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Manual KTM 125 EXC (2015)

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  • KTM 125 EXC (2015) - page 1

    OWNER'S MANUAL 2015 125 EXC EU 125 EXC Six Days EU 125 EXC Factory Edition EU 200 EXC EU 200 EXC AU 200 XC ‑ W US 250 EXC EU 250 EXC AU 250 EXC Six Days EU 250 EXC Factory Edition EU 250 XC ‑ W US 300 EXC EU 300 EXC AU 300 EXC Six Days EU 300 EXC Factory Edition EU 300 XC ‑ W Six Days US 300 XC ‑ W US 300 EXC BR Art. no. 3213233en ...

  • KTM 125 EXC (2015) - page 2

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  • KTM 125 EXC (2015) - page 3

    DEAR KTM CUSTOMER 1 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-ar t sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle. Enter the serial numbers of your vehicle below. Ch ...

  • KTM 125 EXC (2015) - page 4

    TABLE OF CONTENTS 2 TABLE OF CONTENTS 1 MEANS OF REPRESENTAT ION ............................ ......... 5 1.1 Symbols used ....................................... ............ 5 1.2 Formats used ................................ .................... 5 2 SAFETY ADVICE ...................................... ..................... 6 2.1 Use definition - ...

  • KTM 125 EXC (2015) - page 5

    TABLE OF CONTENTS 3 11.4 Adjusting the high-speed compression damping of the shock absorber ......................... 42 11.5 Adjusting the rebound damping of the shock absorber ................. ............................ ............ 42 11.6 Measuring the sag of the unloaded rear wheel .... 43 11.7 Checking the static sag of the shock absorber ...

  • KTM 125 EXC (2015) - page 6

    TABLE OF CONTENTS 4 16 COOLING SYSTEM .......................................... ........... 98 16.1 Cooling system ..................................... .......... 98 16.2 Checking the antifreeze and coolant level .......... 98 16.3 Checking the coolant level ............................... 99 16.4 Draining the coolant ............................ ...

  • KTM 125 EXC (2015) - page 7

    1 MEANS OF REPRESENTATIO N 5 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). All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of you ...

  • KTM 125 EXC (2015) - page 8

    2 SAFETY ADVICE 6 2.1 Use definition - intended use (All EXC models) KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles comply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle is authorized for public road ...

  • KTM 125 EXC (2015) - page 9

    2 SAFETY ADVICE 7 2.5 Safe operation Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Danger Danger of poisoning   Exhaust gases are toxic and inhaling them may result ...

  • KTM 125 EXC (2015) - page 10

    3 IMPORTA NT NOTES 8 3.1 Guarantee, warranty 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- ered for damage resulting from ...

  • KTM 125 EXC (2015) - page 11

    4 VIEW OF VEHICLE 9 4.1 View of vehicle, front left (example) B02140-10 1 Hand brake lever ( p. 13) 2 Kill switch ( p. 13) 2 Kill switch ( p. 14) 3 Clutch lever ( p. 13) 4 Chain guide 5 Air filter box lid 6 Side stand ( p. 19) 7 Shift lever ( p. 18) 8 Fuel tap ( p. 17) ...

  • KTM 125 EXC (2015) - page 12

    4 VIEW OF VEHICLE 10 4.2 View of vehicle, rear right (example) B02141-10 1 Filler cap 2 Throttle grip ( p. 13) 3 Chassis number ( p. 11) 4 Kick starter ( p. 18) 5 Foot brake lever ( p. 18) 6 Level viewer for brake fluid, rear ...

  • KTM 125 EXC (2015) - page 13

    5 SERIAL NUMBERS 11 5.1 Chassis number 401946-10 The chassis number  is stamped on the right side of the steering head. 5.2 Type label 401946-10 The type label  is fixed to the front of the steering head. 5.3 Key number (All EXC models) 402247-10 The key number  for the steering lock is stamped onto the key connector. 5.4 Engine number 401 ...

  • KTM 125 EXC (2015) - page 14

    5 SERIAL NUMBERS 12 5.6 Shock absorber part number 0 0 1 1 401948-10 The shock absorber part number  is stamped on the top of the shock absorber above the adjusting ring on the engine side. ...

  • KTM 125 EXC (2015) - page 15

    6 CONTROL S 13 6.1 Clutch lever 602726-10 (All 125/200 models) The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. B01496-10 (All 250/300 models) The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 6.2 Hand b ...

  • KTM 125 EXC (2015) - page 16

    6 CONTROL S 14 6.5 Kill switch (Six Days EU) 102044-10 The kill switch  is fitted on the left side of the handlebar. Possible states • Kill switch in the basic position – In this position, the ignition circuit is closed and the engine can be started. • Kill switch is pressed – In this position, the ignition circuit is interrupted, a run- ...

  • KTM 125 EXC (2015) - page 17

    6 CONTROL S 15 6.10 Light switch (Six Days EU) 102045-10 The light switch  is fitted on the left side of the handlebar. Possible states Low beam on – Light switch is in the central position. In this position, the low beam and tail light are switched on. High beam on – Light switch is turned to the left. In this position, the high beam and th ...

  • KTM 125 EXC (2015) - page 18

    6 CONTROL S 16 6.15 Electric starter button (All 200/250/30 0 EU/US models, 300 EXC BR) 602699-10 The electric starter button  is fitted on the right side of the handlebar. Possible states • Electric starter button in basic position • Electric starter button pressed – In this position, the electric starter is actuated. 6.16 Electric starte ...

  • KTM 125 EXC (2015) - page 19

    6 CONTROL S 17 Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If ...

  • KTM 125 EXC (2015) - page 20

    6 CONTROL S 18 6.22 Choke B00004-10 The choke lever  is fitted on the left side of the carburetor. Activating the choke function frees an opening in the carburetor through which the engine can draw extra fuel. This creates a richer fuel-air mixture, as is required for a cold start. Info If the engine is warm, the choke function must be deactivat ...

