KTM 125 XC-W 2018 Manual

SETUP INSTRUCTIONS 2018
125 XC‑W
150 XC‑W
Art. no. 3213704en

INTRODUCTION
*3213704en*
3213704en
04/2017
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 XC‑W EU (F7103R3)
150 XC‑W US (F7175R3)

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
Condition
Packaging V2
–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)
–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 and attachments for transport damage.
–Remove the headlight mask with the headlight. ( p. 21)
E00850-10
Condition
Packaging V12
–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 and unpack the separate enclosure and attach-
ments. Check that the scope of supply is complete using
the enclosed packing list.
–Have a lift stand available.
Lift stand (78129955100)
–Remove the two cable ties on the triple clamp.

2 SETUP
4
402051-01
–Together with an assistant, take the vehicle off the pallet.
–Position the vehicle on a lift stand.
–Check the vehicle and attachments for transport damage.
–Install the shock absorber. ( p. 15)
E00789-10
(125 XC‑W EU)
–Position the connector retainer and speedometer on the
upper triple clamp.
–Mount and tighten screws 1.
Guideline
Remaining screws,
chassis
M6 10 Nm
(7.4 lbf ft)
E00788-10
(150 XC‑W US)
–Position the speedometer on the upper triple clamp.
–Mount and tighten screws 1with the collar bushings.
Guideline
Remaining screws,
chassis
M6 10 Nm
(7.4 lbf ft)
–Route the clutch line with the clutch master cylinder
toward the front between the upper and lower triple
clamps.
–Install the fork legs. ( p. 16)
E00792-10
–Take off screws 2and handlebar supports.
–Move the handlebar supports to the desired position and
mount and tighten screws 2.
Guideline
Screw, handle-
bar support
M10 40 Nm (29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.

2 SETUP
5
E00483-01
Warning
Danger of accidents A repaired handlebar poses a
safety risk.
If the handlebar is bent or straightened, the mate-
rial becomes fatigued. The handlebar may break as a
result.
–Change the handlebar if the handlebar is damaged
or bent.
–Position the handlebar.
Info
Make sure the cables and wiring are positioned cor-
rectly.
–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.
S01450-01
(125 XC‑W EU)
–Position the controls on the right half of the handlebar.
S01451-01
(150 XC‑W US)
–Position the controls on the right half of the handlebar.

2 SETUP
6
S01453-01
(125 XC‑W EU)
–Position the controls on the left half of the handlebar.
S01454-01
(150 XC‑W US)
–Position the controls on the left half of the handlebar.
S01455-10
Condition
Packaging V12
(125 XC‑W EU)
–Connect all plug-in connectors to the plug-in holder.
–Route the cable without tension and secure with cable
tie.
E00795-10
(150 XC‑W US)
–Connect all plug-in connectors.
–Connect light pull switch 3with the yellow and white
cables.
–Route the cable without tension and secure with cable
tie.
S01457-10
–Route the cable without tension and secure with cable ties and
cable holder.

2 SETUP
7
E00852-01
–Preassemble the hand guards on the left and right.
E00853-01
–Mount the left hand guard.
–Mount the right hand guard.
S01459-01
–Secure the handlebar cushion with two cable ties.
–Install front fender. ( p. 20)
–Install the front wheel. ( p. 16)
(150 XC‑W US)
–Recharge the battery. ( p. 18)

2 SETUP
8
R01229-10
–Position the right footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
E00794-10
–Position spring as shown.
Spring Aengages in area B.
E00796-10
–Press the spring with special tool 4.
Pliers for footrest spring (79029083000)
The special tool is applied to area Con the footrest.
–Mount pin 5.
E00797-10
–Mount the washer and split pin 6.