Pdf Manual Guidelib.com

2014 KTM 125 and 150 SX, XC Service Repair Manual

2014 KTM 125 and 150 SX, XC Service Repair Manual

Online PDF 2014 KTM 125 and 150 SX, XC Service Repair Manual

Read this repair manual carefully and thoroughly before beginning work, The vehicle will only be able to meet the demands placed on it if the specified service work is performed regularly and properly. This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of technical advancement without at the same time updating this repair manual.

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.

Ail specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical speciticetions, 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, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain speccial equipment that does not belong to the regular scope of supply.

10  KTM 125 and 150 SX, XC manual EXHAUST. ...  83
10.1  KTM 125 and 150 SX, XC manual Removing the manifold. .    83
10.2  KTM 125 and 150 SX, XC manual Installing the manifold. ....   83
10.3  KTM 125 and 150 SX, XC manual Removing main silencer. .... 84
10.4  KTM 125 and 150 SX, XC manual Installing the main silencer. .....  84
10.5  KTM 125 and 150 SX, XC manual Changing the glass fiber yarn filling of the main silencer. .  84

11  KTM 125 and 150 SX, XC manual
KTM 125 and 150 SX, XC manual AIR FILTER. . 86
11.1  KTM 125 and 150 SX, XC manual Removing the air filter box lid. .. 86
11.2  KTM 125 and 150 SX, XC manual Installing the air filter box lid. ... 86
11.3  KTM 125 and 150 SX, XC manual Sealing the air filter box. ..  86
11.4  KTM 125 and 150 SX, XC manual Removing the air filter. ....  86
11.5  KTM 125 and 150 SX, XC manual Installing the air filter. .  87
11.6  KTM 125 and 150 SX, XC manual Cleaning the air filter and air filter box. .  87 

12  KTM 125 and 150 SX, XC manual FUEL TANK, SEAT, TRIM. . 89
12.1  KTM 125 and 150 SX, XC manual Opening filler cap. ...   89
12.2  KTM 125 and 150 SX, XC manual Closing filler cap. ..  89
12.3  Removing the seat.  89
12.4  KTM 125 and 150 SX, XC manual Mounting the seat. .  90
12.5  KTM 125 and 150 SX, XC manual Removing the fuel tank. ..... 90
12.6  KTM 125 and 150 SX, XC manual Installing the fuel tank. ....  91
12.7  KTM 125 and 150 SX, XC manual Changing the fuel screen. .  92
12.8  KTM 125 and 150 SX, XC manual Changing the fuel filter. ..... 93
12.9  KTM 125 and 150 SX, XC manual Changing the fuel pump. ..  95
12.10  KTM 125 and 150 SX, XC manual Checking the fuel pressure.    96 

13  KTM 125 and 150 SX, XC manual MASK, FENDER.. . .. 98
13.1  KTM 125 and 150 SX, XC manual Removing the front fender. .. 98
13.2  KTM 125 and 150 SX, XC manual Installing the front fender.  98
13.3  KTM 125 and 150 SX, XC manual Removing headlight mask with headlight. .... 98
13.4  KTM 125 and 150 SX, XC manual Refitting the headlight mask with the headlight.  99

14  KTM 125 and 150 SX, XC manual WHEELS. ..  100
14.1 KTM 125 and 150 SX, XC manual Checking the tire air pressure. . 100
14.2 KTM 125 and 150 SX, XC manual Checking the tire condition. ....  100
14.3 KTM 125 and 150 SX, XC manual Checking the brake discs. .. 101
14.4 KTM 125 and 150 SX, XC manual Checking spoke tension. .  101
14.5  KTM 125 and 150 SX, XC manual Front wheel. .  102
14.5.1  KTM 125 and 150 SX, XC manual Removing the front wheel. .. 102
14.5.2  KTM 125 and 150 SX, XC manual Installing the front wheel. ...  102
14.5.3  KTM 125 and 150 SX, XC manual Removing the front brake disc. .... 103
14.5.4  KTM 125 and 150 SX, XC manual Installing the front brake disc. .... 103
14.6  KTM 125 and 150 SX, XC manual Rear wheel. .... 103
14.6.1  KTM 125 and 150 SX, XC manual Removing the rear wheel. ...  103
14.6.2  KTM 125 and 150 SX, XC manual Installing the rear wheel. ....  104
14.6.3  KTM 125 and 150 SX, XC manual Removing the rear brake disc. ..... 105
14.6.4  KTM 125 and 150 SX, XC manual Installing the rear brake disc.  105
14.6.5  KTM 125 and 150 SX, XC manual Checking the chain tension. ..  106
14.6.6  KTM 125 and 150 SX, XC manual Adjusting the chain tension. .  106
14.6.7  KTM 125 and 150 SX, XC manual Checking the chain, rear sprocket, engine sprocket and chain guide. ...  107
14.6.8  KTM 125 and 150 SX, XC manual Checking for chain dirt accumulation. ....  109
14.6.9  KTM 125 and 150 SX, XC manual Cleaning the chain. ..... 109 

15  KTM 125 and 150 SX, XC manual WIRING HARNESS, BATTERY. .... 110
15.1  KTM 125 and 150 SX, XC manual Changing the main fuse. .  110
15.2  KTM 125 and 150 SX, XC manual Changing the fuses of individual power consumers.  . Ill
15.3  KTM 125 and 150 SX, XC manual KTM 125 and 150 SX, XC manual Removing the battery. ..... 112
15.4  KTM 125 and 150 SX, XC manual Installing the battery.  112
15.5  KTM 125 and 150 SX, XC manual Checking the charging voltage. ..  113
15.6  KTM 125 and 150 SX, XC manual Checking the quiescent current.  113 