  • KTM 125 EXC (2015) - page 21

    6 CONTROL S 19 6.26 Side stand 401943-10 The side stand  is on the left side of the vehicle. 401944-10 The side stand is used to park the motorcycle. Info When you are riding, side stand  must be folded up and secured with rubber band  . 6.27 Steering lock (All EXC models) B02143-10 Steering lock  is fitted on the left side of the steer ...

  • KTM 125 EXC (2015) - page 22

    6 CONTROL S 20 6.29 Unlocking the steering (All EXC models) 400731-01 – Insert the key in the steering lock, turn it to the left, pull it out and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. ...

  • KTM 125 EXC (2015) - page 23

    7 SPEEDOM ETER 21 7.1 Speedometer overview 401761-01 – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. 7.2 Activation and test 400313-01 Activating the speedometer The speedometer is activated when ...

  • KTM 125 EXC (2015) - page 24

    7 SPEEDOM ETER 22 7.4 Setting the speedometer functions Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated. Condition The motorcycle is stationary. 400318-01 – Repeatedly press the button briefly until H appears at the bottom right of the display. – Press the button for 2 – 3 seconds. The Setup menu ...

  • KTM 125 EXC (2015) - page 25

    7 SPEEDOM ETER 23 400321-01 – Repeatedly press the button briefly until LAP appears at the bottom right of the display. – Briefly press the button . LAP 1 appears on the left side of the display. – The laps 1 – 10 can be viewed with the button . – Press and hold the button for 3 – 5 seconds to clear the lap times. – Briefly press the ...

  • KTM 125 EXC (2015) - page 26

    7 SPEEDOM ETER 24 Briefly press the button . Activates the flashing display and changes to the next display Press the button for 2 – 3 seconds. No function Briefly press the button . Deactivates the flashing display and changes to the next dis- play Press the button for 2 – 3 seconds. No function Wait 3 – 5 seconds Changes to the next display ...

  • KTM 125 EXC (2015) - page 27

    7 SPEEDOM ETER 25 7.12 Setting the clock 400319-01 Condition • The motorcycle is stationary. – Repeatedly press the button briefly until CLK appears at the bottom right of the display. – Press the button for 2 – 3 seconds. Press the button for 2 – 3 seconds. Increases the value Briefly press the button . Increases the value Press the butt ...

  • KTM 125 EXC (2015) - page 28

    7 SPEEDOM ETER 26 7.15 Display mode SPEED/ODO (odometer) 400317-01 – Repeatedly press the button briefly until ODO appears at the bottom right of the display. The total traveled distance is shown in display mode ODO . Press the button for 2 – 3 seconds. No function Briefly press the button . Next display mode Press the button for 2 – 3 second ...

  • KTM 125 EXC (2015) - page 29

    7 SPEEDOM ETER 27 Info The TR2 value can also be corrected manually during the journey with the but- ton and the button . If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0. Press the button for 2 – 3 seconds. Increases value of TR2 . Briefly press the button . Increases value of TR2 . Press the button for 2 – 3 seconds. Reduc ...

  • KTM 125 EXC (2015) - page 30

    7 SPEEDOM ETER 28 7.21 Display mode SPEED/S1 (stop watch 1) 400327-01 – Repeatedly press the button briefly until S1 appears at the top right of the dis- play. S1 (Stop watch 1) shows the riding time based on TR1 and continues running as soon as an impulse arrives from the wheel speed sensor. The calculation of this value starts with the first im ...

  • KTM 125 EXC (2015) - page 31

    7 SPEEDOM ETER 29 Display Press the but- ton for 2 – 3 seconds. Briefly press the button . Press the but- ton for 2 – 3 seconds. Briefly press the button . Wait 3 – 5 sec- onds Wait 10 – 12 sec- onds Display mode SPEED/LAP (lap time) The stop watch and the lap time are reset. Next display mode Stops the clock. Starts the stop watch or stop ...

  • KTM 125 EXC (2015) - page 32

    8 PREPARIN G FOR USE 30 8.1 Advice on first use Danger Danger of accidents   Danger arising from the rider's judgement being impaired. – Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired. Warning Risk of injury   Missing or poor protective clothing presents a ...

  • KTM 125 EXC (2015) - page 33

    8 PREPARIN G FOR USE 31 – Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. – If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes ...

  • KTM 125 EXC (2015) - page 34

    8 PREPARIN G FOR USE 32 8.4 Preparations for riding on dry sand 600872-10 – Check the radiator cap. Value on the radiator cap 1.8 bar (26 psi) » If the displayed value does not equal the setpoint value: Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, ...

  • KTM 125 EXC (2015) - page 35

    8 PREPARIN G FOR USE 33 – Change the radiator cap. 600870-01 – Mount the rain cover for the air filter. Rain cover for air filter (59006021000) Info Read the KTM PowerParts installation instructions. – Adjust the carburetor jetting and setting. Info Your authorized KTM workshop can recommend the right carburetor tuning. 600868-01 – Clean th ...

  • KTM 125 EXC (2015) - page 36

    8 PREPARIN G FOR USE 34 – Change the radiator cap. 600868-01 – Adjust the secondary ratio to the terrain. Info The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary drive. – Clean the chain. Chain cleaner ( p. 137) – Clean the radiator fins. – Carefully align bent radiator fins. – Ch ...

  • KTM 125 EXC (2015) - page 37

    9 RIDING INSTRUCTIO NS 35 9.1 Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the gear oil level. ( p. 107) – Check the electrical system. – Check the front brake fluid level. ( p. 78) – C ...

  • KTM 125 EXC (2015) - page 38

    9 RIDING INSTRUCTIO NS 36 – Pull out the choke lever all the way. (All 200/250/300 models) – Press the electric starter button or press the kick starter robustly through its full range. Info Do not turn the throttle. (All 125 models) – Press the kick starter robustly through its full range. Info Do not turn the throttle. 9.3 Start off Info Be ...

  • KTM 125 EXC (2015) - page 39

    9 RIDING INSTRUCTIO NS 37 – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. 9.6 Stopping, parking Warning Risk of misappropriation   Usage by unauthorize d persons. – Never leave the vehicle while the engine is ...

  • KTM 125 EXC (2015) - page 40

    9 RIDING INSTRUCTIO NS 38 9.8 Refueling Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. – The fuel in the fuel tank expands when war ...

  • KTM 125 EXC (2015) - page 41

    10 SERVICE SCHEDUL E 39 10.1 Service schedule Every 40 operating hours/after every race Every 20 operating hours Check that the electrical equipment is functioning properly. ● ● Check and charge the battery. (All 200/250/300 models) ● ● Check the front brake linings. ( p. 79) ● ● Check the rear brake linings. ( p. 83) ● ● Check the ...

  • KTM 125 EXC (2015) - page 42

    10 SERVICE SCHEDUL E 40 10.2 Service work (as addition al order) Annually Every 80 operating hours/every 40 operating hours when used for motorsports Every 40 operating hours Once after 10 operating hours Change the front brake fluid. ● Change the rear brake fluid. ● Change the hydraulic clutch fluid. ( p. 74) ● Grease the steering head beari ...

  • KTM 125 EXC (2015) - page 43

    11 TUNING THE CHASSIS 41 11.1 Checking the basic chassis setting with the rider's weight Info When adjusting the basic chassis setting, first adjust the shock absorber and then the fork. 401030-01 – For optimal motorcycle riding characteristic s and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the susp ...

  • KTM 125 EXC (2015) - page 44

    11 TUNING THE CHASSIS 42 (All 250/300 models) Compression damping, low-speed Comfort 25 clicks Standard 20 clicks Sport 15 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damp- ing. 11.4 Adjusting the high-speed compression damping of the shock absorber Caution Danger of accidents   Disassembly of pressurized parts ...

  • KTM 125 EXC (2015) - page 45

    11 TUNING THE CHASSIS 43 B00792-10 – Turn adjusting screw  clockwise up to the last perceptible click. Info Do not loosen nut  ! – Turn counterclockw ise by the number of clicks corresponding to the shock absorber type. Guideline (All 125/200 models) Rebound damping Comfort 28 clicks Standard 24 clicks Sport 22 clicks (All 250/300 models) ...

  • KTM 125 EXC (2015) - page 46

    11 TUNING THE CHASSIS 44 11.8 Checking the riding sag of the shock absorber 400990-10 – Measure distance  of the unloaded rear wheel. ( p. 43) – With another person holding the motorcycle, the rider, wearing full protective cloth- ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times. The ...

  • KTM 125 EXC (2015) - page 47

    11 TUNING THE CHASSIS 45 Info Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload. – Tighten screw  . Guideline Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) Finishing work – Install the shock absorber. ( p. 61) – Remove the motorcycle from the lift stand. ( p. 50) 1 ...

  • KTM 125 EXC (2015) - page 48

    11 TUNING THE CHASSIS 46 401000-01 – As with the shock absorber, smaller differences in the rider's weight can be com- pensated by the spring preload. – However, if the fork is often overloaded (hard end stop on compression), harder springs must be fit to avoid damage to the fork and frame. 11.12 Adjusting the compression damping of the fo ...

  • KTM 125 EXC (2015) - page 49

    11 TUNING THE CHASSIS 47 (250/300 Six Days) Compression damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. B02145-10 (EXC, XC ‑ W, E ...

  • KTM 125 EXC (2015) - page 50

    11 TUNING THE CHASSIS 48 (250/300 Six Days) Rebound damping Comfort 15 clicks Standard 13 clicks Sport 11 clicks Info Turn clockwise to increase damping; turn counterclockwise to reduce damping. 11.14 Adjusting the spring preload of the fork (EXC, XC ‑ W, EXC Factory Edition) M00092-01 – Turn the adjusting screws counterclockwise all the way. I ...

  • KTM 125 EXC (2015) - page 51

    11 TUNING THE CHASSIS 49 11.16 Adjusting the handlebar position Warning Danger of accidents   Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. 101488-10 – Remove screws  . Remove the handlebar clamp. Remove the handlebar and lay it to one ...

  • KTM 125 EXC (2015) - page 52

    12 SERVICE WORK ON THE CHASSIS 50 12.1 Raising the motorcycle with the lift stand 401942-01 Note Danger of damage   The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) Neither wheel is in contact with the groun ...

  • KTM 125 EXC (2015) - page 53

    12 SERVICE WORK ON THE CHASSIS 51 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Loosen the fork protection. ( p. 51) M00131-10 Main work – Push dust boots  of both fork legs downwards. Info The dust boots remove dust and coarse dirt particles from the inside fork tubes ...

  • KTM 125 EXC (2015) - page 54

    12 SERVICE WORK ON THE CHASSIS 52 12.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) – Remove the front wheel. ( p. 86) – Remove the headlight mask with the headlight. ( p. 94) B00798-10 Main work – Remove screws  and take off the clamp. – Remove cable binder  . – Remove screws  an ...

  • KTM 125 EXC (2015) - page 55

    12 SERVICE WORK ON THE CHASSIS 53 M00592-10 (EXC Factory Edition) – Position the fork legs. Info 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. Position bleeder screws  toward the front. B02146-11 (EXC, XC ‑ W) – Tighten ...

  • KTM 125 EXC (2015) - page 56

    12 SERVICE WORK ON THE CHASSIS 54 12.10 Installing the fork protector 101327-10 Main work – Position the fork protection on the left fork leg. Mount and tighten screws  . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) – Position the fork protection on the right fork leg. Mount and tighten the screws. Guideline Remaining screws, ch ...

  • KTM 125 EXC (2015) - page 57

    12 SERVICE WORK ON THE CHASSIS 55 602734-10 Main work – Remove screw  . Remove screw  . Pull off the upper triple clamp with the han- dlebar and hang it to one side. Info Protect the components against damage by covering them. Do not bend the cables and lines. 602735-10 – Remove O-ring  . Remove protective ring  . – Take off the l ...

  • KTM 125 EXC (2015) - page 58

    12 SERVICE WORK ON THE CHASSIS 56 B02153-10 – Tighten screws  . Guideline Screw, bottom triple clamp M8 15 Nm (11.1 lbf ft) B02153-11 – Tighten screw  . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) B02153-12 – Tighten screw  . Guideline Screw, top steering stem M8 20 Nm (14.8 lbf ft) B02153-13 – Tighten screws  ...

  • KTM 125 EXC (2015) - page 59

    12 SERVICE WORK ON THE CHASSIS 57 12.14 Installing the lower triple clamp (Six Days, EXC Factory Edition) B01218-10 Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 137) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing. – Check whether the ...

  • KTM 125 EXC (2015) - page 60

    12 SERVICE WORK ON THE CHASSIS 58 602739-10 – Tighten screw  . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) 602740-10 – Mount and tighten screw  . Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite ® 243™ 602741-10 – Tighten screws  . Guideline Screw, top triple clamp M8 17 Nm (12.5 lbf ft) B00798-1 ...

  • KTM 125 EXC (2015) - page 61

    12 SERVICE WORK ON THE CHASSIS 59 400738-11 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: – Adjust the play of the steering head bearing. ( p. 59) – Move the handlebar to ...

  • KTM 125 EXC (2015) - page 62

    12 SERVICE WORK ON THE CHASSIS 60 M00593-10 (EXC Factory Edition) – Loosen screws  . Remove screw  . – Loosen and retighten screw  . Guideline Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) – Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains. – Tighten screws  . Guideline Screw, top triple clamp ...

  • KTM 125 EXC (2015) - page 63

    12 SERVICE WORK ON THE CHASSIS 61 12.19 Installing the front fender B02156-10 Main work – Position the front fender. Mount and tighten screws  . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) B02155-11 – Mount and tighten screws  . Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Finishing work – Refit the headlight ...

  • KTM 125 EXC (2015) - page 64

    12 SERVICE WORK ON THE CHASSIS 62 Guideline Screw, bottom shock absorber M12 80 Nm (59 lbf ft) Loctite ® 2701™ Info The heim joint for the shock absorber at the swing arm is Teflon coated. It must not be lubricated with grease or with other lubricants. Lubricants dissolve the Teflon coating, thereby drastically reducing the service life. B02158- ...

  • KTM 125 EXC (2015) - page 65

    12 SERVICE WORK ON THE CHASSIS 63 B00817-10 – Mount and tighten screw  of the seat fixation. Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) 12.24 Removing the air filter box lid B02159-10 – Pull off the air filter box lid in area  sideways and remove it toward the front. 12.25 Installing the air filter box lid B02159-11 – Ins ...

  • KTM 125 EXC (2015) - page 66

    12 SERVICE WORK ON THE CHASSIS 64 12.27 Installing the air filter 301262-10 Main work – Mount the clean air filter on the air filter support. – Grease the air filter in area  . Long-life grease ( p. 137) B02160-11 – Insert both parts together, position them and fasten them using air filter holder  . The arrow of marking UP faces up. Inf ...

  • KTM 125 EXC (2015) - page 67

    12 SERVICE WORK ON THE CHASSIS 65 12.29 Sealing the air filter box Preparatory work – Remove the air filter box lid. ( p. 63) 401527-10 Main work – Seal the air filter box in the marked area  . Finishing work – Install the air filter box lid. ( p. 63) 12.30 Removing the main silencer Warning Danger of burns   The exhaust system gets very ...

  • KTM 125 EXC (2015) - page 68

    12 SERVICE WORK ON THE CHASSIS 66 401045-10 Main work – Remove screws  . – Pull out inner tube  . – Remove glass fiber yarn filling  from the inner tube. – Clean the parts that need to be reinstalled and check for damage. – Mount the new glass fiber yarn filling  on the inner tube. – Position outer tube  over the inner tu ...

  • KTM 125 EXC (2015) - page 69

    12 SERVICE WORK ON THE CHASSIS 67 602721-10 – Pull both spoilers off of the sides of the radiator bracket  and lift off the fuel tank. 12.34 Installing the fuel tank Danger Fire hazard   Fue l is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no f ...

  • KTM 125 EXC (2015) - page 70

    12 SERVICE WORK ON THE CHASSIS 68 12.35 Checking the chain for dirt 400678-01 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 68) 12.36 Cleaning the chain Warning Danger of accidents   Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning ...

  • KTM 125 EXC (2015) - page 71

    12 SERVICE WORK ON THE CHASSIS 69 M00102-10 Main work – Pull the chain at the end of the chain sliding piece upward to measure chain ten- sion  . Info The bottom chain section  must be taut. When the chain guard is mounted, it must be possible to pull up the chain at least to the point where it makes contact with chain guard  . Chain wea ...

  • KTM 125 EXC (2015) - page 72

    12 SERVICE WORK ON THE CHASSIS 70 12.39 Checking the chain, rear sprocket , engine sprocket and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) 400227-01 Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: – Change ...

  • KTM 125 EXC (2015) - page 73

    12 SERVICE WORK ON THE CHASSIS 71 B00824-01 – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness. » If the chain sliding piece is loose: – Tighten the screw on the chain sliding piece ...

  • KTM 125 EXC (2015) - page 74

    12 SERVICE WORK ON THE CHASSIS 72 12.41 Checking the swingarm 401341-01 – Check the swingarm for damage, cracking, and deformation. » If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 12.42 Checking the routing ...

