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.

2 SETUP
9
S01398-10
–Position the left footrest and pin.
Info
Only insert the pin to the extent that the spring can still
be mounted.
E00798-10
–Position spring as shown.
Spring Dengages in area E.
E00800-10
–Press the spring with special tool 4.
Pliers for footrest spring (79029083000)
The special tool is applied to area Fon the footrest.
–Mount pin 7.
E00799-10
–Mount the washer and split pin 8.

2 SETUP
10
E00801-10
–Position the frame protectors on both sides.
–Mount and tighten screws 9.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount and tighten screws bk with the washers.
Guideline
Screw, frame protector M5 3 Nm (2.2 lbf ft)
–Mount the cable tie(s).
–Unpack and mount the KTM PowerParts included in the deliv-
ery (optional).
Info
Read the accompanying KTM PowerParts fitting instruc-
tions.
–Set kilometers or miles. ( p. 25)
–Adjust the combination instrument function. ( p. 26)
–Set the clock. ( p. 26)
–Refuel. ( p. 24)
–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
11
3.1 Raising the motorcycle with a lift stand
401942-01
Note
Danger of damage The parked vehicle can roll away or fall
over.
–Park the vehicle on a firm and level surface.
–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
Danger of damage The parked vehicle can roll away or fall over.
–Park the vehicle on a firm and level surface.
401943-10
–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 Removing the seat
V00342-10
–Remove screws 1.
–Raise the rear of the seat, pull the seat back, and lift it off.

3 WORK
12
3.4 Mounting the seat
V00343-10
–Hook in the front of the seat on the collar bushing of the fuel
tank, lower it at the rear and push it forward.
–Make sure that the seat is correctly locked in.
V00342-10
–Mount and tighten screws 1.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
3.5 Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.
–Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–Remove the seat. ( p. 11)

3 WORK
13
E00774-10
Main work
–Turn handle 1of the fuel tap to the OFF position.
(Figure V00326-10 p. 25)
–Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
–Remove screws 2with the collar bushings.
E00775-10
–Remove screw 3with the rubber bushing.
–Remove the tube from the fuel tank breather.
E00776-10
–Pull both spoilers off the sides of the radiator bracket and lift
off the fuel tank.
3.6 Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
–Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.
–Switch off the engine for refueling.
–Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
–If any fuel is spilled, wipe it off immediately.
–Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid skin, eye and clothing contact with fuel.
–Immediately consult a doctor if you swallow fuel.
–Do not inhale fuel vapors.
–In case of skin contact, rinse the affected area with plenty of water.
–Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
–Change your clothing in case of fuel spills on them.

3 WORK
14
V00352-11
Main work
–Check throttle cable routing. ( p. 14)
–Position the fuel tank and fit the two spoilers to the sides of
the radiator bracket.
–Make sure that no cables or throttle cables are trapped or dam-
aged.
E00775-11
–Attach the fuel tank breather hose.
–Mount and tighten screw 1with the rubber bushing.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
E00774-10
–Mount and tighten screws 2with the collar bushings.
Guideline
Remaining screws,
chassis
M6 10 Nm (7.4 lbf ft)
–Connect the fuel hose.
Finishing work
–Mount the seat. ( p. 12)
3.7 Checking throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
–Make sure that the throttle cable routing and the play in throttle cable complies with the specifica-
tion.
Preparatory work
–Remove the seat. ( p. 11)
–Remove the fuel tank. ( p. 12)

3 WORK
15
E00779-01
Main work
–Check throttle cable routing.
The throttle cable must be routed behind the handle-
bar, on the right of the frame, and to the carburetor. The
throttle cable must be secured behind the fuel tank con-
tact area rubber band.
» If the throttle cable routing is not as specified:
–Correct throttle cable routing.
Finishing work
–Install the fuel tank. ( p. 13)
–Mount the seat. ( p. 12)
3.8 Installing the shock absorber
V00344-11
Main work
–Push splash protector 1to the side and position the shock
absorber. Mount and tighten screw 2.
Guideline
Screw, top
shock absorber
M12 80 Nm (59 lbf ft)
Loctite®2701™
–Mount and tighten screw 3.
Guideline
Screw, bottom
shock absorber
M12 80 Nm (59 lbf ft)
Loctite®2701™
Info
The heim joint for the shock absorber at the swingarm
is Teflon-coated. It must not be greased with grease or
with other lubricants. Lubricants dissolve the Teflon
coating, thereby drastically reducing the service life.
Finishing work
–Remove the motorcycle from the lift stand. ( p. 11)

