KTM 125 SX 2018 Manual

SETUP INSTRUCTIONS 2018
125 SX
150 SX
Art. no. 3213725en

INTRODUCTION
*3213725en*
3213725en
05/2017
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, deviations from figures and descriptions,
misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the
regular scope of supply.
© 2017 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 assur-
ance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
125 SX EU (F6101R0)
125 SX US (F6175R0)
150 SX EU (F6101R1)
150 SX US (F6175R1)

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.
Indicates a voltage measurement.
Indicates a current measurement.
Indicates a resistance measurement.
Indicates the end of an activity including potential rework.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name®Indicates a protected name.
Brand™ Indicates a brand available on the open market.
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
E00851-10
Package 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 using the enclosed pack-
ing 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.
E00850-10
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 using the enclosed pack-
ing list.
–Have a lift stand available.
Lift stand (78129955100)
–Together with an assistant, take the vehicle off the pallet.

2 SETUP
4
402051-01
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
A00001-11
–Remove the cardboard from around the shock absorber.
–Position the angle lever and linkage lever.
–Mount and tighten fitting 1.
Guideline
Nut, linkage lever
to angle lever
M14x1.5 80 Nm (59 lbf ft)
–Mount and tighten screw 2.
Guideline
Screw, bottom
shock absorber
M10 60 Nm (44.3 lbf ft)
Loctite®2701™
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. 8)
K00620-10
–Remove screws 3. 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 4. Take off handlebar supports 5.
–Position rubber bushings 6and push through nuts 7from
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 4.
Guideline
Screw, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
–Position the handlebar.

2 SETUP
5
Info
Make sure the cables and wiring are positioned cor-
rectly.
–Position the handlebar clamp.
–Mount screws 3but do not tighten yet.
–First bolt the handlebar clamp with screws 3onto the longer,
higher side of the handlebar supports so that both parts touch.
–Tighten screws 3evenly.
Guideline
Screw, handlebar
clamp
M8 20 Nm (14.8 lbf ft)
K00938-10
–Position the controls on the right half of the handlebar.
K00616-10
–Position the controls on the left half of the handlebar.
–Mount cable tie(s).
–Mount the fuel tank breather.
–Install the front wheel. ( p. 9)
–Install front fender. ( p. 10)
–Install the start number plate. ( p. 10)
K00617-10
–Mount the handlebar cushion.

2 SETUP
6
R01229-10
Left and right footrest
–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 Aengages in area B.
K00622-10
–Press the spring with special tool 8.
Pliers for footrest spring (79029083000)
The special tool is applied to area Con the footrest.
–Mount pin 9.
K00623-10
–Mount the washer and split pin bk.
–Repeat these steps on the opposite side.

2 SETUP
7
K00861-12
–Position the frame protectors on the left and right.
–Mount and tighten screws bn with the washers.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws bo.
Guideline
Screw, frame protec-
tor
M5 3 Nm (2.2 lbf ft)
–Mount cable tie(s).
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Apply the sticker included in the delivery (optional).
–Refuel. ( p. 11)
–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 handover to the customer.

3 WORK
8
3.1 Raising the motorcycle with a lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
–Park the vehicle on a firm and level surface.
–Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
401942-01
–Raise the motorcycle at the frame underneath the engine.
Lift stand (78129955100)
Neither wheel is in contact with the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
–Park the vehicle on a firm and level surface.
–Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
0
0
11
402001-10
–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.
3.3 Installing the fork legs
H01182-10
Main work
–Position the fork legs.
Air release screw 1of the right fork leg is positioned to
the front.
Valve Aof the left fork leg faces the front.