2012r 125-150 Repair manual.pdf

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REPAIR MANUAL
2012
125 SX
150 SX
150 XC USA
Art. no. 3206131en
INTRODUCTION
Read this repair manual carefully and thoroughly before beginning work.
INTRODUCTION
1
This vehicle can only fulfill the demands placed on it in the long run if the specified service work is performed regularly by qualified
experts.
The repair manual was written to correspond to the most current state of this model 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 repair work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, 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 spe-
cial equipment that does not belong to the regular scope of supply.
© 2013 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
2
Installing the lower triple clamp .......................
Checking the play of the steering head
bearing ..........................................................
6.35 Adjusting the play of the steering head
bearing ..........................................................
7
HANDLEBAR, CONTROLS...........................................
7.1
Handlebar position..........................................
7.2
Adjusting the handlebar position ......................
7.3
Adjusting the basic position of the clutch
lever ..............................................................
7.4
Checking the throttle cable routing ...................
7.5
Checking the play in the throttle cable ..............
7.6
Adjusting the play in the throttle cable..............
8
SHOCK ABSORBER, SWINGARM ................................
8.1
Adjusting the high-speed compression
damping of the shock absorber.........................
8.2
Adjusting the low-speed compression damping
of the shock absorber ......................................
8.3
Adjusting the rebound damping of the shock
absorber.........................................................
8.4
Measuring the sag of the unloaded rear wheel....
8.5
Checking the static sag of the shock absorber ....
8.6
Checking the riding sag of the shock absorber....
8.7
Adjusting the spring preload of the shock
absorber.........................................................
8.8
Adjusting the riding sag ...................................
8.9
Removing the shock absorber ...........................
8.10 Installing the shock absorber............................
8.11 Servicing the shock absorber............................
8.12 Removing the spring........................................
8.13 Disassembling the damper ...............................
8.14 Disassembling the piston rod ...........................
8.15 Disassembling the seal ring retainer..................
8.16 Changing the pilot bushing ..............................
8.17 Checking the damper ......................................
8.18 Removing the heim joint..................................
8.19 Installing the heim joint...................................
8.20 Assembling the seal ring retainer ......................
8.21 Assembling the piston rod................................
8.22 Assembling the damper ...................................
8.23 Bleeding and filling the damper .......................
8.24 Filling the damper with nitrogen .......................
8.25 Installing the spring (All SX models) .................
8.26 Installing the spring (150 XC USA) ...................
9
EXHAUST ..................................................................
9.1
Removing the main silencer .............................
9.2
Installing the main silencer..............................
9.3
Changing the glass fiber yarn filling of the
main silencer..................................................
