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KTM 400 EXC RACING Motorcycle User Manual

1. 5 Seting tNeclock 1 2 sans ee ee Oe 12 SINTE NCVER aoo die dux d AR ee RE HORNO Cc A 14 SITO RIANNE e Sieb e o as 19 Short circuit button SX MXC 6 SIGE 44 3 8 dux a rcr GR E CR 14 Starter DURON ases des abre SEXE ate sex YE as 7 SEET ci a n Gade Sera ud Ge 19 starting when the engine is cold 19 Starting when the engine is warm 19 saw ME dox ON SR NE 14 stopping and 20 TE 51 Technical Data Chassis 55 Technical Data Engine 52 Tires air pressure 38 Troubles OOUN suc dr ta E Ca a 49 Use after a period of storage 51 What to do when the engine is flooded 19 Wiring Diagram Appendix ENGLISH dh A VLV JIA JIIONJdY DIONIddY INVHNVY multi func digital speedometer flasher control lamp bu br driving light lamp front brake switch c o right front flasher headlight OE ES left front flasher br D speed sensor vp q high low beam switch horn switch stop button BD DH EXC Racing 2005 250 450 525 ignition coil start button flasher switch start
2. CAUTION NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK IF YOU TURN THE HAN DLEBAR TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap 1 Turn the adjusting screws 2 clockwise to increase damping turn it counter clockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork Typ White Power 14187 05 22 clicks SX White Power 14187 06 20 clicks EXC MXC Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 3 REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far as It will go turn it back by as many clicks as are specified for the relevant type of fork Typ White Power 14187 05 20 clicks SX Typ White Power 14187 06 20 clicks EXC MXC Damping action during compression of shock absorber SX The shock absorber on the SX models ca
3. The steering head bearings should be regreased at least once a year e g Motorex Long Therm 2000 AND ENGIN Changing the fork offset caster SX 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 will deliver more directional stability on fast race courses If the mark B is in the rear as illustrated the offset is 20 mm This setting will deliver better handling in curves The offset is set to 20 mm in the condition at delivery To adjust the offset dismount the front wheel and remove the front wheel fender Remove the screw on the starting number plate Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the blind screw 1 from the upper triple clamp loosen the clamp screw and upper triple clamp on the seat Remove the O ring 3 and the pro tection ring 4 Tap gently on the lower triple clamp with a rubber hammer to loosen the steer ing stem 5 out of the bearing seat Take the lower
4. 2005 250 EXC RACING 400 EXC RACING 450 SX MXC EXC RACING 925 SX MXC EXC RACING OWNER 5 MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 211 39 IMPORTANT gt Please read this manual carefully and completely before going on your first ride It contains a great deal of information and advice which will help you use and handle your bike properly In your own interest please pay particular attention to notices that are marked as follows Si WARNING IGNORING THESE INSTRUCTIONS CAN DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR CYCLE S TRAFFIC SAFETY Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inopera tive by any person All information contained is without obligation
5. 925 EXC MXC RACING DESERT RACING EU AUS 12 kW Keihin FCR MX 3900B Main Jet 1 Jet needle OBDVR OBDTR OBDTP OBDVT 78 178 185 178 Idling jet 42 42 40 42 Main air jet 200 200 200 200 00 100 100 100 Idling air jet 1 Needle position 3 from top 4 from top 4 from top 3 from top starting jet 85 85 85 85 Mixture control screw open 1 25 2 0 1 0 1 25 Slide 15 15 15 15 Performance restrictor Slide stop 858 2 15 mm 858 2 15 mm 2 2 mm 858 2 15 858 2 15 Stop pump membrane Hot start device BASIC CARBURATOR SETTING 525 MXC G EXC G 925 EXC RACING 925 SX RACING RACING USA SIXDAYS Keihin FCR MX 3900B 178 OBDVT Keihin FCR MX 3900B 178 OBDTR Keihin FCR MX 4125A 185 OBDTP Type Main jet Jet needle Idling jet 42 42 42 100 100 100 Idling air jet Needle position 3 from top 5 from top 4 from top Starting jet Mixture control screw open Slide Performance restrictor 858 2 15 858 2 15 mm 858 2 15 mm 2 5 mm Stop pump membrane Hot start device TIGHTENING TORQUES Hexagon collar screw engine case clutch cover ignition cover M6 Oil drain plug M12x1 5 Allan head plug oil screen short 16 1 5 10 Nm Hexagon plug oil screen long M20x1 5 15 Nm Collar screw for oil filter cover M5 Plug pressure valve 12 1 5 Jet screw hollow screw oil line M8 Screws oil pum
6. cle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward For readjusting loosen the five pinch bolts 1 of the top triple clamp and turn steering stem bolt 2 clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly tap on the triple clamp to release tension Retighten the five pinch bolts to 15 Nm SX 20 Nm EXC MXC AN WARNING eee IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI ODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED The steering head bearings should be regreased at least once a year e g Motorex Long Therm 2000 AND ENGIN 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 distance 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 be taut see drawing necessary correct the chain tension WARNING EXCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE COMPONENTS OF THE SECONDARY DRIVETRAI
7. 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 2 0 bar 28 psi 2 0 bar 28 psi Fuel tank capacity liters 2 US gallons EXC 8 5 liters 2 1 US gallons MXC 13 Liter 3 5 gallons Final drive ratio 450 14 527 525 14 487 250 15 457 450 15 457 525 15 457 450 14 50Z 525 14 487 Chain X Ring 5 8 x 1 4 Available final sprockets 387 407 427 457 487 507 527 Bulbs headlight 12V 35 35W Sockel BA20D parking light 12V 5W Sockel W2 1x9 5d brake rear light 12V 21 5W Sockel BaY15d flasher light 12V 10W Sockel Bal5s license plate illmination 12V 1 2W Sockel 1x4 6d Battery maintenance free battery 12V 8Ah Steering head angle 63 5 Wheel base 1481 10 mm 58 3 0 4 in Seat height unloaded 925 mm 36 5 in Ground clearance unloaded 380 mm 15 1 in STANDARD ADJUSTMENT FORK STANADARD ADJUSTMENT SHOCK ABSORBER MXC MXC MXC MXC Desert EXC Desert EXC EXC G EXC G WP4860PA MA WP4860MA WP 5018 PDS WP 5018 PDS 14187A05 14187 06 DCC MCC 12187 05 12187 06 Compression adjuster 22 20 Rebound adjuster 20 20 Compression adjuster 2 Se Spring 4 6 N mm 4 2 Rebound adjuster 22 Spring preload 5 mm 5 mm Air chamber length E 2 n SAE 5 SAE 5 SE TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front 8 Loctite 243 25 Nm Brake caliper FTE radial front 10 1 25 Loctite 24
8. KTM Sportmotorcycle AG particularly reserves the right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM may stop manufactur ing certain models without previous notice KTM shall not be held liable for any deviations of availabil ity and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2004 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sport motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics even if this means that you will have to dedicate some of your valuable time to this task Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself agains
9. after every 3 hours 15 hours or or 20 fuel 100 I fuel Change engine oil short and long oil filters Clean oil screen and drain plug magnet EE Check oil lines for damage or bends Replace spark plug after 30 hours Check and adjust valve clearance Check engine mounting bolts for tightness Check carburetor connection boot for cracks and leaks Check idle speed setting Oo Check vent hoses for damage or bends Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY ENGINE CARBURETOR Check cables for damage smooth operation and bends adjust and lubricate Check fluid level of the clutch master cylinder 2 12 Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks Check function smooth operation and adjust free travel of handbrake foot brake lever ADD ON PARTS BRAKES Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean fork dust bellows ose Bleed fork legs CHASSIS Check swing arm bearings Check adjust steering
10. if your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Changing the spring preload on the telescopic fork SX models The telescopic forks of the SX models come with a preload adjuster for easy adjustment of the spring preload You can adjust the spring preload 9 mm by turning the adjusting screws basic position middle position NOTE Always turn the adjusting screws the same distance on both fork legs Different Spring preloads on the fork legs will reduce the telescopic fork s response Changing the spring preload on the telescopic fork MXC EXC models The telescopic forks for these models must be partly disassembled to adjust the spring preload see WP manual Pretension spacers are available in heights of 1 5 2 5 and 5 mm see spare parts catalog The fork springs may not be pretensioned by more than 20 mm The preload adjuster used in the SX models can easily be retrofitted for the telescopic forks of the MXC EXC models NOTE WP precisely adjusts the spring pressure by inserting pretension spacers Fluctuations in production are compensated with pretension spacers in vari ous heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and pretension spacers should always stay together Replacing fork springs If you weigh less than 70 kg or more than 80 kg yo
11. starts stops S2 no function next display mode clears S2 If the CLK LAP MAX TRI TR2 1 A2 SI and S2 figures are suddenly cleared the battery in the electronic speedometer is empty and must be replaced see Replacing the battery in the electronic speedometer A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar Filler cap To open the filler cap Turn the filler cap counter clockwise To close the filler cap Put the filler cap on and tighten it by turning it clockwise Install the tank breather hose 1 without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Reserve MXC 3 01 0 8 US gallons Reserve EXC 1 01 0 3 US gallons Choke If you pull the choke button 2 out as far as possible a bore in the carbure tor will be opened through which the engine may take in additional fuel The result is a fat fuel air mixture of
12. 15 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM AND ENGIN Basic suspension setup for the weight of the driver To 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 motorcycles are set to accommodate a driver weighing 70 80 kg wear ing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accord ingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations Checking the shock absorber and spring You can establish whether or not the shock absorber spring Is suitable for your weight by checking the riding sag The static slag must be correctly adjusted before the riding sag can be determined Determining the static sag of the shock absorber The static sag should be as close as possible to 35 mm Deviations of more than 2 mm can strongly influence the motorcycle s performance Procedure Jack up the motorcycle until the rear wheel no longer touches the ground Measure the vertical distance between the rear wheel axle and a fixed point e g a mark on the side cover and write it down as dimension A Place the motorcycle on the ground again Ask a helper to hold the mot
