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6/2006 FOTO: MITTERBAUER
OWNER’S MANUAL 2007
125 SX
250 SX
ART. NR. 3.211.174 EN
KTM Group Partner
KTM-Sportmotorcycle AG
A–5230 Mattighofen
www.ktm.at
ENGLISH
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IMPORTANT » We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number 1 Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may proh
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ENGLISH INTRODUCTION » INTENDED PURPOSE KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. THE SX MODELS ARE PROHIBITED ON PUBLIC ROADS. OWNER’S MANUAL Please read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will
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INTRODUCTION » The service work specified in the "Lubrication and Maintenance Schedule" must be performed by a KTM workshop and recorded in the service manual otherwise claims under the warranty shall become void. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications must be used in accordance with the maintenance schedule. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines wil
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ENGLISH TABLE OF CONTENTS » Page Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5 Checking the front brake pads . . . . . . . . . . . . . . . . .23 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Replacing the front brake pads . . . . . . . . . . . . . . . . .24 Engine number, engine type . . . . . . . . . . . . . . . . . . . .5 Checking the rear brake fluid level . . . . . . . . . . . . . .24 Refilling the rear brake fluid reservoir . . . . . . . . .
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SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. 5 OPERATION INSTRUMENTS » Clutch lever The clutch lever [1] is located on the left side of the handlebars. The adjust- ing screw [A] is used to change the original position
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ENGLISH OPERATION INSTRUMENTS » Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. 1 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 [2] without kinks. 2 6 Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be tur
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OPERATION INSTRUMENTS » 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. 2,3,4,5, (6) N 1 Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. 7 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 maintenan
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ENGLISH OPERATION INSTRUMENTS » Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound. Remove the protecting cap [1]. By turning the adjusting screw [2], the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counter- clockwise to reduce damping during rebounding. STANDARD ADJUSTMENT: – turn adjusting screw clockwise as far as it will go – turn it back by as many clicks as are specified for the rele
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OPERATION INSTRUMENTS » Rebound damping of shock absorber By using the adjusting screw [4], the degree of damping of the rebound can be adjusted. Turn the knob to the right side to increase damping, turn it to the left side to reduce damping during rebounding. STANDARD ADJUSTMENT: 2 1 – Turn the adjusting screw clockwise to the stop. – Then turn the adjusting screw counterclockwise, counting the number of clicks that corresponds to the respective type of shock absorber. Typ WP Suspension 12187C
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ENGLISH DRIVING INSTRUCTIONS » What you should check before each start When you start off, the motorcycle must be in a perfect technical condition. For safety reasons, you should make it a habit to perform an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK TRANSMISSION OIL LEVEL Too little transmission oil leads to premature wear and will ultimately destroy gear wheels and parts of the shift mechanism. 2 FUEL Check that there is sufficient fu
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DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open fuel tap 2 Put the gear in neutral 3 Activate cold-starting aid (choke) 4 Leave throttle closed or open it no more than 1/3 and kick down kick- starter vigorously all the way. – For starting always put on your motorcycle boots to avoid injuries. You could slip off the kickstarter or the motor could kick back and fling your foot upwards. – Forcefully kick the kickstarter down the whole way and do not open the throttle. A kickstart wit
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ENGLISH DRIVING INSTRUCTIONS » Shifting/Riding You are now in first gear, referred to as the drive or uphill gear. Motorcycle engines produce a great amount of heat while running. Depending on the conditions (hill size, etc.), you can shift to a higher The engine, exhaust pipe, muffler, brake rotors, and shock absorbers gear. Turn down the throttle, at the same time pull the clutch lever can become very hot. Do not touch any of these parts after start- in and shift to the next higher gear. Let t
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PERIODIC MAINTENANCE SCHEDULE » 125/250 SX 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Check gear box oil level Change gear box oil Check spark plugs, adjust distance between electrodes Renew spark plugs Clean the spark-plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Check the carburetor connection boot and intake flange for cracks or leaks Check idle speed setting Check that vent ho
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ENGLISH PERIODIC MAINTENANCE SCHEDULE » 125/250 SX 2007 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Clean and adjust carburetor Replace the throttle slide, jet needle, float needle valve, needle nozzle Check the reed-type intake valve for wear Check the wear on the clutch disks and length of the clutch springs Check the cylinder and piston for wear Check function of exhaust control Check piston pin bearing Replace the cranks
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MAINTENANCE WORK ON CHASSIS AND ENGINE » Maintenance and adjusting work marked with an asterisk * requires expert skills and technical know-how. For your own safety, always have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified, skilled staff. – If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc. The high pressure will cause water to penetrate into the c
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ENGLISH MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 75 bis 85 kg A (wearing full protective clothing). If your weight exceeds or falls short of this range, you will need t
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MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for vari- ous reasons. Similar to the shock absorber, smaller deviations in your weight can be compensated by adjusting the spring preload. However, if your tele- scopic fork bumps frequently (hard end stop during compression), you should install harder fork springs to avoid damaging the telescopic fork and frame. Changing the spring preload
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ENGLISH MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the fork offset (caster The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course. Remove the blind screw [1] to see which offset is set. If the mark [B] is in A front, the offset is 18 mm. This setting will deliver more directional stability on fast race courses. If the mark [B] is in the rear as illustrated
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MAINTENANCE WORK ON CHASSIS AND ENGINE » Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw. Tighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 stages. Adjust the steering head bearing with zero clearance (see section on checking and adjusting the steering head support). Hold the middle clamp screw [A] in place with Loctite