  • KTM 125 EXC (2015) - page 75

    12 SERVICE WORK ON THE CHASSIS 73 12.43 Checking the rubber grip 401197-01 – Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Rubber grip adhesive (00062030051) ( p. 137) 12.44 Additionally securing the rubber gr ...

  • KTM 125 EXC (2015) - page 76

    12 SERVICE WORK ON THE CHASSIS 74 12.46 Checking/co rrecting the fluid level of the hydrau lic clutch Info The fluid level rises with increasing wear of the clutch lining discs. 400245-10 (All 125/200 models) – Move the clutch fluid reservoir mounted on the handlebar to a horizontal posi- tion. – Remove screws  . – Remove cover  with me ...

  • KTM 125 EXC (2015) - page 77

    12 SERVICE WORK ON THE CHASSIS 75 B02164-10 – Fill bleeding syringe  with the appropriate hydraulic fluid. Bleed syringe (503290500 00) Hydraulic fluid (15) ( p. 136) – On the slave cylinder of the clutch, remove bleeder screw  and mount bleed- ing syringe  . 400247-10 – Inject the liquid into the system until it escapes from hole ? ...

  • KTM 125 EXC (2015) - page 78

    12 SERVICE WORK ON THE CHASSIS 76 12.48 Removing the engine guard (Six Days, EXC Factory Edition) B01204-10 – Turn quick release  counterclockwise until it disengages. Remove the engine guard. 12.49 Installing the engine guard (Six Days, EXC Factory Edition) B01205-10 – Attach the engine guard at the back of the frame and swing it up at fron ...

  • KTM 125 EXC (2015) - page 79

    13 BRAKE SYSTEM 7 7 13.1 Checking the free travel of the hand brake lever Warning Danger of accidents   Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit. The front brake can fail due to overheating. Adjust the free travel on hand brake lever according to specifications. 60 ...

  • KTM 125 EXC (2015) - page 80

    13 BRAKE SYSTEM 7 8 13.4 Checking the brake discs Warning Danger of accidents   Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) 400257-10 – Check the thickness of the front and rear brake discs at several places on the disc to see if it c ...

  • KTM 125 EXC (2015) - page 81

    13 BRAKE SYSTEM 7 9 Warning Danger of accidents   Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard   Hazardous substances cause environmental damage. – Oil, grease, filte ...

  • KTM 125 EXC (2015) - page 82

    13 BRAKE SYSTEM 8 0 13.8 Changing the front brake linings Warning Danger of accident   Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation   Br ake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, ...

  • KTM 125 EXC (2015) - page 83

    13 BRAKE SYSTEM 8 1 100397-01 – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. M00112-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the full set of brake linings. – Operate the hand brake lever several times until the b ...

  • KTM 125 EXC (2015) - page 84

    13 BRAKE SYSTEM 8 2 402026-10 – Disconnect spring  . M00595-10 – Loosen nut  and, with push rod  , turn it back until you have maximum free travel. – To adjust the basic position of the foot brake lever to individual requiremen ts, loosen nut  and turn screw  accordingly. Info The range of adjustment is limited. – Turn push r ...

  • KTM 125 EXC (2015) - page 85

    13 BRAKE SYSTEM 8 3 13.12 Adding brake fluid for the rear brake Warning Danger of accidents   Brake system failure. – If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system is leaking or that the brake linings are completely worn down. Check the brake system and do not cont ...

  • KTM 125 EXC (2015) - page 86

    13 BRAKE SYSTEM 8 4 13.14 Changing the brake linings of the rear brake Warning Danger of accident   Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation   Br ake fluid can cause skin irritation on contact. – Avoid contact with sk ...

  • KTM 125 EXC (2015) - page 87

    13 BRAKE SYSTEM 8 5 100407-10 – Check that leaf spring  in the brake caliper and sliding plate  in the brake caliper support are seated correctly. M00115-01 – Insert the new brake linings, insert the pin, and mount the cotter pins. Info Always change the brake linings in pairs. – Operate the foot brake lever several times until the brak ...

  • KTM 125 EXC (2015) - page 88

    14 WHEELS, TIRES 86 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 50) M00116-10 Main work – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes. ...

  • KTM 125 EXC (2015) - page 89

    14 WHEELS, TIRES 87 M00117-11 – Lift the front wheel into the fork, position it, and insert the wheel spindle. The brake linings are correctly positioned. – Mount and tighten screw  . Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) – Operate the hand brake lever several times until the brake linings are lying correctly aga ...

  • KTM 125 EXC (2015) - page 90

    14 WHEELS, TIRES 88 14.4 Installing the rear wheel Warning Danger of accidents   Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. M00124-11 Main work – Check the wheel bearing for damage and wear. » If the wheel bearing ...

  • KTM 125 EXC (2015) - page 91

    14 WHEELS, TIRES 89 400602-10 – Check the front and rear tires for cuts, run-in objects and other damage. » If the tire exhibits cuts, run-in objects or other damage: – Change the tire. – Check the depth of the tread. Info Note local national regulations concerning the minimum tread depth. Minimum tread depth ≥ 2 mm ( ≥ 0.08 in) » If th ...

  • KTM 125 EXC (2015) - page 92

    14 WHEELS, TIRES 90 400694-01 – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions. You should hear a high note. » ...

  • KTM 125 EXC (2015) - page 93

    15 ELECTRIC AL SYSTEM 91 15.1 Removing the battery (All 200/250/300 models) Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep sparks and open flames ...

  • KTM 125 EXC (2015) - page 94

    15 ELECTRIC AL SYSTEM 92 15.3 Recharging the battery (All 200/250/30 0 models) Warning Risk of injury   Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. – Keep sparks and open fla ...

  • KTM 125 EXC (2015) - page 95

    15 ELECTRIC AL SYSTEM 93 15.4 Changing the main fuse (All 200/250/300 models) Warning Fire hazard   The electrical system can be overloaded if the wrong fuses are used. – Use only fuses with the prescribed amperage. Never bypass or repair fuses. Info The main fuse protects all power consumers of the vehicle. It is located in the starter relay h ...

