KTM 125 SX 2010 User manual

REPAIRMANUAL2004-2010
BEDIENUNGSANLEITUNGEN
OWNER’S MANUAL
MANUALE O’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
REPARATURANLEITUNG
REPAIR MANUAL
MANUALE DI REPARAZIONE
MANUEL DE REPARATION
MANUAL DE REPARACION
FEDERBEIN
SHOCK ABSORBER
AMMORTIZZATORE
AMMORTISSEUR
AMORTIGUADOR
GABEL
FORK
FORCELLA
FOURCHE
HORQUILLA

OWNERSMANUAL2010
250 SX
250/300 XC,
XC-W,EXC,EXC SixDays

OWNER'S MANUAL 2010
125 SX
150 SX
250 SX
Art. no. 3211480en

TABLE OF CONTENTS 2
TABLE OF CONTENTS
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
Checking the static sag of the shock absorber .................. 29
Checking the riding sag of the shock absorber .................. 29
Adjusting the spring preload of the shock absorber x...... 29
Adjusting the riding sag x............................................. 30
Removing the shock absorber x..................................... 30
Installing the shock absorber x..................................... 31
Checking the basic setting of the fork.............................. 31
Adjusting the compression damping of the fork ................ 31
Adjusting the rebound damping of the fork....................... 32
Bleeding the fork legs .................................................... 32
Cleaning the dust boots of the fork legs ........................... 32
Loosening the fork protection.......................................... 33
Positioning the fork protection ........................................ 33
Checking the play of the steering head bearing................. 33
Adjusting the play of the steering head bearing x............ 34
Removing the fork legs x.............................................. 34
Installing the fork legs x............................................... 35
Removing the fork protector x....................................... 35
Installing the fork protector x....................................... 35
Removing the lower triple clamp x................................ 36
Installing the lower triple clamp x................................. 36
Greasing the steering head bearing x............................. 37
Removing the front fender.............................................. 37
Installing the front fender............................................... 37
Removing the start number plate .................................... 37
Installing the start number plate ..................................... 38
Handlebar position ........................................................ 38
Adjusting the handlebar position x................................ 38
Checking the play in the throttle cable............................. 39
Adjusting the play in the throttle cable x....................... 39
Checking the chain for dirt ............................................. 39
Cleaning the chain......................................................... 39
Checking the chain tension ............................................ 40
Checking the rear sprocket/engine sprocket for wear ......... 40
Checking chain wear...................................................... 40
Adjusting the chain tension ............................................ 41
Adjusting the chain guide x.......................................... 42
Checking the brake discs................................................ 42
Checking the free travel of the hand brake lever ............... 43
Adjusting the basic position of the hand brake lever.......... 43
Checking the front brake fluid level ................................. 43
Adding front brake fluid x............................................ 44
Checking the front brake linings...................................... 44
Removing the front brake linings x................................ 45
Installing the front brake linings x................................. 45
Changing the front brake linings x................................. 46
Checking the free play of the foot brake lever ................... 46
Adjusting the basic position of the foot brake lever x...... 47
Checking the rear brake fluid level .................................. 47
Adding rear brake fluid x.............................................. 48
Checking the rear brake linings....................................... 48
Removing the rear brake linings x................................. 49
Installing the rear brake linings x.................................. 49
Changing the rear brake linings x.................................. 50
Removing the front wheel x.......................................... 50
Installing the front wheel x........................................... 51
Removing the rear wheel x........................................... 52
Installing the rear wheel x............................................ 52
Checking the tire condition............................................. 53
Checking the tire air pressure ......................................... 54
Checking the spoke tension ............................................ 54

