REPAIR MANUAL 2015 125 SX EU 125 SX US 150 SX EU 150 SX USINTRODUCTION 1 Read tis repair manual carefully and thoroughly before beginning work. The vehicle wil only be able to meet the demands placed on ifthe spectied service work is performed regularly and propel This repair manual was written to correspond to the latest state ofthis model series. We reserve the right to make changes in the interest of technical advancement without updating this repair manual at the same time. 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 repair 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, devi- ations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the reguiar scope of supply. © 2015 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. 10 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality ofthe products, Issued by: TOV Management Service KTM Sportmotorcycle GmbH 5230 Mattighofen, Austria 3206201en 07/2015TABLE 1 MEANS OF REPRESENTATION Ll 12 2 SAFETY ADVICE.. 21 22 23 24 3 IMPORTANT NOTES. 31 32 33 34 4 SERIAL NUMBERS 4a. 42 43 44 45 5 MOTORCYCLE 5. 52 53 5a 6 FORK, TRIPLE CLAMP 61 62 63 64 65 66 67 68 69 69.1 692 69.3 694 695 69.6 697 698 69.9 69.10 69.11 69.12 69.13 69.14 69.15 69.16 69.17 6.10 6.10.1 6.10.2 6.103 6.104 6.105 6.10.6 OF CONTENTS ‘Symbols used... Formats used... Repair Manual Safety advice Degrees of risk and symbols... Work rules, Guarantee, warranty. Operating and auxiliary substances ‘Spare parts, accessories Figures Chassis number ‘Type label Engine number... Fork part number ‘Shock absorber article number Raising the motorcycle with a lft stand, Removing the motorcycle from the lift stand... Starting... Sterting the motorycle for checking... ‘Adjusting the compression damping of the fork 12 ‘Adjusting the rebound damping of the fork....... 12 Bleeding the fork legs. 13 Cleaning the dust boots of the fork legs. 1B Removing the fork legs. 4 Installing the fork legs. Removing the fork protector Installing the fork protector. All EU models Conducting major fork service. Conducting minor fork service... Disassembling the fork legs Disassembling the cartridge Disassembling the piston rod Disassembling the screw cap with the ‘membrane holder. Disassembling the screw sleeve. Checking the fork legs. Checking the fork legs - during a minor fork service Changing the pilct bushing .. Assembling the screw sleeve. Assembling the screw cap with the membrane holder. as Assembling the piston rod Assembling the cartridge Assembling the fork legs. Bleeding and filling the cartridge. Filling the cartridge with nitrogen... AIL US models Performing a fork service... Disassembling the fork legs Removing the spring Disassembling the cartridge... Disassembling the piston rod Disassembling the hydrostop unit... 10 6.107 6.108 6.109 6.10.10 6.10.11 6.10.12 6.10.13 Assembling the fork legs... 6.1L 6.12 613 61d 615 HANDLEBAR, CONTROLS. 7A 72 73 Ta 15 76 ‘SHOCK ABSORBER, SWINGARM... al 82 83 a4 85 86 a7 a8 89 8.10 ail 812 813 ald 815 8.16 8.17 8.18 8.19 8.20 B21 8.22 8.23 B28 8.25 EXHAUST e1 92 93 AIR FILTER 10.1 10.2 10.3 10.4 Disassembling the seal ring retainer. Checking the fork legs. ‘Assembling the seal ring retainer... ‘Assembling the hydrostop unit ‘Assembling the piston rod ‘Assembling the cartridge Greasing the steering head bearing . Removing the lower triple clamp. Installing the lower triple clamp Checking the play of the steering head bearing . Astin the play of the steering ead pearing . 54 54 56 - 56 56 Handlebar position Adjusting the handlebar postion sn. ‘Adjusting the basic position of the clutch lever. ‘Checking the routing of the throttle cable Checking the play in the throttle cable ‘Adjusting the playin the throttle cable. 56 57 57 58 59 ‘Adjusting the high-speed compression damping of the shock absorber Adjusting the low-speed compression damping. of the shock absorber ‘Adjusting the rebound damping of the shock absorber. Measuring the sag ofthe unloaded rear wheel. Checking the static sag of the shock absorber... Checking the riding sag of the shock absorber... ‘Adjusting the spring preload of the shock absorber. ‘Adjusting the riding sag. Removing the shock absorber Installing the shock absorber. Servicing the shock absorber. Removing the spring, Disassembling the damper. Disassembling the piston rod Disassembling the seal ring retainer.. Changing the pilot bushing Checking the damper... Removing the heim joint... Installing the heim joint... ‘Assembling the seal ring retainer. ‘Assembling the piston rod. ‘Assembling the damper: Bleeding and filling the damper Filling the damper with nitrogen Installing the spring 59 59. Removing the main silencer Installing the main silencer. ‘Changing the glass fiber yarn filing in the main silencer.. Removing the ai filter box lid Installing the at filter box lid Removing the air filter... Installing the ai filter.TABLE OF CONTENTS 10.5 Cleaning the air filter and air filter box.. 10.6 Sealing the ar filter box 10.7 _ Securing the air filter box lid. 83 11 FUEL TANK, SEAT, TRIM... 84 11.1 Opening the filler cap. a4 11.2 Closing the filler cap . 84 11.3 Removing the seat .. 84 11.4 Mounting the seat... sir 85 11.5 Removing the fuel tank. 85 11.6 Installing the fuel tank 86 12. MASK, FENDER’ 87 12.1 Removing the front fender 87 12.2 _ Installing the front fender 87 12.3. Removing the start number plate. 87 12.4 _ Installing the start number plate 88 13. WHEELS. 13.1 Checking the tire air pressure. 13.2. Checking the tite condition 13.3. Checking the brake discs 13.4 Checking the spoke tension. 13.5. Front wheel 13.5.1 Removing the front wheel nnn nnnnenenee 90 13.5.2 Installing the front whee! 91 13.5.3 Removing the brake disc of the front brake.... 92 13.5.4 Installing the brake disc of the front brake .... 92 13.6 Rear wheel on Lam 136.1 Removing the rear whee . 13.6.2 _ Installing the rear wheel 13.6.3 Removing the brake disc of the rear brake..... 94 13.6.4 Installing the brake disc of the rear brake..... 94 13.6.5 Checking the chain for dirt 94 13.6.6 Cleaning the chain i 94 13.6.7 Checking the chain tension 95 13.6.8 Checking the chain, rear sprocket, engine sprocket and chain guide... on 9B 13.6.9 Adjusting the chain tension 7 14 WIRING HARNESS, BATTERY... 14.1 Ignition curve plug-in connecter. 98 14.2 Checking the capacitor. 15. BRAKE SYSTEM... ven 15.1 Checking the front brake linings. 99 15.2 Changing the front brake linings... 99 15.3 Checking the free travel of the hand brake Neer en vv 101 15.4 Adjusting the basi position of the hand brake lever 101 15.5 Checking the front brake fluid level sn 101 15.6 Adding front brake fluid... senso, 102! 15.7 Changing the front brake fluid 103 15.8 Checking the rear brake linings 104 15.9 Changing the rear brake linings . 104 15.10 Checking the tree travel of foot brake lever... 105, 15.11 Adjusting the basic position of the foot brake lever stern OB 15.12 Checking the rear brake fluid level sevnn 107 15.13 Adding brake fluid forthe rear brake... 107 15.14. Changing the rear brake fluid 108 16 ENGINE 10 110 113 16.1 Removing the engine... 16.2 _ Installing the engine. 16.3 _ Engine disassembly... 16.3.1 16.3.2 16.33 16.3.4 16.3.5 16.3.6 16.3.7 16.38 16.3.9 16.3.10 16.3.1 16.3.12 16.3.13 16.3.14 16.3.15 16.3.16 16.3.17 16.3.18 16.3.19 16.3.20 163.21 16.3.22 16.3.23 16.3.24 16.3.25 16.3.26 16.3.27 16.3.28 Clamping the engine into the engine work stand. . Draining the gear ol. Removing the shift lever Removing the engine sprocke Removing the clutch push rad. Removing the spacer. Removing the alternator cover Removing the kick starter .. Removing the cylinder head Removing the cylinder Removing the piston .. Removing the water pump cover. Removing the clutch cover. Removing the clutch discs.. Removing the outer clutch hub . Removing the primary gear Removing the kick starter shatt.. Removing the shift shaft. Removing the shift drum locating unit Removing the rotor. Removing the stator... Removing the reed valve housing. Removing the left engine case section Removing the shitt rails. Removing the shift drum Removing the shit forks. Removing the transmission shafts. Removing the crankshaft 16.4 Working on individual part. 16.4.1 16.4.2 16.4.3 16.4.4 16.4.5 16.4.6 16.4.7 16.4.8 16.4.9 16.4.10 164.11 16.4.12 164.13 164.14 164.15 164.16 164.17 16.4.18 164.19 16.4.20 ‘Work on the right section of the engine foaB ets pten a Work on the left section of the engine Removing the crankshaft bearing inner TACs i Installing the crankshaft bearing inner Changing the connecting rod, conrod bearing, and crank pin Checking the crankshaft run-out at the bearing pin. Checking/measuring the cylinder... Removing the exhaust control. Checking the exhaust control in the cylinder . Installing the exhaust control Cylinder - Nikasit® coating Checking/measuring the piston. Checking the piston ring end gap Pistordyinde - measuing the mounting clearance... Disassembling the reed valve housing. Checking the reed valve housing, reed valve and intake flange. ‘Assembling the reed valve housing Changing the water pump bearing Removing the exhaust control in the clutch cover... jo Checking the exhaust control in the clutch COVEE nnn - 17 47 18 18 us 18 18 119 119 119 120 120 a2. 321 122 122 123 124 124 124 125 125 125 . 126 126 126 127 127 wn 127 128 128 129 130 130 130 131 132 132 134 135 137 137 138 . 138 139 140 140 142 144 - 46TABLE OF CONTENTS 16.4.21 Installing the exhaust control in the clutch cover 146 164.22 Checking the clutch soon 148, 16.4.23 Changing the absorbing element of the clutch, 149 16.4.24 Preassembling the shift shaft. 149 164.25 Checking the shift mechanism. 150 16.4.26 Disassembling the main shat. 151 16.4.27 Disassembling the countersha.... 152 16.4.28 Checking the transmission 152 164.29 Assembling the main shaft 154 16.4.30 Assembling the countershat 154 164.31 Checking the kick starter. 156 16.4.32 Preassembling the kick starter shaft 156 16.5 _ Engine assembly. 157 16.5.1 Installing the crankshaft. sacaiicie 1B 16.5.2 Installing the transmission shafts... 158 16.5.3 Installing the shit forks. 158 16.5.4 Installing the shift drum.. 158 16.5.5 Installing the shift rails 159 16.5.6 _ Installing the left engine case section... 159 16.5.7 Installing the reed valve housing 159 16.5.8 Installing the stator 160 16.5.9 Adjusting the ignition.. 160 165.10 Installing the rotor 160 16.5.1 Installing the shift drum locating unit 161 165.12 Installing the shitt shaft 162 16.5.13 Installing the kick starter shaft... 162 16.5.14 Installing the primary gear... 162 16.5.15 Installing the clutch basket. 163 16.5.16 Installing the clutch discs... 165.17 Installing the clutch cover - 165.18 Installing the water pump cover... 16.19 Installing the piston 165 16.5.20 Installing the cylinder. 165 165.21 Checking the X-distance 166 16.5.22 Adjusting the X-distance. 166 165.23 Adjusting the Z-distance 167 165.24 Installing the cylinder head. 168 16.5.25 Installing the kick starter. 16.5.26 Installing the alternator cover. 169 165.27 Installing the spacer. 169 16.5.28 Installing the clutch push rod . 169 165.29 Installing the engine sprocket... 169 16.5.30 Installing the shift lever. 170 165.31 Installing the gear oil drain plug... 170 16.5.32 Removing the engine from the engine work stand. 170 17. CARBURETOR im 17.1 Chok rat 172 Carburetor - adjusting the idle speed im 17.3. Emptying the carburetor float chambers... 172 17.4 Removing the carburetor 172 17.5 _ Installing the carburetor 173 17.6 Checking/adjusting the carburetor ‘components, 174 17-7 Disassembling the carburetor 175 17.8 Checking the choke slide 176 17.9. Checking the jet needle... 176 17.10 Checking the throttle slide... .. 176 17.11 Checking the float needle valve 17 17.12 Assembling the carburetor 77 20 ai 22 23 24 25 4 17.13. Checking/adjusting the float level... 178 CLUTCH. 179, 18.1 Checking/correcting the fluid level of the hydraulic clutch, scene 179 18.2 Changing the hydraulic clute fluid 179 WATER PUMP, COOLING SYSTEM.... sn» 180 19.1 Cooling system 180 19.2 Checking the antifreeze and coolant level... 180 19.3 Checking the coolant level. - 180 19.4 Draining the coolant. 181 19.5 Refilling with coolant 181 LUBRICATION SYSTEM. se 183 20.1 Changing the gear ol . 183 20.2 Draining the gear ol. 183 20.3. Refilling with gear oil 184 20.4 Checking the gear ol level - 184 20.5 Adding gear oil 184 IGNITION SYSTEM. 186 21.1 Checking the ignition system... 186 21.2 Ignition coll - checking the primary winding..... 186 21.3 Ignition coll - checking the secondary winding 187 21.4 Checking the spark plug connector. se 187 21.5. Alternator - checking the charging coil of the ignition . - 188 21.6 188 ‘Checking the ignition pulse generator TECHNICAL DATA... 22.1 Engine . 22.1.1 All 125 models. 22.1.2 All 160 models. 22.2 Engine tolerance, wear limits 22.3 Engine tightening torques... 22.8 Capacities. 22.8.1 Gear oll 22.8.2 Coolant. 22.8.3 Fuel 22.5 Chassis. 22.6 Tires. 22.7 Fork. : 22.7.1 All EU models 22.7.2 All US models, 22.8 Shock absorber: . 22.9 Chassis tightening torques... 22.10 Carburetor... 2.10.1 All 125 models 22.10.2 Carburetor - basic setting for sandy surfaces (All 125 models). . 196 2.10.3 All 150 models. 196 2.10.4 Carburetor - basic setting for sandy surfaces (All 150 models). 197 22.11 Carburetor tuning, : 198 2.11.1 Carburetor tuning (All 125 models) . 198 22.1.2 Carburetor tuning (All 150 models) 199 22.1.3 General carburetor tuning... 200 CLEANING, CARE... i = 201 23.1 Cleaning the motorcycle . 201 ‘STORAGE. 202 24.1 Storage 202 24.2 Preparing for use ater storage. . 202 SERVICE SCHEDULE 203 25.1 Service schedule. 203 25.2 Service work (as additional order) 204TABLE OF CONTENTS 26 27 28 29 30 WIRING DIAGRAM 26.1 Page Lof 1 SUBSTANCES ... = AUXILIARY SUBSTANCES... SPECIAL TOOLS STANDARDS. INDEX . 206 206 208 sn 210 212 223 nw 2241 MEANS OF REPRESENTATION 6 AA Symbols used ‘The meaning of specific symbols is described below. S Indicates an expected reaction (e.g, of a work step or a function). x Indicates an unexpected reaction (e.g, of a work step or a function). ce Indicates a page reference (more information is provided on the specified page). Indicates information with more details or tips. 3 Indicates the result ofa testing step. wi Denotes a voltage measurement. in Denotes a current measurement. a Denotes a resistance measurement. The typographical formats used in this document are explained below. Proprietary name Identifies a proprietary name, Name? Identifies a protected name. Brand™ Identifies a trademark. Undertined terms Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.2 SAFETY ADVICE 7 21 RepairMamual Read this Repair Manual carefully and thoroughly before beginning work. It contains useful information and tips that will help you repair and maintain your vehicle. This manual assumes that the necessary special KTM tools and KTM workplace and workshop equipment are available. ‘A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to atthe relevant passages. © Info TThe vehicle has various information and waning labels at prominent locations. Do not remove information/varning labels. If they are missing, you ot others may not recognize dangers and may therefore be injured. Danger Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are ‘not taken, Warning Indicates a danger that i likely to lead to fatal or serious injury ifthe appropriate measures are not taken. Caution Indicates a danger that may lead to minor injuries if the appropriate measures are not taken. Note Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken. Warning Indicates a danger that will lead to environmental damage if the appropriate measures are nat taken, ‘Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in paren- theses. Eg: bearing puller (15112017000) During assembly, non reusable parts (.. sel-locking crews and nuts, seals and seal rings, O-rings, pin, lock washers) must be replaced by new pats. In some instances, a tread locker (e.g Lotte) is required. The manufacturer instructions fr use must be followed! After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn pars. ‘ter you complete the repair or service work, check the operating safety ofthe vehicle.3 IMPORTANT NOTES ‘The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM Dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- tered for damage resulting from manipulations and/or alterations to the vehicle. ‘Additional information on the guarantee or warranty and the procedures involved can be found in the Service & Warranty Booklet Warning Environmental hazard Improper handling of fuel is a danger to the environment. = Do not allow fuel to get into the ground water, the ground, or the sewage system. Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual. Only use spare parts and accessories approved andior recommended by KTM. KTM accepts no liability for other products and any resulting damage or loss. ‘The current KTM PowerParts for your vehicle can be found on the KTM website International KTM Website: http:/iwww.ktm.com ‘The figures contained in the manual may depict special equipment In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to dis- assemble the component to perform the activity in question. Please follow the instructions in the text.4 — SERIAL NUMBERS ° = ‘The chassis number @ is stamped on the right sie ofthe steering head. 401945-10 : The type label @ is fired tothe front ofthe steering head 401946-10 >] The engine number @ is stamped on the let side ofthe engine under the engine |. sprocket. 401949110] The fork part number @ is stamped onthe inner side of the fork tub -401947-10 The shock absorber part number @ is stamped on the top of the shock absorber above the adjusting ring towards the engine side . 401948-105 MOTORCYCLE 10 ‘5.1 Raising the motorcycle with alitstand Note Material damage The vehicle may be damaged by incorrect procedure when parking, Significant damage may be caused if the vehicle rolls away or falls over. The components for parking the vehicle are designed only for the weight of the vehicle. = atk the vehicle on a firm and level surface. = Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. — Raise the motorcycle atthe frame underneath the engine. Tift stand (64829055000) (* p. 215) — The wheels must no longer touch the ground, = Secure the motorcycle against falling over. -401942.01, Note ‘Material damage The vehicle may be damaged by incorrect procedure when parking. Significant damage may be caused if the vehicle rolls away or falls over. ‘The components for parking the vehicle are designed only for the weight of the vehicle. = Park the vehicle on a firm and level surface. = Ensure that nobody sits on the vehicle when the vehicle is parked on a stand. = Remove the motorcycle from the lift stand. = Remove the lift stand. = To patk the motorcycle, insert plug-in stand @ into the left side ofthe wheel spin- dee. = Info © Remove te pin stand before ising 40200110 Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine. = Always warm up the engine at low engine speeds. Info If the motorcycle is unuilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Engine has been out of use for more than 1 week = Empty the carburetor float chamber. ( p. 172)5 MOTORCYCLE " = Turn handle @ of the fuel tap to the ON position, Fuel can flow from the fuel tank to the carburetor. = Remove the motorcycle from the stand, = Shift gear to neutral, The engine is cold = Pull the choke lever out as far as possibe. Press the kick starter forcefully through its full range. Info Hd not open the thrttle, Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness andior death. = When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system. = Shift gear to neutral ~ Press the kick starter forcefully through its full range. Info Ho not open the throttle.