Instruction/ maintenance manual of the product 250 SX KTM
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 125 SX 144 SX 250 SX OWNER’S MANUAL 2008 3211225en *3211225en* 3211225en.
ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer All information contained is without obligation.
ENGLISH 2 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.
ENGLISH 3 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.
ENGLISH 4 TABLE OF CONTENTS » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS .
ENGLISH 5 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.
ENGLISH 6 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. Filler cap T o open it: Press the release button [2] and turn the tank cap in a coun- terclockwise direction.
ENGLISH 7 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 . OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the left side of the engine.
ENGLISH 8 Damping action during compression of shock absorber The shock absorber on the SX models can synchronize the compression damp- ing in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle.
ENGLISH 9 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for your first ride – Make sure the work for the "pre-delivery inspection" was per- formed by your authorized KTM workshop. The DELIVERY CER- TIFICA TE and SERVICE MANUAL will be handed over when you pick up your vehicle.
ENGLISH 10 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.
ENGLISH 11 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 .
ENGLISH 12 DRIVING INSTRUCTIONS » Shifting/Riding Y ou are now in first gear , referred to as the drive or uphill gear . Depending on the conditions (hill size, etc.), you can shift to a higher gear . T urn down the throttle, at the same time pull the clutch lever in and shift to the next higher gear .
ENGLISH 13 PERIODIC MAINTENANCE SCHEDULE » 125/144/250 SX 2008 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY Before each race 1st service after 10 hours every 20 hours every 40 hou.
ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE » 125/144/250 SX 2008 IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOP UNDER A SEPARATE ORDER Every 20 hours Every 40 hours Every 6.
ENGLISH 15 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.
ENGLISH 16 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o 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.
ENGLISH 17 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.
ENGLISH 18 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.
ENGLISH 19 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 . T ighten 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.
ENGLISH 20 Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The dis- tance between the chain and the swing arm should be approx.
ENGLISH 21 MAINTENANCE WORK ON CHASSIS AND ENGINE » Chain maintenance For a long chain life, good maintenance is very important. Chains without X-rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (e.
ENGLISH 22 General information about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series use a „floating“ mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to ”float” for maximum braking contact.
ENGLISH 23 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw [1] .
ENGLISH 24 Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips [1] and pull out bolt [2] . Remove brake pads from the brake caliper . Clean the brake caliper and the brake caliper support with compressed air .
ENGLISH 25 Changing the basic position of the foot brake pedal * T o change the basic position of the foot brake lever , loosen the counternut [1] and turn the stop screw [2] as needed.
ENGLISH 26 Before remounting the front wheel, clean and grease the shaft seal rings [A] and the bearing surface [B] of the distance bushings and mount the distance bushing. T o install the front wheel, lift it into the fork, position and mount the axle shaft [3] .
ENGLISH 27 Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Remove the collar nut [1] , remove the chain tensioner [2] and pull out the wheel spindle [3] until you can push the rear wheel forwards.
ENGLISH 28 Cooling system The water pump [1] in the engine circulates the cooling liquid. The cooling liquid is cooled by the air stream. This means that the cooling effect decreases with the traveling speed. Dirty radiators additionally reduce the cooling effect.
ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Bleeding the cooling system By removing the screw [1] at the water pump cover you can drain the coolant. T o bleed the cooling system, add coolant up to approx. 10 mm above the radi- ator fins when the engine is cold.
ENGLISH 30 Changing the original position of the clutch lever The adjusting screw [4] can be used for individual adjustment of the original position of the clutch lever , thus allowing adjustment to an optimal position for every hand size.
ENGLISH 31 Bleeding the hydraulic clutch * The clutch control needs to be bled as soon as the resistance in the clutch lever starts to feel unresponsive. Y ou will need to use a bleeding syringe (spe- cial tool). Make sure to use Motorex clutch fluid 75 for the 125/144 SX models and Motorex DOT .
ENGLISH 32 Carburetor adjustment * Basic information on the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20° C (68° F), mainly for off-road use and central European premium-grade fuel (95 ROZ).