  • KTM 125 EXC (2015) - page 96

    15 ELECTRIC AL SYSTEM 94 15.5 Removing the headlight mask with the headlight 602762-10 – Switch off all power consumers and switch off the engine. – Remove screw  and take off the clamp. – Release rubber straps  . Slide the headlight mask up and swing it forward. M00589-10 (All EXC models) – Detach plug-in connectors  and take off ...

  • KTM 125 EXC (2015) - page 97

    15 ELECTRIC AL SYSTEM 95 602762-11 – Position the headlight mask and fix it with rubber straps  . The holding lugs engage. – Position the brake line and wiring harness. Put the clamp on and mount and tighten screw  . Finishing work – Check the headlight setting. ( p. 96) 15.7 Changing the headlight bulb Note Damage to reflector   Redu ...

  • KTM 125 EXC (2015) - page 98

    15 ELECTRIC AL SYSTEM 96 101722-10 Main work – Remove the screw on the rear of the turn signal housing. – Carefully remove turn signal glass  . – Lightly squeeze orange cap  in the area of the holding lugs and take it off. – Press the turn signal bulb carefully into the socket, turn it counterclockwise by about 30°, and take it out o ...

  • KTM 125 EXC (2015) - page 99

    15 ELECTRIC AL SYSTEM 97 15.11 Changing the speedometer battery Preparatory work – Remove the headlight mask with the headlight. ( p. 94) 602746-10 Main work – Remove screws  . – Pull the speedometer upward out of the holder. 602748-10 – Using a coin, turn protection cap  all the way counterclockwise and remove it. – Remove speedome ...

  • KTM 125 EXC (2015) - page 100

    16 COOLING SYSTEM 98 16.1 Cooling system B02167-10 (All 125/200 models) Water pump  in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap  . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunction ...

  • KTM 125 EXC (2015) - page 101

    16 COOLING SYSTEM 99 16.3 Checking the coolant level Warning Danger of scalding   During motorcycle operation, the coolant gets very hot and is under pressure. – Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse i ...

  • KTM 125 EXC (2015) - page 102

    16 COOLING SYSTEM 100 B02168-11 (All 250/300 models) – Remove screw  . Take off radiator cap  . – Completely drain the coolant. – Mount and tighten screw  with a new seal ring. Guideline Drain plug, water pump cover M10x1 15 Nm (11.1 lbf ft) 16.5 Refilling with coolant Warning Danger of poisoning   Coolant is poisonous and a health ...

  • KTM 125 EXC (2015) - page 103

    16 COOLING SYSTEM 101 – Place the vehicle back on a level surface. M00597-10 – Fill the radiator completely with coolant. – Mount radiator cap  . – Run the engine until it is warm. Finishing work – Check the coolant level. ( p. 99) ...

  • KTM 125 EXC (2015) - page 104

    17 TUNING THE ENGINE 102 17.1 Checking the play in the throttle cable 400192-10 – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3… 5 mm (0.12… 0.2 in) » If the throttle cab ...

  • KTM 125 EXC (2015) - page 105

    17 TUNING THE ENGINE 103 The idle speed is adjusted with adjusting screw  . The idle mixture is adjusted with the idle air adjusting screw  . 500282-01 Idle air range A Operation with the throttle slide closed. This range is influenced by adjusting screw  and the idle air adjusting screw  . Transition range B Behavior of the engine when ...

  • KTM 125 EXC (2015) - page 106

    17 TUNING THE ENGINE 104 – Adjust the idle speed with adjusting screw  . Guideline Choke function deactivated – The choke lever is pushed in all the way. ( p. 18) Idle speed 1,400… 1,500 rpm – Turn idle air adjusting screw  slowly in a clockwise direction until the idle speed begins to fall. – Note the position and turn the idle air ...

  • KTM 125 EXC (2015) - page 107

    17 TUNING THE ENGINE 105 17.6 Checking the basic position of the shift lever 400692-10 – Sit on the vehicle in the riding position and determine the distance  between the upper edge of your boot and the shift lever. Distance between shift lever and upper edge of boot 10… 20 mm (0.39… 0.79 in) » If the distance does not meet specifications ...

  • KTM 125 EXC (2015) - page 108

    17 TUNING THE ENGINE 106 B02129-10 Main work – Remove screws  . B00056-11 – Take cap  , adjusting spring  , auxiliary spring  , and spring insert  out of the clutch cover. – Pull both springs off of the spring insert. B02130-10 – Mount the required auxiliary spring  and adjusting spring  and slide them into the clutch c ...

  • KTM 125 EXC (2015) - page 109

    18 SERVICE WORK ON THE ENGINE 107 18.1 Checking the gear oil level Info The gear oil level must be checked while the engine is cold. Preparatory work – Stand the motorcycle upright on a horizontal surface. B02173-10 Main work (All 125/200 models) – Remove screw  from the opening used to check the gear oil level. – Check the gear oil level. ...

  • KTM 125 EXC (2015) - page 110

    18 SERVICE WORK ON THE ENGINE 108 18.3 Draining the gear oil Warning Danger of scalding   Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard   Hazardous substances cause environmental ...

  • KTM 125 EXC (2015) - page 111

    18 SERVICE WORK ON THE ENGINE 109 – Mount and tighten the oil filler plug. 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 ventila- tion, and do not start or run the engine in an enclosed space without an effectiv ...

  • KTM 125 EXC (2015) - page 112

    18 SERVICE WORK ON THE ENGINE 110 – Start the engine and check that it is oil-tight. Finishing work – Check the gear oil level. ( p. 107) ...

  • KTM 125 EXC (2015) - page 113

    19 CLEANING , CARE 111 19.1 Cleaning the motorcycle Note Material damage   Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors , cables, bearings, etc. Maintain a minimum distance of 60 cm between ...

