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.
© 2013 KTM-Sportmotorcycle AG, 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 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.

3 WORK 9
–Position the brake line. Position the clamp and mount and tighten screw 2.
3.6 Removing the seat
101683-10
–Remove screw 1. Lift up the seat at the rear, pull it back and then remove from
above.
3.7 Mounting the seat
L00950-01
–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.
101683-10
–Mount and tighten screw 1of the seat fixation.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
3.8 Recharging the battery (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.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner.
Give the battery to your authorized KTM dealer or dispose of it at a collection point for 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.

3 WORK 10
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.
Preparatory work
–Switch off all power consumers and the engine.
–Remove the seat. ( p. 9)
–Disconnect the negative cable of the battery to avoid damage to the motorcycle's
electronics.
400240-10
Main work
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove lid 1.
Charge the battery with a maximum of 10% of the capacity specified on the
battery housing 2.
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
Finishing work
–Mount the seat. ( p. 9)
3.9 Installing the battery (250/300 XC)
L01205-10
Main work
–Insert the battery into the battery compartment with the terminals facing to the
front.
Battery (YTX5L-BS)
–Attach rubber band 1.
–Connect the positive cable 2and negative cable 3.
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
Info
Contact disks Amust be mounted between screws 4and cable sockets 5
with the claws facing down.
–Slide positive terminal cover 6over the positive terminal.
Finishing work
–Mount the seat. ( p. 9)

3 WORK 11
3.10 Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Store fuel properly in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
L00933-10
(All SX models)
–Turn filler cap 1counterclockwise and lift it off.
L00903-10
(All XC models)
–Press release button 1, turn the filler cap counterclockwise, and lift it off.
3.11 Closing the filler cap
L00960-10
(All SX models)
–Mount filler cap 1and turn it clockwise until the fuel tank is tightly closed.
Info
Run the fuel tank breather hose 2without kinks.
L01201-10
(All XC models)
–Mount filler cap 1and turn it clockwise until the release button engages.
Info
Run the fuel tank breather hose 2without kinks.

3 WORK 12
3.12 Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with
the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with
soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
–Switch off the engine.
–Open the filler cap. ( p. 11)
400382-10
–Fill the fuel tank with fuel up to measurement A.
Guideline
Measurement of A35 mm (1.38 in)
Total fuel tank
capacity, approx.
7.5 l
(1.98 US gal)
Super unleaded gasoline (98 octane),
mixed with 2-stroke engine oil (1:40)
( p. 14) (125/150 SX)
Super unleaded gasoline (95 octane),
mixed with 2-stroke engine oil (1:60)
( p. 14) (250 SX EU, 250 SX USA)
Total fuel tank
capacity, approx.
10 l (2.6 US gal) Super unleaded gasoline (95 octane),
mixed with 2-stroke engine oil (1:40)
( p. 14) (150 XC USA)
Super unleaded gasoline (95 octane),
mixed with 2-stroke engine oil (1:60)
( p. 14) (250/300 XC)
2-stroke engine oil ( p. 14)
–Close the filler cap. ( p. 11)

4 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 13
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Nut, cable on starter motor
(250/300 XC)
M6 4 Nm (3 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, throttle grip M6 5 Nm (3.7 lbf ft) –
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701™
Nut, rim lock M8 12 Nm (8.9 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, front brake caliper M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, side stand attachment M8 45 Nm (33.2 lbf ft) Loctite®2701™
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®2701™
Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine bracket screw M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701™
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701™
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, frame to linkage lever M14x1.5 80 Nm (59 lbf ft) Loctite®2701™
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft) –

5 SUBSTANCES 14
2-stroke engine oil
According to
–JASO FC ( p. 17)
Guideline
–Only use high quality 2-stroke engine oil of a well-known brand. KTM recommends Motorex®products.
Fully synthetic
Supplier
Motorex®
–Cross Power 2T
Super unleaded (ROZ 98 / RON 98 / PON 94)
According to
–DIN EN 228 (ROZ 98 / RON 98 / PON 94)
Super unleaded (ROZ 95/RON 95/PON 91)
According to
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
Super unleaded gasoline (95 octane), mixed with 2-stroke engine oil (1:60)
According to
–DIN EN 228
–JASO FC ( p. 17) (1:60)
Mixture ratio
1:60 2-stroke engine oil ( p. 14)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 14)
Supplier
Motorex®
–Cross Power 2T
Super unleaded gasoline (95 octane), mixed with 2-stroke engine oil (1:40)
According to
–DIN EN 228
–JASO FC ( p. 17) (1:40)
Mixture ratio
1:40 2-stroke engine oil ( p. 14)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 14)
Supplier
Motorex®
–Cross Power 2T
Super unleaded gasoline (98 octane), mixed with 2-stroke engine oil (1:40)
According to
–DIN EN 228
–JASO FC ( p. 17) (1:40)
Mixture ratio
1:40 2-stroke engine oil ( p. 14)
Super unleaded (ROZ 98 / RON 98 / PON 94) ( p. 14)

5 SUBSTANCES 15
Supplier
Motorex®
–Cross Power 2T

6 AUXILIARY SUBSTANCES 16
Long-life grease
Guideline
–KTM recommends Motorex®products.
Supplier
Motorex®
–Bike Grease 2000

7 STANDARDS 17
JASO FC
JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

*3213126en*
3213126en
08/2013
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM