KTM 144 SX manual

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. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,[...]

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. THE SX MODELS ARE PROHIBITED ON PUBLIC ROADS. OWNER?[...]

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. The fuels and lubricants specified in the Owner's Manual or automotive fluids with equivalent specifications m[...]

ENGLISH 4 TABLE OF CONTENTS » Page SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . .5 OPERA TION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .5 Clutch lever . . . . . . . . . . . . . . [...]

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. Enter this number on page 1. Clutch lever[...]

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. T o close it: Put the tank cap back on and turn in a clockwi[...]

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. Its upper part can be swivelled. Foot brake pe[...]

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. The low and hi[...]

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. – Thoroughly read the whole instru[...]

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. The following checks should be performed: 1 CHECK TRANSMISSION OIL LEVEL T oo little [...]

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 . – For starting always put on your motorcycle boots to avoid injuries. Y ou could slip off the ki[...]

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 . Let the clutch lever go again and open the th[...]

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 hours at least once a year ENGINE Check gear box oil level z Change gear box oil z z z z Check spark plugs, adjust distance between electrodes z z Renew [...]

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 60 hours Every 80 hours At least once a year Every 2 years Clean and adjust carburetor z Replace the throttle slide, jet needle, float needle valve, ne[...]

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. – If using a pow[...]

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. At delivery , KTM's offroad motorcycle[...]

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. However , if your tele- scopic fork bumps[...]

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. If the mark [B] is in front, the offset is 18 mm. This setting [...]

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. Adjust the st[...]

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. 8 - 10 mm (0.31 - 0.39 in). In the course of this procedure, the upper chain portion [A] must b[...]

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.g. Motorex Chainlube 622).. No lubrication is allowed to reach the rear tire or the brake d[...]

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.Secure the screws of the caliper support with Loctite 243 and tighten to [...]

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] . In this way , the position of the point of pressure (i.e. the resis-tance you feel on the hand brake lever when the brake pads are pressed against the brake disc[...]

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 . Check the sleeves of the guide bolts for damage, and[...]

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. Be sure to adjust the free travel of the foot brake lever . Measured on the outside, the foot brake lever should have 3-5 mm free travel before the piston rod moves[...]

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] . Mount the collar nut [1] , tighten the clamping screws [2] on the right fork leg axle[...]

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. T ake the chain off the rear sprocket, pull out the wheel spindle and ca[...]

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. Pressure induced by heating of the coolant in the system is controlled by a valve in [...]

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. After a short ride, check the coolant level once more. 1 1 2 2 3 4 3 Cleaning t[...]

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. The clutch lever moves closer to the handlebar if the adjusting screw is turned in a counterclockwise directio[...]

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 . 5.1 brake fluid for the 250 SX models. Both are avai[...]

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). Mixing ratio (2-stroke[...]

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. Make sure you do this while the engine is cold. Close the fuel tap, and place a [...]

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 . The SOFT ignition curve can easily be activated by disconnecting the socket c[...]

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. If necessary , remove the plug [2] and top up with oil (e. g. Motorex T op Speed 4T 1[...]

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. The hard dirt can be removed before washing with the help of a soft wa[...]

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 (11.8/13.2 in) Rear suspension WP PDS 5018 DCC (Progressive Damping System) Front brake Disc brake with c[...]

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 (10.9) 17 Nm Clamping screws, lower fork bridge M8 (1[...]

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 / 54.5 mm 54 / 58.4 mm 66.4 / 72 mm Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91[...]

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 Nuts-cylinder base (125/144 SX) M8 30 Nm Nuts-cylinder base (250 SX) M10 35 Nm Flywheel collar nut M12x1 60 Nm Nut for primary sprocket (125/144 SX) M16[...]

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 15°C 42°F to 60°F 16°C bis 24°C 61 °F to 78°F 25°C bis 36°C 79°F to 98°F 37°C bis 49°C 99°F to 120°F 3000 m 10000 ft 2301 m 7501 ft LSO[...]

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 42°F to 60°F 16°C bis 24°C 61 °F to 78°F 25°C bis 36°C 79°F to 98°F 37°C bis 49°C 99°F to 120°F 3000 m 10000 ft 2301 m 7501 ft LSO ASO LD[...]

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°C 42°F to 60°F 16°C bis 24°C 61 °F to 78°F 25°C bis 36°C 79°F to 98°F 37°C bis 49°C 99°F to 120°F 3000 m 10000 ft 2301 m 7501 ft LSO A[...]

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 . 2 3 0 . 9 3 . 8 4 5 s s e n r a h I D C r o t c e l e s e v r u c n o i t i n g i red-white red-black e t i h w - e u l b n w o r b k c a l b - w o l l e y k c a l b gree[...]

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 gr: green gr: grün gr: verde re: red re: rot re: rosso wh: white wh: weiß wh: bianco br: brown br: braun br: marrone or: orange or: orange or: aranc[...]

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 . . . . .23 Basic suspension setup for the weight of the driver . . .16 Bleeding the co[...]

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[...]