  • KTM 125 EXC (2015) - page 114

    19 CLEANING , CARE 112 19.2 Checks and maintenance steps for winter operation Info If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corro- sion. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of ...

  • KTM 125 EXC (2015) - page 115

    20 STORAGE 113 20.1 Storage Warning Danger of poisoning   Fuel is poisonous and a health hazard. – Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap ...

  • KTM 125 EXC (2015) - page 116

    21 TROUBLE SHOOTING 114 Faults Possible cause Action The engine cannot be cranked (elec- tric starter) (All 200/250/300 models) Operating error – Carry out the start procedure. ( p. 35) Battery discharged – Recharge the battery. ( p. 92) – Check the charging voltage. – Check the closed current. – Check the alternator. Main fuse is blown ? ...

  • KTM 125 EXC (2015) - page 117

    21 TROUBLE SHOOTING 115 Faults Possible cause Action Engine stalls or is popping into the carburetor Engine takes in bad air – Check the intake flange and carburetor for tightness. The connector or ignition coil is loose or oxidized – Clean the connector and treat it with contact spray. Engine overheats Too little coolant in cooling system – ...

  • KTM 125 EXC (2015) - page 118

    22 TECHNICA L DATA 116 22.1 Engine 22.1.1 All 125 models Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 124.8 cm³ (7.616 cu in) Stroke 54.5 mm (2.146 in) Bore 54 mm (2.13 in) Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing ...

  • KTM 125 EXC (2015) - page 119

    22 TECHNICA L DATA 117 5th gear 17:19 6th gear 22:20 Ignition Contactless controlled fully electronic ignition with digital igni- tion adjustment, type Kokusan Ignition point (BTDC) 1.6 mm (0.063 in) Spark plug NGK BR 8 EG Spark plug electrode gap 0.60 mm (0.0236 in) Starting aid Kick starter and electric starter 22.1.3 All 250 models Design 1-cyli ...

  • KTM 125 EXC (2015) - page 120

    22 TECHNICA L DATA 118 Crankshaft bearing 1 grooved ball bearing/1 roller bearing Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons Aluminum cast Piston rings 2 half keystone rings X (upper edge of piston to upper edge of cylinder) 0… 0.10 mm (0… 0.0039 in) Z (height of control flap) 48.5 mm (1.909 in) Primary transmission ...

  • KTM 125 EXC (2015) - page 121

    22 TECHNICA L DATA 119 Screw, gear oil level check M6 10 Nm (7.4 lbf ft) – Screw, ignition system/sta tor (All 200 models) M6 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) – Screw, kick starter stop plate M6 10 Nm (7.4 lbf ft) Loctite ® 243™ Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite ...

  • KTM 125 EXC (2015) - page 122

    22 TECHNICA L DATA 120 Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite ® 243™ Screw, slave cylinder of the clutch M6 10 Nm (7.4 lbf ft) – Screw, starter motor M6 8 Nm (5.9 lbf ft) – Screw, stator M6 8 Nm (5.9 lbf ft) Loctite ® 243™ Screw, water pump cover M6 10 Nm (7.4 lbf ft) – Screw, cylinder head M8 27 Nm (19.9 lbf ft) – Screw, k ...

  • KTM 125 EXC (2015) - page 123

    22 TECHNICA L DATA 121 Front 2.5 mm (0.098 in) Rear 3.5 mm (0.138 in) Tire air pressure, road (All EXC models) Front 1.5 bar (22 psi) Rear 1.5 bar (22 psi) Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) Secondary ratio (All 125 models) 14:50 (13:50) Secondary ratio (200 EXC EU, 200 EXC AU) 14:45 Secondary ratio (200 XC ‑ ...

  • KTM 125 EXC (2015) - page 124

    22 TECHNICA L DATA 122 22.6 Tires Validity Front tires Rear tires (125 EXC EU) 80/100 - 21 M/C 51M TT MAXXIS MAXX CROSS SI PRO 120/90 - 18 M/C 65R TT MAXXIS MAXX ENDURO (125 EXC Six Days EU, 125 EXC Fac- tory Edition EU) 90/90 - 21 M/C 54M TT Metzeler 6 DAYS EXTREME 120/90 - 18 M/C 65M TT Metzeler 6 DAYS EXTREME (200/250/300 EXC EU/AU) 80/100 - 21 ...

  • KTM 125 EXC (2015) - page 125

    22 TECHNICA L DATA 123 Comfort 20 clicks Standard 18 clicks Sport 16 clicks Spring preload - Preload Adjuster Comfort 1 turn Standard 2 turns Sport 2 turns Spring length with preload spacer(s) Weight of rider: 65… 75 kg (143… 165 lb.) 513 mm (20.2 in) Weight of rider: 75… 85 kg (165… 187 lb.) 513 mm (20.2 in) Weight of rider: 85… 95 kg (1 ...

  • KTM 125 EXC (2015) - page 126

    22 TECHNICA L DATA 124 Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 3.8 N/mm (21.7 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 4.0 N/mm (22.8 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 4.2 N/mm (24 lb/in) Fork length 932 mm (36.69 in) Air chamber length 100 mm (3.94 in) Oil capacity per fork leg 635 ml (21.47 fl. oz. ...

  • KTM 125 EXC (2015) - page 127

    22 TECHNICA L DATA 125 Comfort 28 clicks Standard 24 clicks Sport 22 clicks Spring preload Comfort 7 mm (0.28 in) Standard 7 mm (0.28 in) Sport 7 mm (0.28 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 66 N/mm (377 lb/in) Weight of rider: 75… 85 kg (165… 187 lb.) 69 N/mm (394 lb/in) Weight of rider: 85… 95 kg (187… 209 lb.) 7 ...