13. AN ELECTRIC BLOWER 4 IS OFFERED FOR MODELS WITH ELECTRIC STARTERS ASK YOUR KTM DEALER Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system CAUTION IF POSSIBLE ALWAYS CHECK THE LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP 3 WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Bleeding the cooling system By removing the screw 5 at the front end of the cylinder you can drain the coolant To bleed the cooling system fill in approx O 8 liters 0 2 US gallons of coolant and remove the bleeder screw 6 Do not reinstall the bleeder screw until coolant escapes at the bore without any bubbles Then fill in the coolant until it reaches a level about 10mm above the radiator fins After a short ride check the coolant level once more SNS AND ENGIN Replacing the glassfiber yarn packing of the silencer Aluminum silencers are filled with glassfiber yarn to muffle noise The effect of heat causes the glassfiber yarn to become loose This may lead to a loss of performance and reduce the silencer s muffling power By experience the front glass
14. BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC AND ENGIN 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 grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the Sliding metal sheet 3 in the caliper support and of the leaf spring 41 WARNING eee IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY AFTER WORKING ON THE BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK
15. C 248 F is admissible without fear of problems AN WARNING eee IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP 3 WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRES SURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS IN CASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN IN CASE COOLANT IS INGESTED CONSULT A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDI ATELY AND CONSULT DOCTOR A mixture of 50 antifreeze liquid and 50 water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION THE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQ UID OR AFTER ADDING MORE THAN 0 25 L 0 06 US GALLONS COOLING LIQUID SEE BELOW FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZE E G MOTOREX ANTI FREEZE USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING EXTREME CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVER HEATING PROBLEMS TO AVOID THIS
16. after you press the button all 10 mem ory locations are occupied To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode Up to 10 lap times can be stored in this way Changes to the next display mode lf no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped Clears all LAP figures FWltrnic wi CAC LESC ETC DE ED I LAP LAP LAP display mode to view lap times The LAP LAP display mode will only be shown if lap times have been stored and the front wheel has stopped It will display the lap number and the stopped lap time in hours minutes and seconds Press the button to access the next lap time To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode button changes to the next lap time button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode SPEED MAX display mode maximum speed MAX displays the maximum speed traveled and 15 always active button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the MAX figure SPEED TR1 display mode tripmaster 1 The TR1 tripmaster is always active and counts to 999 9 It is used to meas ure the length of a trip or the distance between 2 refueling stops 15 linked to Al average speed 1 The calculat
17. are available from your KTM dealer Turn the handlebar until the master cylinder is in a horizontal position remove the screws 2 the cover 3 and the rubber boot 4 Fill the bleeder syringe 6 with biodegradable hydraulic oil Motorex Kupplungs fluid 75 Remove the bleeder screw 5 from the slave cylinder and mount the bleeder syringe Press oil into the system until the oil runs out of the hole 7 in the master cylinder without bubbles Occasionally extract the oil from the master cylinder reservoir to keep it from overflowing After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the oil level in the reservoir and mount the cover see above CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON TROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID AND ENGIN CARBURETOR Adjust idling Keihin FCRMX 37 39 41 Idling adjustment of the carburetor strongly affects the engine s starting behavior That 15 an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2 The adjusting wheel is used to adjust the basic set ting of the slide The mixture control screw is used to control the idle mixture which arrives at the engine by
18. brake pedal 35 Changing the engine oil 47 Changing the fork offset caster SX 29 Changing the original position of the clutch lever 44 Changing the spring preload on the telescopic fork MXC EXC models 27 Changing the spring preload on the telescopic fork SX THOGGlS cinco noe Debe de Rome Lines 27 Changing the spring preloading of the shock absorber 25 Charging the battery 39 CHASSIS UTI DOE air ac ea ocn as de 5 Check chain tension 31 Check the following before each start 18 Check set distance of the magnetic sensor 38 Checking and adjusting the steering head bearing 30 Checking and adjusting the steering head bearing 28 Checking spoke tension 37 Checking the adjustment of the hand decompression release cable 43 Checking the basic setup of the telescopic fork 27 Checking the brake fluid level front brake 34 Checking the coolant level 41 Checking the engine oil level 46 Checking the float level float height 45 Checking the front brake pads 34 Checking the oil level of the hydraulic clutch 44 Checking the rear brake fluid level 35 Checking the rear brake pads 36 Checking the shock absorber and
