KTM 125 XC 2022 (01) PDF Document

The manual for the KTM 125 XC 2022 uses the following degrees of risk and symbols:

Danger: Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning: Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution: Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note: Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note: Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

Danger of accidents: A rider who is not fit to ride poses a danger to him or herself and others.

• Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

• Do not operate the vehicle if you are physically or mentally impaired.

Danger of poisoning: Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

• Always make sure there is sufficient ventilation when running the engine.

• Use effective exhaust extraction when starting or running the engine in an enclosed space.

Danger of burns: Some vehicle components become very hot when the vehicle is operated.

• Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

• Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.

Missing or poor protective clothing presents an increased safety risk.

• Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

• Always wear protective clothing that is in good condition and meets the legal regulations.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

Clutch lever: Fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically.

Hand brake lever: Fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

Throttle grip: Fitted on the right side of the handlebar.

Stop button: Fitted on the left side of the handlebar.

• Basic position: The ignition circuit is closed and the engine can be started.

• Pressed: The ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

Start button (125 XC US): Fitted on the right side of the handlebar.

• Basic position: The starter motor is not active.

• Pressed: The starter motor is actuated.

Opening the cap (125 XC US):

1. Press the release button.

2. Turn the fuel tank filler cap counterclockwise and lift it off.

Closing the cap (125 XC US):

1. Mount the filler cap and turn it clockwise until the release button engages.

2. Ensure the fuel tank breather hose is routed without kinks.

The fuel tap is on the left side of the fuel tank. Use the tap handle to open or close the fuel supply.

Possible states (125 XC US):

• OFF: Fuel supply is closed. Fuel cannot flow from the fuel tank to the carburetor.

• ON: Fuel supply is open. Fuel can flow from the fuel tank to the carburetor until the reserve level is reached.

• RES: Fuel reserve supply is open. Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.

The choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor, allowing the engine to draw extra fuel for a richer fuel-air mixture needed for a cold start. If the engine is warm, the choke function must be deactivated.

Possible states:

• Choke function activated: The choke lever is pulled out to the stop.

• Choke function deactivated: The choke lever is pushed in to the stop.

During the running-in phase, do not exceed the specified engine performance. Avoid fully opening the throttle.

Use of the vehicle under difficult conditions can result in significantly increased wear. It may be necessary to inspect or replace parts before the next scheduled service.

General Preparation:

• Prepare the air filter box cover for securing.

• Clean the air filter and air filter box. Check the air filter approx. every 30 minutes.

• Check the electrical connector for humidity and corrosion.

For Riding on Dry Sand:

• Check the radiator cap. The value should be 1.8 bar (26 psi).

• Mount the air filter dust cover (79006920000).

• Mount the air filter sand cover (79006922000).

• Adjust the carburetor jetting and setting.

• Clean the chain and grease it.

• Mount a steel sprocket.

• Clean and straighten radiator fins.

• Change the piston every 10 operating hours of regular use in sand.

For Riding on Wet Sand or Wet and Muddy Circuits:

• Check the radiator cap. The value should be 1.8 bar (26 psi).

• Mount the air filter rain cover (79006921000).

• Adjust the carburetor jetting and setting.

• Clean the chain and grease it.

• Mount a steel sprocket.

• Clean and straighten radiator fins.

• Clean the motorcycle after riding.

Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated.

• Check the gear oil level.

• Check the front and rear brake fluid levels.

• Check the front and rear brake linings.

• Check that the brake system is functioning properly.

• Check the coolant level.

• Check the chain for dirt, tension, and wear on the sprockets and guide.

• Check the tire condition and pressure.

• Check the spoke tension.

• Clean the dust boots of the fork legs.

• Bleed the fork legs.

• Check the air filter.

• Check the settings of all controls and ensure they can be operated smoothly.

• Check all screws, nuts, and hose clamps for tightness.

• Check the fuel level.

Always run the engine warm at a low speed, as high revving with a cold engine negatively impacts its lifespan.

If the motorcycle has been out of use for more than 1 week:

• Empty the carburetor float chamber to remove old fuel.

Starting Procedure (125 XC US):

1. Turn the tap handle of the fuel tap to the ON position.

2. Take the motorcycle off the side stand and secure the stand with the rubber strap.

3. Shift the transmission into neutral.

4. If the engine is cold, pull the choke lever out as far as possible.

5. Press the start button or press the kick starter lever forcefully all the way. Do not open the throttle.

Shifting and Riding:

• First gear is for starting off and for steep inclines.

• To shift up, release the throttle, pull the clutch lever, shift into the next gear, release the clutch lever, and open the throttle.

• Deactivate the choke function after the engine has warmed up.