  • KTM 125 EXC (2015) - page 128

    22 TECHNICA L DATA 126 Screw, top steering stem (EXC, XC ‑ W) M8 20 Nm (14.8 lbf ft) – Screw, top steering stem (Six Days, EXC Factory Edition) M8 17 Nm (12.5 lbf ft) Loctite ® 243™ Screw, top triple clamp (EXC, XC ‑ W) M8 20 Nm (14.8 lbf ft) – Screw, top triple clamp (Six Days, EXC Factory Edition) M8 17 Nm (12.5 lbf ft) – Engine brac ...

  • KTM 125 EXC (2015) - page 129

    22 TECHNICA L DATA 127 22.10 Carburetor 22.10.1 All 125 models Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK125 Needle position 4th position from top Jet needle N84I (N1EF / N1EG) Main jet 100 (172/175) Idling jet 38x38 (42/45) Starting jet 50 (85) Idle air adjusting screw Open 2.75 turns Throttle slide 7 with cut-out Slide ...

  • KTM 125 EXC (2015) - page 130

    22 TECHNICA L DATA 128 402138-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! ...

  • KTM 125 EXC (2015) - page 131

    22 TECHNICA L DATA 129 22.10.3 200 EXC EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK027 Needle position 3rd position from top Jet needle NPRH (N1EH / N1EI / N1EJ) Main jet 100 (162/165) Idling jet 35x35 (40) Starting jet 50 (85) Idle air adjusting screw Open 1.5 turns Throttle slide 7 with cut-out Slide stop Present 22.10 ...

  • KTM 125 EXC (2015) - page 132

    22 TECHNICA L DATA 130 402139-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! ...

  • KTM 125 EXC (2015) - page 133

    22 TECHNICA L DATA 131 22.10.7 250 EXC EU, 250 EXC Six Days EU, 250 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK028 Needle position 2nd position from top Jet needle N84K (N2ZW / N2ZH / N2ZJ) Main jet 110 (172/175) Idling jet 38x38 (38/40) Starting jet 50 (85) Idle air adjusting screw Open 1.5 turns Th ...

  • KTM 125 EXC (2015) - page 134

    22 TECHNICA L DATA 132 402140-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! ...

  • KTM 125 EXC (2015) - page 135

    22 TECHNICA L DATA 133 22.10.11 300 EXC EU, 300 EXC Six Days EU, 300 EXC Factory Edition EU Carburetor type KEIHIN PWK 36S AG Carburetor identification number FK029 Needle position 2nd position from top Jet needle N84K (N8RG / N8RH) Main jet 115 (170/172/175) Idling jet 38X38 (35) Starting jet 50 (85) Idle air adjusting screw Open 1.75 turns Thrott ...

  • KTM 125 EXC (2015) - page 136

    22 TECHNICA L DATA 134 402141-01 M/FT ASL Sea level TEMP Temperature ASO Idle air adjusting screw open IJ Idling jet NDL Needle POS Needle position from above MJ Main jet Does not apply to sand surfaces! 22.10.15 General carburetor tuning 0 0 4 4 0 0 3 3 0 0 5 5 0 0 2 2 0 0 1 1 B00075-10 1... 5 Needle position from above The five needle positions a ...

  • KTM 125 EXC (2015) - page 137

    23 SUBSTAN CES 135 Brake fluid DOT 4 / DOT 5.1 Standard/classific ation – DOT Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corre- sponding properties. Recommended supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 Motorex ® – Brake Fluid DOT 5.1 Cool ...

  • KTM 125 EXC (2015) - page 138

    23 SUBSTAN CES 136 Hydraulic fluid (15) Standard/classific ation – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. Recommended supplier Motorex ® – Hydraulic Fluid 75 Shock absorber fluid (SAE 2.5) (50180751S1) St ...

  • KTM 125 EXC (2015) - page 139

    24 AUXILIAR Y SUBSTANCES 137 Air filter cleaner Recommended supplier Motorex ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier Motorex ® – Chain Clean Fuel additive Recommended supplier Motorex ® – Fuel Stabilizer High viscosity grease Recommended supplier SKF ® – LGHB 2 Long-life grease Recommended supplier Motorex ® – ...

  • KTM 125 EXC (2015) - page 140

    24 AUXILIAR Y SUBSTANCES 138 Universal oil spray Recommended supplier Motorex ® – Joker 440 Synthetic ...

  • KTM 125 EXC (2015) - page 141

    25 STANDAR DS 139 JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. Whereas long service intervals are demanded fo ...

  • KTM 125 EXC (2015) - page 142

    INDEX 140 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 A ...

  • KTM 125 EXC (2015) - page 143

    INDEX 141 Fork basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 45 Fork legs bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 51 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 removing . . . . . . ...

  • KTM 125 EXC (2015) - page 144

    INDEX 142 installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 44 spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 44 static sag, checking . . . . . . . ...

Manufacturer KTM Category Motorcycle

Documents that we receive from a manufacturer of a KTM 125 EXC (2015) can be divided into several groups. They are, among others:
- KTM technical drawings
- 125 EXC (2015) manuals
- KTM product data sheets
- information booklets
- or energy labels KTM 125 EXC (2015)
All of them are important, but the most important information from the point of view of use of the device are in the user manual KTM 125 EXC (2015).

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals KTM 125 EXC (2015), service manual, brief instructions and user manuals KTM 125 EXC (2015). Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product KTM 125 EXC (2015).

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A complete manual for the device KTM 125 EXC (2015), how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use KTM 125 EXC (2015) by users. Manuals are usually written by a technical writer, but in a language understandable to all users of KTM 125 EXC (2015).

A complete KTM manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual KTM 125 EXC (2015) - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the KTM 125 EXC (2015), FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the KTM 125 EXC (2015), that we can find in the current document
3. Tips how to use the basic functions of the device KTM 125 EXC (2015) - which should help us in our first steps of using KTM 125 EXC (2015)
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with KTM 125 EXC (2015)
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of KTM 125 EXC (2015) in a specific country, if it was not possible to solve the problem on our own.

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