19. fuel leaks out the carburetor may need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap In order to pump the engine free pull the hand decompres Sion lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it Clean and dry the spark plug or exchange It respectively Adjust spark plug electrode gap to 0 6 mm Dismount spark plug connect ignition cable hold to ground blank place on engine and actuate starter a strong spark must be produced at the spark plug If no spark is created replace the spark plug Ifthe new spark plug doesn t produce a spark either disconnect the spark plug connector from the ignition cable hold it a distance of approx 5 mm from ground and start Ifa spark now occurs replace spark plug cap f no spark is produced control ignition system Dismount the fuel tank disconnect the black yellow cable from the cable of the emergency OFF switch and the short circuit button respectively and check the ignition spark If a spark is generated look for the problem in the short circuit circuit Remove the seat and the fuel tank Clean the plug con nection and treat it with contact spray Dismount and clean the carburetor Engine fails to idle Glogged idling jet Incorrect adjustm
20. head bearings Check tightness of chassis screws triple clamps fork leg axle passage Check spoke tension and rim joint 2 12 Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wear fit and tension Lubricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN CARRIED OUT BY EXTRA ORDER WHEELS once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements L 2 Clean and adjust carburetor est ge ogi oa nie E Treat electric contacts and switches with contact spray I EE Change hydraulic clutch fluid Change brake fluid E IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each After every For cross start cleaning country use Check oil level e y yY O e S Check brake pads for wear Se Check horn for function PDC TS Bleed fork legs regularly Remove clean fork dust bellows regularly Clean lubricate chain check tension and adjust if necessary Clean air fi
21. in the distribution of weight If you are taking luggage with you this should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is comprised of the following components Motorcycle ready for operation and tank full Luggage Driver with protective clothing and helmet Pay attention to the running in procedure Running in the Racing models Even very precisely machined sections of engine components have rougher surfaces than components which have been slid ing across one another for quite some time Therefore every engine needs to be broken in For this reason do not load the engine more than 50 of its capacity during the first 3 operating hours Besides the engine speed must not exceed 7000 rpm Avoid going full throttle In the following 12 operating hours you may load the engine up to 75 of its capacity Use the motorcycle on various types of terrain road easy off road trails CAUTION THE 250 400 450 525 SX MXC EXC RACING MODELS WERE UNCOM PROMISINGLY DESIGNED FOR OFF ROAD COMPETITION PURPOSES ONLY ON THE ROAD APPROVED MODELS ARE ONLY ALLOWED ON PUBLIC ROADS IN THE ORIGINAL HOMOLOGATED THROTTLED VERSION AVOID EXTENDED ON ROAD RIDES AT FULL THROTTLE LS Fu 9 m WEAR SUITABLE CLOTHING WHEN DRIVING A
22. is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not drop below the middle of the glass IF THE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE SYSTEM HAS A LEAK OR THE BRAKE PADS COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reser voir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the front brake pads The brake pads can be Inspected from below The linings must be at least 1 mm 0 04 in thick WARNING OOOO AT THEIR MOST WORN POINT
23. of the clutch lever The adjusting screw 1 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 Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER TAIN LIMITS ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizontal standing master cylinder should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Kupplungs Fluid 75 Biodegradable hydraulic oil is available from your KTM dealer bOml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON TROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Bleeding of the hydraulic clutch If the clutch lever starts to feel unresponsive the clutch control system needs to be bled You will need a bleeder syringe special tool and biodegradable hydraulic oil Both
24. plug 3 at the engine bottom Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dismount the oil screen clean the components thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and tighten the plug to 10 Nm CLEANING THE LONG OIL SCREEN The long oil screen is accommodated in the hexagon plug 4 adjacent to the engine number Dismount the plug together with the oil screen clean the com ponents thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them To mount the long oil screen 5 place it on an approx 300 mm 12 in long pin type key or a similar tool Insert the pin type key through the opening into the bore of the opposite engine casing wall Then push the oil screen into the engine casing as far as possible Remove the pin type key mount the plug and tighten it to 15 Nm CAUTION THE OIL SCREEN IS MOUNTED SLIGHTLY DOWNWARDS INCORRECTLY FITTED THE SCREEN LOOSES ITS FUNCTION AND THIS CAN CAUSE INCREASED ENGINE WEAR AND ENGIN Changing the oil filters Remove the screw 1 and swing the brake fluid container sideward Place a receptacle underneath the engine to collect the drained oil Remove the 4 screws 2 and dismount the two oil filter covers Using circlip pliers pul
