KTM 125 SX User guide

125 / 200 / 250 / 300 / 380
125 / 200 / 250 / 300 / 380
SX / MXC / EXC / EGS
SX / MXC / EXC / EGS
‘99
‘99
BEDIENUNGSANLEITUNG
BEDIENUNGSANLEITUNG
OWNER’S HANDBOOK
OWNER’S HANDBOOK MANUEL D’UTILISA
MANUEL D’UTILISATION TION
MANUAL DE INSTRUCCIONES
MANUAL DE INSTRUCCIONES
MANUALE D’USO
MANUALE D’USO AR
ART T. NR. 3.205.51 . NR. 3.205.51
6.98
6.98

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1
IMPORTANT
WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL
CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST
RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND
ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE
PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR
ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS:

WARNING

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR
BODY AND YOUR LIFE.
!
CAUTION
!
IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO
PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE
IS NOT ROAD-SAFE ANYMORE.
Please insert the series numbers of your motorcycle in the boxes below
Frame number
Engine number
Stamp of dealer
Tampering with noise control system prohibited
Owners are warned that the law may prohibit:
(a) The removal or rendering inoperative by any person other than for purposes of mainten-
ance, repair or replacement, of any device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser
or while it is in use; and
(b) the use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
COMSUMER INFORMATION FOR AUSTRALIA ONLY

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2
Introduction
We would like to congratulate you on your purchase of a KTM motorcycle. Let us also
take this opportunity to thank you for putting your trust in us; we will not let you down.
You are now owner of a sporty and modern motorcycle which you are bound to have a
great time with provided you care for it properly. Your owner’s handbook will furnish you
with important information on how to operate and maintain your new KTM motorcycle.
At the time of printing, the handbook covered the most up-to-date models in this series.
It is, however, possible that we may have made slight modifications in the meantime due
to development in our motorcycle design.
Many motorcyclists have a good working knowledge of motorcycle mechanics; if this is
true in your case, you will be able to use this manual to carry out most of the mainten-
ance steps yourself. If, on the other hand, you are not very familiar with motorcycles, it
might be better to have a professional KTM dealer perform those steps marked by *
found in the chapter entitled “Maintenance Work on Chassis and Engine” of this
manual.
Take special care to follow the recommended run in, inspection, and maintenance inter-
vals. Heeding these guidelines will significantly increase the life of your motorcycle. Be
sure to have any maintenance jobs performed by an authorized KTM dealer.
Address your special requests to an authorized KTM dealer who, should the need arise,
will be supported by the KTM importer.
Riding an off-highway motorcycle is a wonderful form of outdoor recreation and we cer-
tainly hope that you will enjoy it to the full. However, this enjoyable outdoor activity can
cause environmental problems or lead to conflicts with other people. Responsible use of
the motorcycle will prevent such problems and conflicts. You can contribute to securing
the future of motorcycling by making sure that you only use the motorcycle within the
limits established by the applicable laws, making environmental protection one of your
top priorities and never violating other people’s rights.
We wish you a lot of fun when driving !
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments : 1 spare parts manual chassis 1 owner handbook for telescopic fork
1 spare parts manual engine 1 owner handbook for shock absorber
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the
beginning of an on-going total re-engineering quality plan for a brighter tomorrow.