ENGLISH 33 Draining the float chamber of the carburetor Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. W ater in the float chamber leads to engine malfunction.
ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the engine characteristic via the ignition curve (125/144/250) 2 ignition curves (PERFORMANCE and SOFT) are stored in the digital box. The PERFORMANCE ignition curve is activated in the condition at delivery .
ENGLISH 35 Check transmission oil level (125/144 SX) In order to check the transmission oil level the control screw [1] on the clutch cover is to be removed. Oil should just barely escape from the inspection open- ing when the motorcycle is in an upright position.
ENGLISH 36 CLEANING » CONSERVATION FOR WINTER OPERATION » STORAGE » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.
ENGLISH 37 TECHNICAL SPECIFICATIONS – CHASSIS 125/144/250 SX 2008 » CHASSIS 125 SX 144 SX 250 SX Frame Central chrome-moly-steel frame Fork WP – Up Side Down 4860 MXMA CC (Multi Adjuster Closed Cartridge) Wheel travel front/rear 300/335 mm (11.8/13.
ENGLISH 38 TECHNICAL SPECIFICATIONS – CHASSIS 125/144/250 SX 2008 » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Colear screws brake caliper , front M8 (10.9) Loctite 243 + 25 Nm Collar screws brake disks M6 (10.9) 14 Nm Clamping screws, upper fork bridge M8 (10.
ENGLISH 39 TECHNICAL SPECIFICATIONS – ENGINE 125/144/250 SX 2008 » ENGINE 125 SX 144 SX 250 SX Design Liquid-cooled, single-cylinder , two-stroke engine with intake and exhaust control Piston displacement 124.8 ccm 143.6 ccm 249 ccm Bore / stroke 54 / 54.
ENGLISH 40 TECHNICAL SPECIFICATIONS – ENGINE 125/144/250 SX 2008 » TIGHTENING TORQUES - ENGINE Flange bolts - cylinder -head (125/144 SX) M7 18 Nm Flange bolts - cylinder -head (250 SX) M8 27 Nm Nu.
ENGLISH 41 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 39 125 SX 2007 / 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C bis 5°C 19°F to 41°F 6°C bis .
ENGLISH 42 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK 39 144 SX 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C bis 5°C 19°F to 41°F 6°C bis 15°C 4.
ENGLISH 43 VERGASERREGULIERUNG CARBURETOR SETTING KEIHIN PWK-S 36 AG 250 SX 2008 MEERESHÖHE ALTITUDE TEMPERATUR TEMPERATURE - 20°C bis -7°C -2°F to 20°F - 6°C bis 5°C 19°F to 41°F 6°C bis 15.
ENGLISH 44 SCHALTPLAN » WIRING DIAGRAMM » 8 0 0 2 - 7 0 0 2 X S 0 5 2 , 4 4 1 , 5 2 1 l i o c n o i t i n g i n o t t u b p o t s G 3 r o t a r e n e g p u k c i p C D I 0 0 3 .
ENGLISH 45 SCHALTPLAN » WIRING DIAGRAMM » ENGLISH DEUTSCH IT ALIANO CABLE COLOURS KABELF ARBEN CAVO COLORA TO bl: black bl: schwarz bl: nero ye: yellow ye: gelb ye: giallo bu: blue bu: blau bu: blu .
INDEX » Page Adapting the chain guide . . . . . . . . . . . . . . . . . . . . .20 Adjusting the engine characteristic via the ignition curve . .34 Adjusting the engine characteristic via the auxiliary spring .34 Adjusting the free travel at the hand brake lever .
KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.com KTM Group Partner 4/2007 FOTO: MITTERBAUER 125 SX 144 SX 250 SX OWNER’S MANUAL 2008 3211225en *3211225en* 3211225en.
An important point after buying a device KTM 250 SX (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 250 SX yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 250 SX - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 250 SX you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 250 SX will certainly help you make a decision on the purchase.
If you already are a holder of KTM 250 SX, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 250 SX.
However, one of the most important roles played by the user manual is to help in solving problems with KTM 250 SX. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 250 SX along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