25. triple clamp with the steer ing stem out of the steering head Remove the collar screw from the lower triple clamp and pull out the steer ing stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp tighten the collar screw all the way to the stop WARNING PLASTIC INSERT IN THE COLLAR SCREW THREAD MAKES THE COLLAR SCREW SELF LOCKING REPLACE IF THE COLLAR SCREW CAN BE SCREWED IN BY HAND DO NOT CONFUSE THE COLLAR SCREW WITH THE BLIND SCREW THE COL LAR SCREW IS SELF LOCKING Grease the steering head bearing and sealing elements AND ENGIN Mount the lower triple clamp upper steering head bearing protection ring O ring upper triple clamp and the blind screw Tighten the collar screw on the lower triple clamp to 80 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 stages Adjust the steering head bearing without clearance see Checking and adjust ing the steering head support and tighten the clamp screws on the upper triple clamp to 15 Nm in 3 stages Mount the front wheel fender and tighten the screws to 10 Nm Mount the hand brake cylinder and tighten the screws to 10 Nm Mount the staring number plate Mount the front wheel see Dismounting and mounting the front wheel Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcy
26. tus a tr Sat anak rates 20 GT Neil OE s nonet Batata 46 Stopping parking 20 Checking the engine oil level 46 SE e ee AE Veg ech d 20 Bet ME 47 Changing the engine oil 47 PERIODIC MAINTENANCE 21 TROUBLESHOOTING uude Son eo eee 49 MAINTENANCE WORK ON CHASSIS AND ENGINE 24 Changing the spring preloading of the shock absorber 25 STORAGE s su ace sot scaena Moret de wr Nea oe gs Do o eoe 51 Eet ege Pr TT 25 Basic suspension setup for the weight of the driver 26 CONSERVATION FOR WINTER OPERATION 51 Checking the shock absorber and spring 26 USE AFTER PERIOD OF STORAGE 51 Determining the static sag of the shock absorber 26 Determining the riding sag of the shock absorber 26 CEEBNING 26 rds tato Sp NECS ERR 51 Checking the basic setup of the telescopic fork 27 Changing the spring preload on the telescopic fork TECHNICAL DATA ENGINE 52 OX models ee ies SCR Rd de 27 Changing the spring preload on the telescopic fork TECHNICAL 5515 55 MXC EXG models 3 09 Neal ie nana os 27 Replacing fork SPRINGS 2 WIRING DIAGRAM appendix Chassis number The chassis number is stamped on the right side of th
27. 3 40 Nm Clamping screws upper fork bridge EXC 8 20 Clamping screws lower fork bridge EXC 8 15 Nm Clamping screws upper fork bridge SX 8 15 Nm Clamping screws lower fork bridge SX 8 10 collar screw handlebar clamp 8 20 Allan head srew handlebar support 10 Loctite 243 40 Nm Shock absorber top M12 80 Nm Shock absorber bottom M12 80 Nm Collar nut swing arm bolt M20x1 5 M8 Sprocket Screws Loctite 243 35 Nm Ball joint for push rod Loctite 243 10 Nm Engine mounting bolt 10 60 Engine brace 33 Nm Spoke nipple 5 Nm Screw adjusting ring spring preload shock abs M6 Other screws on chassis M6 8 10 Other collar nuts on chassis 6 10 Activating and deactivating display modes 9 Adjusting the free travel at the hand brake lever 34 Adjusting the mixture control screw 45 Adjusting the throttle cables 43 Basic suspension setup for the weight of the driver 26 Battery MXC EXC 39 Bleeding of the hydraulic clutch 44 Bleeding the cooling system 41 Se ee aeons tunes 20 Breather plug front fork 28 Carburetor Adjust idling Keihin FCRMX 37 39 41 Ab Chain Maintenance ahs Derecha 32 ChalliWegr e armani REOR S eds 32 Changing the basic position of the foot
28. A2 display mode average speed 2 A2 shows the average speed based on the TR2 tripmaster 2 and S2 stop watch 2 figures The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip no function no function changes to the next display mode changes to the next display mode button button briefly press O button hold O button 3 secs SPEED 51 display mode stop watch 1 51 shows the traveling time based on TRI and continues to run whenever it receives impulses from the wheel sensor The calculation of this figure is acti vated by the first impulse received from the wheel sensor and stops 3 sec onds after the last impulse is received no function no function changes to the next display mode clears the TR1 51 Al figures button button briefly press O button hold O button 3 secs SPEED S2 display mode stop watch 2 S2 is a manual stop watch Start the stop watch by pressing the button press again to hold Press again to continue timing Press the O button to change to the next mode The S2 display will blink in the other modes if S2 continues to run in the background To stop S2 return to the SPEED S2 mode and press the button button button briefly press O button hold O button 3 secs Starts and stops the stop watch no function changes to the next display mode clears the S2 figure Kilometers or mi
29. AND THE PRESSURE POINT IS ESTABLISHED Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw 5 The free play at the foot brake pedal must then be adjusted by means of the piston rod 6 Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylin der to be recognised from the resistance on the foot brake pedal IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motor cycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked in a vertical position IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 7 Fill DOT5 1 brake fluid e g Motorex Brake Fluid DOT 5 1 up to the mark B on the inside of the reservoir and remount the screw Spilled brake fluid must be rinsed of