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3
Page
SERIAL NUMBER LOCATIONS.............................................4
Chassis number................................................................4
Engine number, engine type (125/200)............................4
Engine number, engine type (250/300/380)....................4
OPERATION INSTRUMENTS ...............................................4
Clutch lever .....................................................................4
Hand brake lever..............................................................4
Speedometer, indicator lamp (EXC)..................................5
Odometer (EXC USA).......................................................5
Speedometer, indicator lamps (EGS).................................5
Ignition lock.....................................................................5
Short circuit button (SX)...................................................6
Combination switch (EXC)................................................6
Headlamp switch (EXC USA)............................................6
Flasher switch...................................................................6
Emergency OFF switch (Australia)....................................6
Filler cap...........................................................................7
Refueling, fuel..................................................................7
Fuel tap............................................................................7
Choke knob .....................................................................8
Shift lever.........................................................................8
Kickstarter........................................................................8
Foot brake pedal..............................................................8
Compression damping of fork..........................................8
Rebound damping of fork................................................9
Compression damping of shock absorber.........................9
Rebound damping of shock absorber...............................9
Steering lock ....................................................................9
Center stand ....................................................................9
DRIVING INSTRUCTIONS ..................................................10
PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE .....12
MAINTENANCE WORK ON CHASSIS AND ENGINE ..........13
Changing the original position of the clutch lever ..............13
Checking and adjusting the steering head bearing..........13
Pivot bearing..................................................................14
Check chain tension ......................................................14
Correct chain tension ....................................................14
Chain maintenance ........................................................14
Chain wear ....................................................................15
General informations about KTM disc brakes ................15
Adjusting of free travel at the hand brake lever..............15
Checking of brake fluid level - front brake......................16
Refilling the front brake fluid reservoir............................16
Page
Checking the front brake pads .......................................16
Replacing the front brake pads.......................................16
Changing the basic position of the brake pedal..............17
Checking rear brake fluid level .......................................17
Refilling the rear brake fluid reservoir.............................17
Checking the rear brake pads.........................................18
Replacing the rear brake pads ........................................18
Dismounting and mounting the front wheel...................18
Dismounting and mounting the rear wheel ....................19
Tires, air pressure ...........................................................19
Checking spoke tension..................................................19
Fuse (CH, Singapore) .....................................................20
Battery (CH, Singapore) .................................................20
Replacing head light lamp (H4)......................................20
Cooling system...............................................................20
Checking the coolant level .............................................21
Bleeding the cooling system...........................................21
Cleaning the air filter......................................................22
Exhaust system...............................................................22
Cleaning the spark arrestor (EXC USA)...........................22
Carburetor adjustment...................................................23
Checking the float level..................................................24
Checking the oil level of the hydraulic clutch..................24
Bleeding of the hydraulic clutch......................................24
Check transmission oil level (125/200)...........................25
Changing the transmission oil (125/200)........................25
Check transmission oil level (250/300/380) ...................25
Changing the transmission oil (250/300/380)................25
CLEANING..........................................................................26
CONSERVATION FOR WINTER OPERATION ....................26
STORAGE...........................................................................26
Use after period of storage .................................................26
TECHNICAL SPECIFICATIONS - CHASSIS (125/200)..........27
TECHNICAL SPECIFICATIONS - ENGINE (125/200)
...................28
TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)
Only USA
........................................................................30
TECHNICAL SPECIFICATIONS - ENGINE (250/300/380)
All models out of USA
.......................................................32
TECHNICAL SPECIFICATIONS - CHASSIS (250/300/380).....34
WIRING DIAGRAMME, CARBURETOR SETTING.......Appendix
INDEX

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4
Chassis number
The chassis number is stamped on the right side of the steering head tube.
Write this number into the field on page no 1.
Engine number, engine type (125/200)
The engine number and the engine type are stamped into the left side of
the engine below the engine sprocket. Please note this number down on
page 1.
Engine number, engine type (250/300/380)
Engine number and engine type are stamped on the right hand side of the
engine in front of the kickstarter. Write this number into the relevant area
on page 1.
Clutch lever
The clutch lever 1is located on the left side of the handlebar. The adju-
sting screw Ais used to change the original position of the clutch lever (see
maintenance work on chassis and angine).
Hand brake lever
The hand brake lever is mounted on the handle bars on the right and actua-
tes the front wheel brake.

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”
(TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE
BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE
BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
1
A

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5
Speedometer, indicator lamp (EXC)
The mileage indicator Ain the speedometer 1indicates overall mileage.
For further adjustment options and handling, see the appended user’s guide
of the SIGMA SPORT BASELINE 500 speedometer.
On default factory models, a wheel circumference of 2150 mm (standard
tires) is adjusted on the speedometer.
The blue indicator lamp 2is lit when the high beam is on.
Odometer (EXC USA)
The odometer is a mileage indicator and can be set to 0 by means of the
adjustment wheel 3.
Speedometer, indicator lamps (EGS)
The mileage indicator Bin the speedometer 4indicates overall mileage.
When the turn indicator is on, the green indicator lamp 5will be flashing in
the same rhythm.
The blue indicator lamp 6will be lit when the high beam is on
Ignition lock
Switch positions of ignition lock 7
= Ignition off
= Ignition on, parking light on (only for models with battery)
!
CAUTION
!
DONT TURN THE PARK LIGHT FOR MORE THAN 90 MINUETS, WHEN THE MOTOR
IS NOT RUNNING, BECAUSE THE BATTERY WILL BE COMPLETLY EMPTIED AND
DESTRYED.
The ignition key 8can be removed when in its position.
1
A
2
B
3
4
56
7
8

