicle may roll away or fall over.

–Always place the vehicle on a firm and even surface.

L00936-10

(All SX models)

–Remove the motorcycle from the lift stand.

–Remove the lift stand.

–To park the motorcycle, insert plug-in stand 1into the left side of the wheel

spindle.

Info

Remove the plug-in stand before riding.

L00900-10

(All XC models)

–Remove the motorcycle from the lift stand.

–Remove the lift stand.

–To park the motorcycle, press side stand 1to the ground with your foot and

lean the motorcycle on it.

Info

When you are riding, the side stand must be folded up and secured with

the rubber band.

3.3 Installing 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.

3 WORK 8

101745-11

–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 1and bearing surface Aof the spacers.

Long-life grease ( p. 16)

–Insert the spacers.

101744-11

–Lift the front wheel into the fork, position it, and insert the wheel spindle.

–Mount and tighten screw 2.

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 the brake disc.

–Remove the motorcycle from the lift stand. ( p. 7)

–Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

–Tighten screws 3.

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

3.4 Installing the front fender

101724-10

Main work

–Position the front fender. Mount and tighten screws 1and 2.

Guideline

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

Finishing work

–Install the start number plate. ( p. 8)

3.5 Installing the start number plate

L00948-10

–Position the start number plate. Mount and tighten screw 1.

Guideline

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

Info

Ensure that the holding lugs engage in the fender.

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