30. Ath Gear 5th Gear 6th Gear 22 26 22 26 22 26 22 26 24 23 24 24 24 23 22 25 21 18 Ignition system Generator Spark plug 12V 150W NGK DCPR 8 E 12V 150W 12V 150W Spark plug gap 0 6 mm 0 02367 in Cooling system Cooling liquid liquid cooled permanent rotation of cooling liquid through mechanically driven water pump 1 liter 40 antifreeze 60 water at least 25 13 F Starting equipment kick electric starter kickstarter kick electric starter kickstarter kick electric starter BASIC CARBURATOR SETTING 250 EXC RACING EU AUS 11 kW 400 EXC RACING EU AUS 12 kW 400 EXC G RACING USA 450 EXC RACING EU AUS 12 kW Main Jet Jet needle Keihin FCR MX 3700A Keihin FCR MX 3900C Keihin FCR MX 3900C Keihin FCR MX 3900A Idling jet Main air jet 200 200 200 200 Idling air jet 100 100 100 100 Needle position Starting jet 3 from top 1 from top 1 from top 3 from top Mixture control screw open Slide 15 15 15 15 Performance restrictor Slide stop Slide stop Slide stop Stop pump membrane Hot start device BASIC CARBURATOR SETTING Type 858 2 15 mm 450 EXC G MXC G RACING USA Keihin FCR MX 3900A 858 2 15 mm 450 EXC RACING SIXDAYS Keihin FCR MX 3900A 858 2 15 mm 450 SX RACING Keihin FCR MX 4122A 858 2 15 mm
31. CAUTIONS IN THIS RESPECT NEED TO BE TAKEN THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADI ATORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVER REV DAMAGING THE VALVES IN ADDITION THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMME DIATELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed When driving down hill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat AN WARNING IN CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF ROAD TRACKS HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAK ING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN RIDES ON SALT STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRAK ING EFFECT TH
32. E BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEAKER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH PLAY THIS IS AN INDICA TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Stopping and parking Apply the brakes fully and put the engine into neutral To turn off the engine push the short circuit button or the emergency OFF button with the engine at idling speed until the engine stops Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle WARNING Oe MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN NING THE ENGINE EXHAUST PIPE MUFFLER BRAKE ROTORS AND SHOCK ABSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED CAUTION NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE USE THE SHORT CIRCUIT BUTTON OR THE EMERGENCY OFF BUTTON INSTEAD CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE CARBURET
33. MIGHT SLIP OFF THE KICKSTARTER OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT FORCE ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE IF YOU DO NOT KICK HARD ENOUGHT WITH AN OPEN THROT TLE GRIP THE KICK BACK HAZARD WILL BE HIGHER DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS NESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE WILL MOVE FORWARD CAUTION MAXIMAL PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV UP THE ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE Starting when the engine is warm 1 Open the fuel tap 1 2 Swing up the side stand 3 Put the gear in neutral 4 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter What to do when the engine is flooded In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decompression lever fully rev up the engine actuate the kickstarter 5 to 10 times or ac
34. MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER VEHICLES CAN SEE YOU AS EARLY AS POSSIBLE ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORIES RECOMMENDED BY KTM FOR EXAM PLE FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHI CLES DRIVING PROPERTIES THEFRONT AND REAR WHEEL MAY ONLY BE FITTED WITH TIRES THAT HAVE THE SAME PROFILE TYPE THE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR 1 PERSON ONLY NEVER TAKE ANOTHER RIDER ALONG OBSERVE THE TRAFFIC REGULATIONS DRIVE DEFENSIVELY AND TRY TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDI TIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SEC OND MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE REPLACE THE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR DAMAGED IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR LENS THE OPERATOR WILL BE BLINDED NEVE
35. N CHAIN BEARINGS OF TRANS MISSION AND REAR WHEEL ASIDE FROM RESULTING PREMATURE WEAR IF WORST COMES TO WORST THE CHAIN MAY RUPTURE OR THE COUNTERSHAFT OF THE TRANSMISSION MAY BREAK TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks B Tighten the counter nut of the adjusting screws Before tightening thr collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm WARNING eee IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE NOTE The large adjusting range of the chain adjusters 32mm allows yo
36. NIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 4 15MM AND VVAKNIN Instructions for initial operation Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs see Customer Service Manual Read these operating instructions carefully before your first ride Familiarize yourself with the operating elements Set the clutch lever the handbrake lever the footbrake pedal to the positions that are most convenient for you Get used to handling the motorcycle on an empty parking lot or open space before starting on longer drive Also try to drive as slowly as possible and in a standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your abi tily and experience Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking the foot brake lever is not released the brake pads rub continuously and the braking system 15 overheated Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations
37. R LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING THE SX SXS MXC MODELS ARE NOT APPROVED FOR USE ON PUB LIC ROADS AND FREEWAYS WHEN RIDING YOUR MOTORCYCLE PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE Check the following before each start When you start off the motorcycle must be in perfect technical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks CHAIN A loose chain can fall from the chain wheels an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear to the chain and chain wheels Excessive tensioning of the chain will put additional load on the components of the secondary drivetrain chain bearings of transmission and rear wheel Aside from resulting in premature wear If worst comes to worst the chain may rupture or the countershaft of the transmission may break TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure dete
38. THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED IF THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PRE VENT THE THREAD FROM JAMMING The rear wheel is remounted in the reverse order Before tightening the col lar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws Si WARNING IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension espe cially on a new motorcycle at regular intervals For checking tap on each spoke w
39. TOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE ARE FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMA BLE MATERIALS NOTE REGARDING THE SIDE STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground Is solid and that your motorcycle is standing securely Just in case you can shift into first gear CAUTION THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE THE SIDE STAND AND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR CYCLE THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND Fuel The racing engine needs unleaded fuel with at least RON 95 USA Premium RON 91 CAUTION USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE 95 OCTANES NEVER USE GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig 1 service after
40. The compression damping during compression can be adjusted for the MXC and EXC shock absorbers Mono Compression Control The degree of damping be adjusted by turning adjusting screw 1 with a screwdriver Turning in a clockwise direction will increase the damping turn ing in a counterclockwise direction will decrease the damping STANDARD ADJUSTMENT turn the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber Type White Power 12187A06 15 clicks ZS THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 2 24MM Rebound damping of shock absorber SX MXC EXC By using the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber Type White Power 12187A05 22 clicks Type White Power 12187A06 22 clicks WARNING ee THE DAMPING U
41. XPERT 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 SERV ICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION IF THE MOTORCYCLE SHOULD FALL OVER NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER OF USED OIL CONTAMINATES 1 000 000 LITERS OF WATER Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusti
42. a de emergencia Potenci metro del carburador COLOR DE CABLE bl negro ye amarillo bu azul gn verde re rojo wh blanco br marron or naranja pi rosado gr gris pu violeta z ANHANG APPENDICE LA LA ct gt lt LA ct Ol ANHANG APPENDICE de APPENDIX APENDICE suspension gt Oil of Switzerland KTM Group Partner KTM Sportmotorcycle AG 5230 Mattighofen www ktm at
43. ability shorter service life for dry terrain TOSHIBA H38 Sinter longer service life than FERODO 4424 higher braking performance BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases The brake disk must be at least 2 80 mm thick at the thinnest point A Check the thickness of the brake disk at several points WARNING aANTSEECERTEENIREEEWITETEET BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTITUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMMEDI ATELY AS SOON AS THEY REACH THE WEAR LIMIT HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID RESERVOIRS The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are completely worn in this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid DOT 5 1 brake fluid one of the best brake currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible with DOT 5 1 Never
44. as the flash SPEED SPEED L 99 Km TR2 Al A2 Si 82 TET 00 WS Km h Mph Mies 000 MAX LAP CLK H ri LI Km h rice LILI D ZI CI 000 Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sen sor The display lights up when the engine is running The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor The O button is used to change between display modes The and buttons are used to control various functions TEST All of the display segments briefly light up for the display function test WS wheel size The display changes and the circumference of the front wheel is briefly dis played in millimeters 2205 mm corresponds to a front wheel circumference of 21 with production tires Afterwards the display will return to the previous display mode SPEED display mode H service hours Only the SPEED H and SPEED ODO display modes are activated in the condition at delivery SPEED H is displayed whenever the display is activated and the front wheel is not turning It automatically changes to the SPEED ODO display mode as soon as the front wheel starts turning SPEED displays the speed H displays the engine s service hours The service hour counter starts to count as soon as you Start the engine The displa
45. ass valve spring of the bypass valve spring Le e NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED RECOMMENDED INSPECTION OF THE 250 400 450 525 EXC ENGINE USED FOR HOBBY ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP 30 a 100 liter fuel consumption is equivalent to approx 15 operating hours e liter Check the clutch disks for wear Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear visual check Check the camshaft for wear visual check Replace the camshaft bearings Check the length of the valve springs Check the spring cap for wear het terre we Pf po Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for eames visual check GE E ER Replace the conrod bearings 00000000000 the conrod bearings Check piston pin bearing EBENE eres Replace the crankshaft main mr 20 20 p Check the Check the length of the bypass valve spring of the bypass valve spring Le e NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED V MAINTENANCE AND ADJUSTING WORK MARKED WITH ASTERISK REQUIRES E