TABLE OF CONTENTS 3
Ignition curve plug connection........................................ 54
Changing the ignition curve ............................................ 55
Engine characteristic - auxiliary spring (250 SX)............... 55
Engine characteristic - adjusting the auxiliary spring x
(250 SX) ...................................................................... 55
Removing the seat......................................................... 56
Mounting the seat ......................................................... 56
Removing the fuel tank x............................................. 56
Installing the fuel tank x.............................................. 57
Cooling system .............................................................. 58
Checking the antifreeze and coolant level ........................ 58
Checking the coolant level.............................................. 59
Draining the coolant x.................................................. 59
Refilling with coolant x................................................ 60
Removing the main silencer............................................ 61
Installing the main silencer ............................................ 61
Glass fiber yarn filling of main silencer ............................ 61
Changing the glass fiber yarn filling of the main
silencer x................................................................... 61
Removing the glass fiber yarn filling of the main
silencer x................................................................... 62
Installing the glass fiber yarn filling of the main
silencer x................................................................... 62
Removing the air filter box lid......................................... 62
Installing the air filter box lid.......................................... 62
Removing the air filter x............................................... 63
Installing the air filter x............................................... 63
Cleaning the air filter x................................................ 63
Adjusting the basic position of the clutch lever................. 64
Checking the fluid level of the hydraulic clutch ................ 64
Changing the hydraulic clutch fluid x............................ 65
Checking the basic position of the shift lever.................... 66
Adjusting the basic position of the shift lever x.............. 66
Carburetor .................................................................... 66
Carburetor - adjusting the idle speed x.......................... 67
Emptying the carburetor float chamber x....................... 68
Checking the gear oil level.............................................. 68
Changing the gear oil x................................................ 69
Draining the gear oil x................................................. 69
Refilling with gear oil x................................................ 70
Adding gear oil x......................................................... 70
TROUBLESHOOTING......................................................... 72
CLEANING........................................................................ 74
Cleaning the motorcycle................................................. 74
STORAGE ......................................................................... 75
Storage......................................................................... 75
Putting into operation after storage ................................. 75
TECHNICAL DATA - ENGINE.............................................. 76
125 SX......................................................................... 76
150 SX......................................................................... 76
250 SX......................................................................... 77
Capacity - gear oil.......................................................... 77
Capacity - coolant.......................................................... 77
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 78
125 SX, 150 SX............................................................ 78
250 SX......................................................................... 78
TECHNICAL DATA - CARBURETOR..................................... 80
125 SX......................................................................... 80
Carburetor - basic setting for sandy surfaces (125 SX) ...... 80
Carburetor configuration (125 SX)................................... 81
150 SX......................................................................... 82
Carburetor - basic setting for sandy surfaces (150 SX) ...... 82
Carburetor configuration (150 SX)................................... 83
250 SX......................................................................... 84
Carburetor - basic setting for sandy surfaces (250 SX) ...... 84
Carburetor configuration (250 SX)................................... 85
TECHNICAL DATA - CHASSIS ............................................ 86
Tires ............................................................................ 86
Capacity - fuel............................................................... 86
TECHNICAL DATA - FORK.................................................. 87
125 SX, 150 SX............................................................ 87
250 SX......................................................................... 87
TECHNICAL DATA - SHOCK ABSORBER ............................. 88
125 SX, 150 SX............................................................ 88
250 SX......................................................................... 88
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS .......................................................................... 90
WIRING DIAGRAM ............................................................ 92
Wiring diagram.............................................................. 92
SUBSTANCES................................................................... 94
AUXILIARY SUBSTANCES.................................................. 96
STANDARDS..................................................................... 98
INDEX .............................................................................. 99

MEANS OF REPRESENTATION 4
Symbols used
The symbols used are explained 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).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand available on the open market.

IMPORTANT INFORMATION 5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only in closed off areas remote from public road traffic.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break-
age of components.
Using the motorcycle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of compo-
nents such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the
limit specified in the service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's
service record, since otherwise no warranty claims will be honored. No warranty claims can be considered for damage resulting from
manipulations and/or alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parenthe-
ses. E.g.: bearing puller (15112017000)
When the vehicle is assembled, non-reusable parts (e.g., self-locking screws and nuts, gaskets, seal rings, O-rings, splints, lock wash-
ers) must be replaced with new parts.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts.
After you complete the repair or maintenance work, check the roadworthiness of the vehicle.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
–Switch off the engine.
–Turn handle of the fuel tap to the OFF position. (Figure B00003-10 p. 11)
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT INFORMATION 6
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and
tips that will assist you in operating and handling your motorcycle properly. Only then will you learn how to adjust the motorcycle
to your own requirements and how to protect yourself from injury. The owner's manual also contains important information on ser-
vicing the motorcycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.

VIEW OF VEHICLE 7
3.1View of the vehicle from the left front (example)
B00010-10
1 Hand brake lever
2 Short circuit button
3 Clutch lever
4 Air filter box lid
5 Fuel tap
6 Choke button
7 Shift lever
8 Chain guide

VIEW OF VEHICLE 8
3.2View of the vehicle from the right rear (example)
B00014-10
1 Shock absorber rebound adjustment
2 Level viewer for brake fluid, rear
3 Fork rebound adjustment
4 Foot brake lever
5 Kickstarter
6 Shock absorber compression adjustment
7 Throttle grip
8 Fork compression adjustment
9 Filler cap

LOCATION OF SERIAL NUMBERS 9
4.1Chassis number
B00015-10
The chassis number is stamped on the right side of the steering head.
4.2Type label
400284-10
The type label is fixed to the front of the steering head.
4.3Engine number
B00016-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.4Fork part number
500082-10
The fork part number is stamped on the inner side of the fork stub.
4.5Shock absorber part number
500083-10
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

CONTROLS 10
5.1Clutch lever
B00001-10
(125 SX, 150 SX)
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
B00009-10
(250 SX)
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
5.2Hand brake lever
400196-10
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
5.3Short circuit button
B00002-10
Short circuit button is fitted on the left side of the handlebar.
Possible states
• Short circuit button in basic position –In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed –In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
5.4Throttle grip
B00060-10
Throttle grip is fitted on the right side of the handlebar.

CONTROLS 11
5.5Fuel tap
B00003-10
The fuel tap is on the left side of the fuel tank.
With tap handle on the fuel tap, you can open or close the supply of fuel to the car-
buretor.
Possible states
• Fuel supply closed OFF –No fuel can flow from the tank to the carburetor.
• Fuel supply open ON –Fuel can flow from the tank to the carburetor. The fuel tank
empties completely.
5.6Opening the filler cap
400199-10
–Press release button , turn the filler cap counterclockwise and lift it free.
5.7Closing the filler cap
400199-11
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Run the fuel tank breather hose without kinks.
5.8Choke
B00004-10
The choke is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated –The choke lever is pulled out to the stop.
• Choke function deactivated –The choke lever is pushed in to the stop.