• To shift down, apply the brakes and close the throttle. Pull the clutch lever, shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.

• Avoid changing into a low gear at high engine speed, as this can cause the rear wheel to block.

• Avoid frequent or lengthy slipping of the clutch.

Applying the Brakes:

• Excessively forceful application of the brakes can block the wheels. Adjust brake application to the riding situation and surface.

• On sandy, wet, or slippery surfaces, use the rear brake mostly if possible.

• Always finish braking before you go into a bend.

• If moisture and dirt impair the brake system, brake carefully several times to dry out and remove dirt from the brake linings and discs.

• Use the braking effect of the engine on long downhill stretches by changing down one or two gears.

Stopping and Parking:

1. Park the vehicle on a firm and level surface.

2. Apply the brakes.

3. Shift the transmission to neutral.

4. Press and hold the stop button until the engine stops.

5. Turn the tap handle of the fuel tap to the OFF position.

6. Rest the vehicle on the side stand.

Transporting:

1. Switch off the engine.

2. Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

1. Switch off the engine.

2. Open the fuel tank filler cap.

3. Fill the fuel tank with fuel up to the specified measurement.

4. Close the fuel tank filler cap.

The following table outlines the required service tasks. (● = Periodic interval, ○ = One-time interval)

The shock absorber on your KTM 125 XC 2022 has adjustments for low-speed compression, high-speed compression, and rebound damping. Turn clockwise to increase damping and counterclockwise to reduce damping.

Adjusting Low-Speed Compression Damping:

1. Turn the adjusting screw clockwise as far as the last perceptible click.

2. Turn counterclockwise by the number of clicks for your desired setting.

Adjusting High-Speed Compression Damping:

1. Turn the adjusting screw all the way clockwise with a socket wrench.

2. Turn counterclockwise by the number of turns for your desired setting.

Adjusting Rebound Damping:

1. Turn the adjusting screw clockwise up to the last perceptible click.

2. Turn counterclockwise by the number of clicks for your desired setting.

Checking Static Sag:

1. Raise the motorcycle with a lift stand so the rear wheel is off the ground. Measure the distance from the rear axle to a marking on the rear fender (Dimension A).

2. With an assistant holding the motorcycle upright, measure the distance again between the same two points (Dimension B).

3. The static sag is the difference between Dimension A and Dimension B. The target value is 35 mm (1.38 in). If the value is incorrect, adjust the spring preload.

Checking Riding Sag:

1. Measure Dimension A as described above.

2. With the rider in full protective clothing sitting in a normal riding position (feet on footrests), have another person measure the distance again between the same two points (Dimension C).

3. The riding sag is the difference between Dimension A and Dimension C. The target value is 105 mm (4.13 in). If the sag differs, adjust it by changing the spring preload or using a different spring.

Adjusting Spring Preload:

1. Remove the shock absorber.

2. Loosen the screw on the adjusting ring.

3. Turn the adjusting ring to increase or decrease the spring preload. The standard spring preload is 7 mm (0.28 in).

4. Tighten the screw on the adjusting ring.

The WP Suspension XACT 5448 fork uses air suspension in the left fork leg and damping in the right fork leg.

Adjusting Fork Air Pressure:

1. Raise the motorcycle with a lift stand.

2. Remove the protection cap from the left fork leg.

3. Connect the fork airpump (included accessory) to the valve.

4. Adjust the air pressure as specified. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting Compression Damping:

1. Turn the adjusting screw at the upper end of the right fork leg clockwise all the way.

2. Turn counterclockwise by the number of clicks for your desired setting.

Adjusting Rebound Damping:

1. Turn the adjusting screw at the lower end of the right fork leg clockwise all the way.

2. Turn counterclockwise by the number of clicks for your desired setting.

Bleeding the Fork Legs:

1. Raise the motorcycle on a lift stand.

2. Release the bleeder screws on top of the fork legs to let any excess pressure escape.

3. Tighten the bleeder screws.

Cleaning the Dust Boots of the Fork Legs:

1. Raise the motorcycle on a lift stand and remove the fork protector.

2. Push the dust boots of both fork legs downward.

3. Clean and oil the dust boots and inner fork tubes of both fork legs using universal oil spray.

4. Press the dust boots back into their normal position and remove excess oil.

5. Install the fork protector.

1. Remove the air filter box cover and then remove the air filter.

2. Wash the air filter thoroughly in a special cleaning liquid (air filter cleaner) and allow it to dry properly. Only press the air filter to dry it; never wring it out.