16  KTM 125 and 150 SX, XC manual BRAKE SYSTEM.   114
16.1  KTM 125 and 150 SX, XC manual Checking the front brake linings. ..... 114
16.2  KTM 125 and 150 SX, XC manual Changing the front brake linings. ..... 114
16.3  KTM 125 and 150 SX, XC manual Checking free travel of hand brake lever. ... 116
16.4  KTM 125 and 150 SX, XC manual Adjusting the basic position of the hand brake lever (XC-W). ..  116
16.5  KTM 125 and 150 SX, XC manual Adjusting free travel of hand brake lever (all EXC models). .  116
16.6  KTM 125 and 150 SX, XC manual Checking the brake fluid level of the front brake.    117
16.7 KTM 125 and 150 SX, XC manual Adding front brake fluid. .  117
16.8 KTM 125 and 150 SX, XC manual Changing the front brake fluid. ..  118
16.9 KTM 125 and 150 SX, XC manual Checking the rear brake linings.  119
16.10 KTM 125 and 150 SX, XC manual Changing the rear brake linings.  119
16.11 KTM 125 and 150 SX, XC manual Checking the free travel of foot brake lever. ..... 121
16.12  KTM 125 and 150 SX, XC manual Adjusting the basic position of the foot brake lever.    121
16.13  KTM 125 and 150 SX, XC manual Checking the rear brake fluid level. .  122
16.14  KTM 125 and 150 SX, XC manual Adding rear brake fluid. ..  122
16.15  KTM 125 and 150 SX, XC manual Changing the rear brake fluid. . 123 

17  KTM 125 and 150 SX, XC manual LIGHTING SYSTEM, INSTRUMENTS. ..  125
17.1  KTM 125 and 150 SX, XC manual Checking the headlight setting. .  125
17.2  KTM 125 and 150 SX, XC manual Adjusting the headlight range. . 125
17.3  KTM 125 and 150 SX, XC manual EXC EU/AUS/USA, XC-W. .. 125
17.3.1  KTM 125 and 150 SX, XC manual Speedometer overview. .. 125
17.3.2  KTM 125 and 150 SX, XC manual Activation and test. ..... 126
17.3.3  KTM 125 and 150 SX, XC manual Setting kilometers or miles. ..  126
17.3.4  KTM 125 and 150 SX, XC manual Adjusting the speedometer functions. ... 126
17.3.5 KTM 125 and 150 SX, XC manual Setting the clock. . 127
17.3.6 KTM 125 and 150 SX, XC manual Setting the wheel circumference. .... 127
17.3.7 KTM 125 and 150 SX, XC manual Querying lap time . .....  128
17.4  KTM 125 and 150 SX, XC manual EXC SIX DAYS. ...  128
17.4.1  KTM 125 and 150 SX, XC manual Speedometer overview. .. 128
17.4.2  KTM 125 and 150 SX, XC manual Activation and test. ..... 129
17.4.3 KTM 125 and 150 SX, XC Setting kilometers or miles. ..  129
17.4.4 KTM 125 and 150 SX, XC Setting the speedometer functions.   129
17.4.5 KTM 125 and 150 SX, XC Setting the clock. .  130
17.4.6  KTM 125 and 150 SX, XC Activating the additional functions.   130
17.4.7  KTM 125 and 150 SX, XC Setting the wheel circumference. .... 131
17.4.8  KTM 125 and 150 SX, XC Viewing the lap time. .   131 

18 KTM 125 and 150 SX, XC ENGINE. ...  133
18.1  KTM 125 and 150 SX, XC Removing the engine.  133
18.2  KTM 125 and 150 SX, XC Installing the engine. .  137
18.3  KTM 125 and 150 SX, XC Engine disassembly. ..  142
18.3.1  KTM 125 and 150 SX, XC Preparations. ..  142
18.3.2  KTM 125 and 150 SX, XC Draining the engine oil. . 142
18.3.3  KTM 125 and 150 SX, XC Removing the clutch push rod. ...  143
18.3.4  KTM 125 and 150 SX, XC Removing the oil filter. .. 143
18.3.5  KTM 125 and 150 SX, XC Removing the starter motor. ..  144
18.3.6  KTM 125 and 150 SX, XC Removing the kickstarter. ... 144
18.3.7  KTM 125 and 150 SX, XC Removing the spark plug. ... 144
18.3.8  KTM 125 and 150 SX, XC Removing the valve cover. ... 144
18.3.9  KTM 125 and 150 SX, XC Removing the alternator cover. .... 145
18.3.10  KTM 125 and 150 SX, XC Positioning the engine at ignition top dead center. . 145
18.3.11  KTM 125 and 150 SX, XC Removing the timing chain tensioner. ... 146

Managing the Vehicle Damage Repair Process
In the event that your vehicle requires damage repairs, GM recommends that you take an active role in its repair. If you have a pre-determined repair facility of choice, take your vehicle there, or have it towed there. Specify to the facility that any required replacement collision parts be original equipment parts, either new Genuine GM parts or recycled original GM parts. Remember, recycled parts will not be covered by your GM vehicle warranty.

Insurance pays the bill for the repair, but you must live with the repair. Depending on your policy limits, your insurance company may initially value the repair using aftermarket parts. Discuss this with your repair professional, and insist on Genuine GM parts. Remember if your vehicle is leased you may be obligated to have the vehicle repaired with Genuine GM parts, even if your insurance coverage does not pay the full cost.

If another party’s insurance company is paying for the repairs, you are not obligated to accept a repair valuation based on that insurance company’s collision policy repair limits, as you have no contractual limits with that company. In such cases, you can have control of the repair and parts choices as long as cost stays within reasonable limits.

Share:

Related KTM User Manuals

Popular User Manual (Show All)