CONTROLS 12
5.9Shift lever
B00005-10
Shift lever is mounted on the left side of the engine.
B00005-12
(125 SX, 150 SX)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
B00005-11
(250 SX)
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
5.10Kickstarter
B00006-10
The kickstarter is fitted on the right side of the engine. The top part can be
swiveled.
5.11Foot brake lever
B00007-10
Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.

CONTROLS 13
5.12Plug-in stand
400203-10
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
To park the motorcycle, insert plug-in stand into the left side of the wheel spindle.
Info
Remove the plug-in stand before riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 14
6.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
–The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical handling characteristic due to inappropriate riding style.
–Adapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
–Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
–If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Unstable riding behavior.
–Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
–Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
–Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
–Before your first trip, read the entire operating instructions carefully.
–Get to know the controls.
–Adjust the basic position of the clutch lever. ( p. 64)
–Adjust the basic position of the hand brake lever. ( p. 43)
–Adjust the basic position of the foot brake lever. x( p. 47)
–Become accustomed to the handling of the motorcycle on suitable terrain.
Info
Your motorcycle is not authorized for riding on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
–Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
–Do not make any offroad trips that over-stress your ability and experience.
–Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–Do not transport luggage.
–Do not exceed the overall maximum permitted weight and the axle loads.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 15
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
–Check the spoke tension. ( p. 54)
Info
The spoke tension must be checked after riding the motorcycle for one half hour.
–Run the engine in.
6.2Running in the engine
–During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 service hours < 70 %
During the first 5 service hours < 100 %
–Avoid fully opening the throttle!
6.3Preparing the vehicle for difficult operating conditions
–The use of motorcycles under difficult operating conditions can lead to above-average wear of components such as the drive train
or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is
reached.
Difficult operating conditions are:
–Riding on dry sand. ( p. 15)
–Riding on wet sand. ( p. 16)
–Riding on wet and muddy surfaces. ( p. 17)
–Riding at high temperatures and riding slowly. ( p. 18)
–Riding at low temperatures and in snow. ( p. 18)
6.4Preparations for riding on dry sand
600872-10
–Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the value displayed does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter. x( p. 63)
Info
Check the air filter approx. every 30 minutes.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 16
600869-01
–Mount the dust cover for the air filter.
Dust cover for air filter (59006019000)
Info
Follow the KTM PowerParts mounting instructions.
600871-01
–Mount the sand cover for the air filter.
Sand cover for air filter (59006022000)
Info
Follow the KTM PowerParts mounting instructions.
–Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized KTM
workshop.
600868-01
–Clean the chain.
Chain cleaner ( p. 96)
–Mount the steel sprocket.
Tip
Do not lubricate the chain.
–Clean the radiator fins.
–Carefully align bent radiator fins.
6.5Preparations for riding on wet sand
600872-10
–Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the value displayed does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter. x( p. 63)
Info
Check the air filter approx. every 30 minutes.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 17
600870-01
–Mount the rain cover for the air filter.
Rain cover for air filter (59006021000)
Info
Follow the KTM PowerParts mounting instructions.
–Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized KTM
workshop.
600868-01
–Clean the chain.
Chain cleaner ( p. 96)
–Mount the steel sprocket.
Tip
Do not lubricate the chain.
–Clean the radiator fins.
–Carefully align bent radiator fins.
6.6Preparations for riding on wet and muddy surfaces
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter. x( p. 63)
Info
Check the air filter approx. every 30 minutes.
600870-01
–Mount the rain cover for the air filter.
Rain cover for air filter (59006021000)
Info
Follow the KTM PowerParts mounting instructions.
–Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized KTM
workshop.
600868-01
–Mount the steel sprocket.
–Clean the motorcycle. ( p. 74)
–Carefully align bent radiator fins.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 18
6.7Preparations for riding at high temperatures and riding slowly
600872-10
–Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the value displayed does not meet specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter. x( p. 63)
Info
Check the air filter approx. every 30 minutes.
600868-01
–Adjust the secondary ratio to the nature of the terrain.
Info
The engine oil heats up quickly if the clutch needs to be activated
frequently because the secondary ratio is too long.
–Clean the chain.
Chain cleaner ( p. 96)
–Clean the radiator fins.
–Carefully align bent radiator fins.
–Check the coolant level. ( p. 59)
6.8Preparations for riding at low temperatures and in snow
–Seal the air filter box. x
Tip
Seal the air filter box at the edges to prevent dirt from entering.
–Clean the air filter. x( p. 63)
Info
Check the air filter approx. every 30 minutes.
600870-01
–Mount the rain cover for the air filter.
Rain cover for air filter (59006021000)
Info
Follow the KTM PowerParts mounting instructions.
–Adjust the carburetor jetting and setting.
Info
The recommended carburetor tuning is available from your authorized KTM
workshop.