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6
Short circuit button (SX)
The short circuit button 1turns off the engine. When pressing this button,
the ignition circuit is short-cicuited.
Combination switch (EXC)
The light switch has 2, respetively 3 switch positions.
A= Light off (this function is not available in all models)
B= Low beam on
C= High beam on
You may use button 2to actuate the horn.
The red short circuit button 3serves to switch off the engine. Leave the
switch pressed until the engine stops.
Headlamp switch (EXC USA)
In this model the headlamp is switched on with the pull switch 4.
Flasher switch
Flasher left
Flasher right
Emergency OFF switch (Australia)
The emergency OFF switch 5is located next to the throttle grip. Primarily
designed as safety or emergency OFF switch, it should normally not be in its
activated state.
In this position, the ignition circuit is shorted; if the engine is running,
it will stall immediately, if it is at standstill, it will not start.
In this position, the ignition circuit is enabled; the engine should start.
1
23
A
B
C
5
4

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7
Filler cap
To open it: turn filler cap counter-clockwise.
To close it: put filler cap back on and tighten it by turning it clockwise.
Install tank breather hose 1without kinks.
Refueling, fuel
125: Unleaded premium gasoline RON 98 mixed with high grade two
stroke oil. Mixture ratio 1:40
200-380: Unleaded premium gasoline RON 95 mixed with high grade two
stroke oil. Mixture ratio 1:40 – 1:60
Fuel and engine oil should only be mixed immediately before use.
KTM recommends SHELL ADVANCE RACING X.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED
WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR
BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELING. BE CAREFUL
NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT.
WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK
A DOCTOR’S ADVICE IMMEDIATELY.
!
CAUTION
!
–
O NLY USE PREMIUM - GRADE GASOLINE ROZ 98 RESPECTIVELY 95 MIXED WITH HIGH -
GRADE TWO - STROKE ENGINE OIL . O THER TYPES OF GASOLINE CAN CAUSE ENGINE FAI -
LURE .
–DO NOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD ENGINES OR NOR-
MAL ENGINE OIL TO PREPARE THE MIXTURE.
–D
O NOT USE GASOLINE AND OIL MIXTURES THAT ARE OLDER THAN ONE WEEK. THE
LUBRICATION PROPERTIES OF SOME TWO-STROKE OILS CAN DETERIORATE VERY
RAPIDLY.
–O
NLY USE KNOWN BRANDS OF HIGH-GRADE 2-STROKE ENGINE OIL.
–N
EVER MIX SYNTHETIC OILS AND MINERAL OILS.
–N
OT ENOUGH OIL OR LOW-GRADE OIL CAN CAUSE EROSION OF THE PISTON. WHEN
USING TOO MUCH OIL, THE ENGINE MAY START SMOKING AND FOUL THE SPARK
PLUG.
–F
UEL EXPANDS WHEN ITS TEMPERATURE RISES. THEREFORE DO NOT FILL THE TANK TO
THE TOP. (SEE FIG.)
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the carbure-
tor.
ON During operation the twist grip must be turned to ON. This means
that the fuel can flow to the carburetor. With the twist grip in this
position the tank will be emptied until only the reserve is left.
RES The reserve tank cannot be tapped until the rotating handle is turned
to the RES position. Fill the tank as soon as possible and remember to
turn the rotating handle back to the ON position so that you will have
backup fuel next time, too.
Reserve of the 9,5 l tank: 1.3 l (0,35 US gallons)
Reserve of the 12 l tank: 1.7 l (0,45 US gallons)
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP
IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.
35 mm
ON RESOFF
SX
MXC
EXC
EGS
1

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8
Choke knob
When pulling the choke knob 1fully towards the top, a bore is opened in
the carburetor. Through this bore the engine can take in additional fuel.
This encoure the rich fuel-air mixture, that is needed for a cold start.
When pressing the choke knob downward in the carburetor, the bore is
closed again.
Shift lever
The shift lever is mounted on the left side of the engine. The position of the
gears is shown in the illustration. Neutral, or the idle speed, is located bet-
ween first and second gear.
Kickstarter
The kickstarter is mounted on the right side of the engine. Its upper part
can be swivelled.

WARNING

WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJU-
RIES. YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN
KICKING NOT VEHEMENTLY ENOUGH.
Foot brake pedal
The foot brake pedal is disposed in front of the right foot rest. Its basic posi-
tion can be adjusted to your seat position (see maintenance work).

WARNING

IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”
(TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE
BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE
BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.
Compression damping of fork
The compression damping mechanism is built into the left fork tube. It only
regulates the degree of damping during compression.
By turning the adjusting screw 2(C, COM), the degree of damping of the
compression can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during compression.
STANDARD ADJUSTMENT
– turn adjusting screw clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of fork
Type Marzocchi 91...............................15 clicks
Type White Power 918T767 ................12 clicks
Type White Power 918T768 ................12 clicks
Type White Power 918T769 ................12 clicks
2,3,4,5 (6)
1
N
1
2
2