3 WORK
16
3.9 Installing the fork legs
H01595-10
Main work
–Position the fork legs.
Bleeder screws 1are positioned toward the front.
Info
The rebound damping is located in right fork leg REB
(red adjusting screw). The compression damping is
located in left fork leg COM (white adjusting screw).
Grooves are milled into the side of the upper end of the
fork legs. The second milled groove (from the top) must
be flush with the top edge of the upper triple clamp.
V00334-11
–Tighten screws 2.
Guideline
Screw, top triple
clamp
M8 20 Nm (14.8 lbf ft)
–Tighten screws 3.
Guideline
Screw, bottom triple
clamp
M8 15 Nm (11.1 lbf ft)
E00375-11
–Position the brake caliper, and mount and tighten screws 4.
Guideline
Screw, front
brake caliper
M8 25 Nm (18.4 lbf ft)
Loctite®243™
–Mount the cable tie(s).
–Position the brake line, wiring harness, and clamp. Mount and
tighten screws 5.
Finishing work
–Install the front wheel. ( p. 16)
–Install the headlight mask with the headlight. ( p. 21)
–Check the headlight setting. ( p. 22)
3.10 Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
–Always keep the brake discs free of oil and grease.
–Clean the brake discs with brake cleaner when necessary.

3 WORK
17
H00935-10
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change front wheel bearing.
–Clean and grease shaft seal rings 1and contact surface A
of the spacers.
Long-life grease ( p. 31)
–Insert the spacers.
–Clean and grease the wheel spindle.
Long-life grease ( p. 31)
–Lift the front wheel into the fork, position it, and insert the
wheel spindle.
The brake linings are correctly positioned.
V00364-11
–Mount and tighten screw 2.
Guideline
Screw, front wheel
spindle
M20x1.5 35 Nm (25.8 lbf ft)
–Operate the hand brake lever several times until the brake lin-
ings are seated correctly against the brake disc.
–Remove the motorcycle from the lift stand. ( p. 11)
–Operate the front brake and compress the fork a few times
firmly.
The fork legs straighten.
–Tighten screws 3.
Guideline
Screw, fork stub M8 15 Nm (11.1 lbf ft)
3.11 Removing the battery (150 XC‑W US)
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.
Preparatory work
–Press and hold the kill switch while the engine is idling until
the engine stops.
–Remove the seat. ( p. 11)

3 WORK
18
F00138-10
Main work
Warning
Risk of injury Batteries contain harmful substances.
–Keep batteries out of the reach of children.
–Keep sparks and open flames away from the batter-
ies.
–Only charge batteries in well-ventilated rooms.
–Maintain a minimum clearance from inflammable
materials when charging batteries.
Minimum clearance 1 m (3 ft)
–Do not charge deeply discharged batteries if charge
is already below the minimum voltage.
Minimum voltage before
the start of the charge
9 V
–Dispose of batteries with less than the minimum
voltage correctly.
–Disconnect negative cable 1from the battery.
–Pull back positive terminal cover 2and disconnect the posi-
tive cable from the battery.
–Remove screw 3.
–Pull holding bracket 4forward and remove battery toward
the top.
3.12 Recharging the battery (150 XC‑W US)
Warning
Risk of injury Batteries contain harmful substances.
–Keep batteries out of the reach of children.
–Keep sparks and open flames away from the batteries.
–Only charge batteries in well-ventilated rooms.
–Maintain a minimum clearance from inflammable materials when charging batteries.
Minimum clearance 1 m (3 ft)
–Do not charge deeply discharged batteries if charge is already below the minimum voltage.
Minimum voltage before the start of the charge 9 V
–Dispose of batteries with less than the minimum voltage correctly.
Warning
Environmental hazard Batteries contain environmentally-hazardous materials.
–Do not dispose of batteries as household waste.
–Dispose of batteries at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with
the applicable regulations.