KTM 125 SX 2017 Manual

SETUP INSTRUCTIONS 2017
125 SX
150 SX
250 SX
250 XC
300 XC
Art. no. 3213573en

INTRODUCTION 1
*3213573en*
3213573en
08/2016
INTRODUCTION
Perform the work described in these setup instructions before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the interest
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 GmbH 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, devi-
ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not
belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
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 GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
125 SX EU (F6101Q0)
125 SX US (F6175Q0)
150 SX EU (F6101Q1)
150 SX US (F6175Q1)
250 SX EU (F6301Q0)
250 SX US (F6375Q0)
250 XC US (F6375Q5)
300 XC US (F6475Q5)

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.
Underlined terms Refer to technical details of the vehicle or indicate technical terms, which are explained
in the glossary.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
B02176-10
Package 2
–Remove the box and the plastic film.
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 everything is
included and complete using the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Carefully loosen and remove the tension belt of the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
402050-01
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
B02008-10
Package 12
–Remove the box and the plastic film.
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 everything is
included and complete using the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Together with an assistant, take the vehicle off the pallet.
402051-01
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
K00613-10
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten fitting .
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft)
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M10 60 Nm
(44.3 lbf ft)
Loctite®2701™

2 SETUP 4
Info
Raise the wheel slightly to be able to mount the screw more easily.
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
–Install the fork legs. ( p. 10)
K00620-10
–Remove screws . Take off the handlebar clamp. Remove the handlebar and lay it
to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
–Remove screws . Take off handlebar supports .
–Position rubber bushings and push through nuts from below.
–Place the handlebar supports in the required position.
Info
The handlebar supports are longer and higher on one side.
Position the left and right handlebar supports evenly.
–Mount and tighten screws .
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
–Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
–Position the handlebar clamp.
–Mount screws but do not tighten yet.
–First bolt the handlebar clamp with screws onto the longer, higher side of the
handlebar supports so that both parts touch.
–Tighten screws evenly.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
K00615-10
–Position the controls on the right half of the handlebar.
K00616-10
–Position the controls on the left half of the handlebar.
–Mount the cable tie(s).
–Mount the fuel tank breather.
–Install the front wheel. ( p. 10)
–Install the front fender. ( p. 11)
–Install the start number plate. ( p. 13)

2 SETUP 5
K00617-10
–Mount the handlebar cushion.
D00674-10
Left and right footrest (All SX models)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can still be mounted.
K00621-10
–Position spring as shown.
Spring engages in area .
K00622-10
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
K00623-10
–Mount the washer and split pin .
–Repeat these steps on the opposite side.

2 SETUP 6
R00757-10
Left footrest (All XC models)
–Raise the motorcycle with a lift stand. ( p. 9)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can still be mounted.
K00624-10
–Position spring as shown.
Spring engages in area .
K00625-10
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
K00626-10
–Mount the washer and split pin .
–Remove the motorcycle from the lift stand. ( p. 9)
D00674-10
Right footrest (All XC models)
–Position the new footrest and pin.
Info
Only insert the pin to the extent that the spring can still be mounted.

2 SETUP 7
K00621-11
–Position spring as shown.
Spring engages in area .
K00622-11
–Press the spring with special tool .
Pliers for footrest spring (79029083000)
The special tool is applied to area on the footrest.
–Mount pin .
K00623-11
–Mount the washer and split pin .
K00618-10
(All XC models)
–Recharge the battery. ( p. 11)
–Install the battery. ( p. 12)
K00512-12
–Position the frame protector on the left and right.
–Mount and tighten screws  with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws .
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount the cable tie(s).

2 SETUP 8
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts fitting instructions.
–Apply the sticker included in the delivery (optional).
–Refuel. ( p. 13)
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Prepare the vehicle according to the specifications in the KTM Dealer.net for han-
dover to the customer.