KTM 1998 125sx User manual

BEDIENUNGSANLEITUNG
OWNER’S HANDBOOK
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.205.24
7.97
125/200
250/300/380
SX/MXC/EXC/EGS
’98
’98
BEDIENUNGSANLEITUNG OWNER’S HANDBOOK ART. NR. 3.205.24
7.97
125/200/250/300/300/380 SX/MXC/EXC/EGS

ENGLISH
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 ren-
dered 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 spare parts manual engine
1 owner handbook for telescopic fork
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
Frame number........................................................................4
Engine number, engine type (125/200)...................................4
Engine number, engine type (250/300/380)...........................4
OPERATION INSTRUMENTS .....................................................4
Clutch control lever (125/200)...............................................4
Clutch control lever (250/300/380).......................................4
Hand brake lever.....................................................................5
Speedometer, indicator lamps (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
Side 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 (125/200)
......13
Checking and adjusting the steering head bearing..................13
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
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 (A, CH).........................................................................20
Battery (A, CH).....................................................................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 (125/200).......24
Adjusting the clutch cable (250/300/380)............................24
Check transmission oil level (125/200).................................25
Changing transmission oil (125/200)....................................25
Check transmission oil level (250/300/380).........................25
Changing 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...................................................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 (125/200)
The clutch lever 1is located on the left side of the handlebar. The adjusting screw
Ais used to change the original position of the clutch lever (see maintenance
work on chassis and angine).
Clutch lever (250/300/380)
The clutch lever 2is fitted on the left hand side of the handle bar. When engine is
cold, there should allways be a play of 10 mm (0.4 in) at this lever (measured at
outer edge). !
CAUTION
!
IF THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE CLUTCH
WILL THEN OVERHEAT, DESTROYING THE CLUTCH LININGS.
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS
10 mm
2
1
A

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5
Hand brake lever
The hand brake lever is mounted on the handle bars on the right and actuates 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 LOO-
KED OVER BY A KTM DEALER.
Speedometer, indicator lamps (EXC)
The mileage indicator Ain the speedometer 1indicates overall mileage.
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 adjust-
ment 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 thythm.
The blue indicator lamp 6will be lit when the high beam is on
Ignition lock
Switch positions of ignition lock 7:
AUS/OFF= Ignition off
PARK = Ignition off, parking light on (only versions with battery)
EIN/ON = Ignition on
EIN/ON = Ignition on
The ignition key can be withdrawn in positions AUS/OFF and PARK.
12
A
3
B
4
56
7

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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 3 switch positions.
A= Light off (this function is not available in all models)
B= Low beam on
C= High beam on
The red short circuit button 2serves to switch off the engine. Leave the switch
pressed until the engine stops. You may use button 3to actuate the horn.
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 5 is 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.
4
23
A
B
C
1
5

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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: Unleaded premium gasoline RON 95 mixed with high grade two
stroke oil. Mixture ratio 1:40
250/300/380: 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 BUR-
NING 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 FAILURE .
–DO NOT USE PREMIXED TWO-STROKE OILS, OILS FOR OUTBOARD ENGINES OR NORMAL
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 carburetor.
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 rota-
ting handle back to the ON position so that you will have backup fuel next
time, too.
Reserve of the 9 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.
1
35 mm
ON RESOFF
SX
MXC
EXC
EGS

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8
Choke knob
When pulling the choke knob 1fully towards the top, a bore is opened in the car-
buretor. 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 between 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 INJURIES.
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 position 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 LOO-
KED OVER BY A KTM DEALER.
Compression damping of fork
The compression damping mechanism is built into the left fork tube. It only regula-
tes the degree of damping during compression.
By turning the adjusting screw 2(C, COM), the degree of damping of the com-
pression 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 81....................................20 clicks
Type Marzocchi 82....................................20 clicks
Type Marzocchi 82....................................20 clicks
Type White Power 09.18.S7.41.................12 clicks
Type White Power 09.18.S7.42.................10 clicks
2,3,4,5(6)
1
N
22
1