10 AIR FILTER ...............................................................
10.1 Removing the air filter box lid ..........................
10.2 Installing the air filter box lid ...........................
10.3 Removing the air filter .....................................
10.4 Installing the air filter......................................
10.5 Cleaning the air filter and air filter box ..............
10.6 Sealing the air filter box ..................................
11 FUEL TANK, SEAT, TRIM ...........................................
11.1 Opening the filler cap......................................
11.2 Closing the filler cap .......................................
11.3 Removing the seat ..........................................
11.4 Mounting the seat ...........................................
11.5 Removing the fuel tank....................................
6.33
6.34
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MEANS OF REPRESENTATION ..................................... 6
1.1
Symbols used ................................................... 6
1.2
Formats used.................................................... 6
SAFETY ADVICE........................................................... 7
2.1
Repair Manual .................................................. 7
2.2
Safety advice.................................................... 7
2.3
Degrees of risk and symbols ............................... 7
2.4
Work rules........................................................ 7
IMPORTANT INFORMATION ......................................... 8
3.1
Guarantee, warranty .......................................... 8
3.2
Operating and auxiliary substances ..................... 8
3.3
Spare parts, accessories .................................... 8
3.4
Figures ............................................................ 8
SERIAL NUMBERS ...................................................... 9
4.1
Chassis number ................................................ 9
4.2
Type label ........................................................ 9
4.3
Engine number ................................................. 9
4.4
Fork part number .............................................. 9
4.5
Shock absorber part number .............................. 9
MOTORCYCLE ........................................................... 10
5.1
Raising the motorcycle with the lift stand.......... 10
5.2
Removing the motorcycle from the lift stand...... 10
5.3
Starting.......................................................... 10
5.4
Starting the motorcycle for checking ................. 11
FORK, TRIPLE CLAMP ............................................... 12
6.1
Adjusting the compression damping of the
fork ............................................................... 12
6.2
Adjusting the rebound damping of the fork ........ 12
6.3
Bleeding the fork legs...................................... 13
6.4
Cleaning the dust boots of the fork legs............. 13
6.5
Loosening the fork protection ........................... 13
6.6
Positioning the fork protection.......................... 14
6.7
Removing the fork legs .................................... 14
6.8
Installing the fork legs ..................................... 14
6.9
Removing the fork protector ............................. 15
6.10 Installing the fork protector.............................. 15
6.11 Conducting major fork service .......................... 15
6.12 Conducting minor fork service .......................... 16
6.13 Disassembling the fork legs.............................. 16
6.14 Disassembling the cartridge ............................. 19
6.15 Disassembling the piston rod ........................... 21
6.16 Disassembling the screw cap with the
membrane holder............................................ 22
6.17 Disassembling the screw sleeve ........................ 23
6.18 Checking the fork legs (All SX models) .............. 24
6.19 Checking the fork legs (150 XC USA)................ 25
6.20 Checking the fork legs - during a minor fork
service (All SX models) .................................... 27
6.21 Checking the fork legs - during a minor fork
service (150 XC USA)...................................... 28
6.22 Changing the pilot bushing .............................. 29
6.23 Assembling the screw sleeve ............................ 30
6.24 Assembling the screw cap with the membrane
holder ............................................................ 30
6.25 Assembling the piston rod................................ 31
6.26 Assembling the cartridge ................................. 32
6.27 Assembling the fork legs (All SX models)........... 34
6.28 Assembling the fork legs (150 XC USA) ............ 37
6.29 Bleeding and filling the cartridge...................... 41
6.30 Filling the cartridge with nitrogen ..................... 42
6.31 Greasing the steering head bearing ................... 43
6.32 Removing the lower triple clamp....................... 43
TABLE OF CONTENTS
12
11.6 Installing the fuel tank .................................... 77
MASK, FENDER......................................................... 78
12.1 Removing the front fender ............................... 78
12.2 Installing the front fender ................................ 78
12.3 Removing the start number plate ...................... 78
12.4 Installing the start number plate....................... 78
WHEELS ................................................................... 79
13.1 Checking the tire air pressure........................... 79
13.2 Checking the tire condition .............................. 79
13.3 Checking the brake discs ................................. 79
13.4 Checking the spoke tension.............................. 80
13.5 Front wheel .................................................... 80
13.5.1
Removing the front wheel ............................ 80
13.5.2
Installing the front wheel ............................. 81
13.5.3
Removing the brake disc of the front brake.... 82
13.5.4
Installing the brake disc of the front brake .... 82
13.6 Rear wheel ..................................................... 82
13.6.1
Removing the rear wheel ............................. 82
13.6.2
Installing the rear wheel .............................. 83
13.6.3
Removing the brake disc of the rear brake ..... 84