3. Oil the dry air filter with a high-grade air filter oil.

4. Clean the air filter box and the intake flange, checking for damage and tightness.

5. Install the clean air filter and then the air filter box cover.

Checking the Chain Tension:

1. Raise the motorcycle on a lift stand.

2. Shift the transmission into neutral.

3. Pull the chain upward at the end of the chain sliding piece.

4. Measure the distance between the chain and the swingarm. The lower chain section must be taut. The chain tension should be 55 to 58 mm (2.17 to 2.28 in).

Adjusting the Chain Tension:

1. Loosen the rear wheel spindle nut.

2. Loosen the lock nuts on the adjusting screws on both sides of the swingarm.

3. Turn the adjusting screws left and right to set the correct chain tension. Ensure the markings on the left and right chain adjusters are in the same position relative to the reference marks for proper wheel alignment.

4. Tighten the lock nuts on the adjusting screws.

5. Tighten the rear wheel spindle nut to 80 Nm (59 lbf ft).

Removing the 12-V battery:

1. Remove the seat.

2. Disconnect the negative cable from the 12-V battery.

3. Pull back the positive terminal cover and disconnect the positive cable.

4. Remove the screw from the holding bracket.

5. Pull the holding bracket forward and remove the 12-V battery upwards.

Installing the 12-V battery:

1. Position the 12-V battery in the battery compartment with the terminals facing forward and secure it with the holding bracket.

2. Mount and tighten the screw for the holding bracket.

3. Connect the positive cable to the 12-V battery. Tighten the screw to 2.5 Nm (1.84 lbf ft).

4. Slide the positive terminal cover over the positive terminal.

5. Connect the negative cable to the 12-V battery. Tighten the screw to 2.5 Nm (1.84 lbf ft).

6. Mount the seat.

The main fuse is located in the starter relay housing under the seat.

1. Remove the seat.

2. Pull the starter relay from its holder.

3. Take off the protection caps.

4. Remove the faulty main fuse. A spare fuse is located in the starter relay.

5. Insert a new 10 A main fuse.

6. Check that the electrical system is functioning properly.

7. Mount the protection caps.

8. Mount the starter relay onto the holder and route the cable.

9. Mount the seat.

Checking the Gear Oil Level (Engine Cold):

1. Stand the motorcycle upright on a horizontal surface.

2. Remove the gear oil level monitoring screw.

3. A small quantity of gear oil should run out of the drilled hole. If no oil runs out, add gear oil.

4. Mount and tighten the monitoring screw to 8 Nm (5.9 lbf ft).

Changing the Gear Oil (Engine at Operating Temperature):

1. Park the motorcycle on a level surface and position a container under the engine.

2. Remove the gear oil drain plug with the magnet and the second gear oil drain plug.

3. Let the gear oil drain completely.

4. Clean the drain plugs and sealing surfaces.

5. Mount and tighten the drain plug with the magnet to 20 Nm (14.8 lbf ft) and the second drain plug to 15 Nm (11.1 lbf ft), using new seal rings.

6. Remove the filler plug and fill with 0.80 L (0.85 qt.) of Engine oil (15W/50).

7. Mount the filler plug with its O-ring.

8. Start the engine, check for leaks, and then re-check the oil level.

1. Close off the exhaust system to keep water from entering.

2. Remove coarse dirt particles with a gentle water jet.

3. Spray heavily soiled parts with a commercial motorcycle cleaner and clean with a brush.

4. Rinse the motorcycle with a gentle spray of water and allow it to dry thoroughly.

5. Empty the carburetor float chamber.

6. Remove the closure from the exhaust system.

7. Ride the vehicle a short distance until the engine warms up to evaporate water from inaccessible locations.

8. After the motorcycle has cooled, lubricate all moving parts and pivot points.

9. Clean the chain.

10. Treat bare metal (except brake discs and exhaust) with a corrosion inhibitor.

11. Treat all plastic and powder-coated parts with a mild cleaning and care product.

1. When refueling for the last time, add fuel additive.

2. Refuel the vehicle.

3. Clean the motorcycle.

4. Change the gear oil.

5. Check the antifreeze and coolant level.

6. Empty the carburetor float chamber.

7. Check the tire pressure.

8. Store the vehicle in a dry location that is not subject to large temperature fluctuations.

9. Raise the motorcycle with a lift stand.

10. Cover the vehicle with a permeable tarp or similar cover. Do not use non-porous materials.

If the engine turns over but fails to start, check the following possible causes:

If you experience a lack of power, consider these potential issues:

The following table provides standard carburetor tuning settings for the MIKUNI TMX 38 on your KTM 125 XC 2022. Adjustments may be needed for specific conditions.

Legend: ASL=Altitude, ASO=Idle air screw open, IJ=Idling jet, NDL=Needle, POS=Needle position, MJ=Main jet