13.6.4
Installing the brake disc of the rear brake...... 84
13.6.5
Checking the chain for dirt .......................... 84
13.6.6
Cleaning the chain ...................................... 85
13.6.7
Checking the chain tension.......................... 85
13.6.8
Checking the chain, rear sprocket, engine
sprocket and chain guide............................. 85
13.6.9
Adjusting the chain tension ......................... 87
13.6.10 Adjusting the chain guide ............................ 88
WIRING HARNESS..................................................... 89
14.1 Plug-in connection, ignition timing map ............ 89
14.2 Checking the capacitor .................................... 89
BRAKE SYSTEM ........................................................ 90
15.1 Checking the front brake linings ....................... 90
15.2 Changing the front brake linings ....................... 90
15.3 Checking the free travel of the hand brake
lever .............................................................. 92
15.4 Adjusting the basic position of the hand brake
lever .............................................................. 92
15.5 Checking the front brake fluid level .................. 92
15.6 Adding front brake fluid................................... 93
15.7 Changing the front brake fluid .......................... 93
15.8 Checking the rear brake linings ........................ 94
15.9 Changing the rear brake linings ........................ 95
15.10 Checking the free travel of foot brake lever ........ 96
15.11 Adjusting the basic position of the foot brake
lever .............................................................. 96
15.12 Checking the rear brake fluid level.................... 97
15.13 Adding brake fluid for the rear brake................. 97
15.14 Changing the rear brake fluid ........................... 98
ENGINE .................................................................... 99
16.1 Removing the engine....................................... 99
16.2 Installing the engine...................................... 102
16.3 Engine disassembly....................................... 106
16.3.1
Clamping the engine into the engine work
stand ....................................................... 106
16.3.2
Draining the gear oil.................................. 106
16.3.3
Removing the shift lever ............................ 106
16.3.4
Removing the engine sprocket.................... 107
16.3.5
Removing the clutch push rod.................... 107
16.3.6
Removing the spacer................................. 107
16.3.7
Removing the alternator cover .................... 107
16.3.8
Removing the kick starter .......................... 108
16.3.9
Removing the cylinder head .......................
16.3.10 Removing the cylinder...............................
16.3.11 Removing the piston .................................
16.3.12 Removing the water pump cover.................
16.3.13 Removing the clutch cover.........................
16.3.14 Removing the clutch discs .........................
16.3.15 Removing the outer clutch hub ..................
16.3.16 Removing the primary gear ........................
16.3.17 Removing the kick starter shaft ..................
16.3.18 Removing the shift shaft............................
16.3.19 Removing the shift drum locating unit ........
16.3.20 Removing the rotor....................................
16.3.21 Removing the stator ..................................
16.3.22 Removing the reed valve housing................
16.3.23 Removing the left engine case section ........
16.3.24 Removing the shift rails.............................
16.3.25 Removing the shift drum ...........................
16.3.26 Removing the shift forks............................
16.3.27 Removing the transmission shafts...............
16.3.28 Removing the crankshaft ...........................
16.4 Work on individual parts ................................
16.4.1
Work on the right section of the engine
case ........................................................
16.4.2
Work on the left section of the engine
case ........................................................
16.4.3
Removing the crankshaft bearing inner
race.........................................................
16.4.4
Installing the crankshaft bearing inner
race.........................................................
16.4.5
Changing the connecting rod, conrod
bearing, and crank pin ..............................
16.4.6
Checking the crankshaft run-out at the
bearing pin...............................................
16.4.7
Checking/measuring the cylinder ................
16.4.8
Removing the exhaust control ....................
16.4.9
Checking the exhaust control in the
cylinder ...................................................
16.4.10 Installing the exhaust control .....................
16.4.11 Cylinder - Nikasil
®
coating .........................
16.4.12 Checking/measuring the piston...................
16.4.13 Checking the piston ring end gap ...............
16.4.14 Piston/cylinder - measuring the mounting
clearance .................................................
16.4.15 Checking the reed valve housing, reed
valve and intake flange..............................
16.4.16 Changing the water pump bearing ..............
16.4.17 Removing the exhaust control in the clutch
cover .......................................................
16.4.18 Checking the exhaust control in the clutch
cover .......................................................
16.4.19 Installing the exhaust control in the clutch
cover .......................................................
16.4.20 Checking the clutch ..................................
16.4.21 Changing the absorbing element of the
clutch......................................................
16.4.22 Preassembling the shift shaft .....................
16.4.23 Checking the shift mechanism ...................
16.4.24 Disassembling the main shaft ....................
16.4.25 Disassembling the countershaft..................
16.4.26 Checking the transmission .........................
16.4.27 Assembling the main shaft.........................
16.4.28 Assembling the countershaft ......................
16.4.29 Checking the kick starter ...........................
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