46. bbagliante Avvisatore acustico Bobina d accensione Interruttore d accensione Indicatore ant sx Indicatore post sx Tachimetro digitale multifunzione Pick up Luce di posizione Interruttore luce post di stop Luce post di posizione stop Regolatore raddrizzatore Indicatore ant dx Indicatore post dx sensore velocit Pulsante d avviamento Rel d avviamento Motorino d avviamento Interrutore di aresto d mergenza Potenziometro carburatore sensore TPS CAVO COLORATO bl nero ye giallo bu blu gn verde re rosso wh bianco br marrone or arancione pi rosa gr grigio pu violetto gt y D TA AIN ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Front brake switch Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button Throttle position sensor TPS CABLE COLOURS bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple FRANCAIS Batterie Ventilateur temoin feu route Relais de clignotants temoin de cli
47. 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 water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS You should use normal brand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush Before cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Drain the float chamber of the carburetor Then take a short drive until the engine has reached the working temperature and also use the brakes By war ming these components the residual water can evaporate from inaccessable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate Once the motorcycle has cooled down oil or grease all sliding and bearing points Treat the chain with a chain spray Also oil the fuel tap To avoid any failures in of the electric system you should treat the emergency OFF sw
48. box cover and unhitch both rubber bands 1 Remove battery Install the battery with the terminals facing the front see illus tration connecting the negative terminal post to the battery last WARNING OOO IF ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER IN THE CASE OF CONTACT WITH THE EYES THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 15 MINUTES IMMEDIATELY CONSULT A DOCTOR THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLO SIVE GASES AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR 2 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature O 35 C 30 95 F Do not expose to direct sunlight Charging the battery Remove the battery and check the charging level Use a voltmeter to measure the voltage between the battery poles off load voltage Accurate results can o
49. d battery Low outside temperature Turn on the emergency OFF switch Australia only Dismount the left paneling and the filter box cover and replace the fuse in the starter relay Recharge the battery and investigate the causes for discharging contact a KTM dealer Start the engine with the kickstarter Engine cranks but doesn t start E Starter Engine will not start Kickstarter Operating error The motorcycle has been out of opera tion for a longer period of time Therefore old fuel has accumulated in the float chamber Fuel supply interrupted Flooded engine Sooty or wet spark plug Electrode gap too large Spark plug connector or spark plug faulty Short circuit cable scored in wiring har ness emergency OFF switch or short cir cuit button faulty The plug connection of the CDl unit the pulse generator or the ignition coil has oxydized Water in carburetor or jets blocked Open fuel tap tank fuel actuate choke Pay attention to Starting information see driving instructions The easily inflammable components of the new fuels evap orate during longer periods of standing still When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start when the float chamber 15 filled with new fuel Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if
50. d the long waiting times at your mechanic at the beginning of the next biking season TYPE 250 EXC 400 EXC 450 SX 450 MXC 925 EXC 925 MXC DESERT Design Liquid cooled single cylinder 4 stroke engine with balancer shaft Displacement 250 398 Bore Stroke 75 56 5mm 89 64 95 63 4 mm 89 72 mm 95 72 mm Ratio 11 1 Fuel unleaded fuel with at least RON 95 USA Premium RON 91 Valve timing 4 valves over rocker arm 1 overhead camshaft camshaft drive through single chain Camshaft Valve diameter Intake 5532 595 0121 590 5521 590 5521 55 21 590 5521 28 mm 35 mm 35 mm Titan Valve diameter Exhaust 24 mm 30 mm 30 mm Titan Valve clearence cold Intake 0 12 mm 0 0047 in Valve clearence cold Exhaust 0 12 mm 0 0047 in Crank shaft bearing Connecting rod bearing 2 cylinder roller bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy Piston rings cast 1 compression ring 1 oil scraper ring Engine lubrication Engine oil pressure circulation lubrication with two rotor pumps full synthetic oil Motorex Power Synt 4T 10W 50 Quantity of engine oil 1 25 liters Primary ratio Clutch Straight geared spur wheels 33 76 Z multi disc clutch in oil bath Transmission claw shifted Gear ratio Gear 6 speed 6 speed 4 speed 2nd Gear 3rd Gear
51. dip ap ans dada esha OV a 13 Fuse MXC EAC RC ae CR Seas dos 40 General information about KTM disc brakes 33 General tips and warnings for starting the motorcycle 17 Hand brake lever 6 Hand decompression lever 6 Head Word Index s 3x C CR ONE C s 57 Hot start device 450 525 SX 13 Instructions for initial operation 17 cce tur anaa e re Bee o Las D Peas AE 14 Kilometers or miles 11 Maintence work on chassis and engine 25 OCMC IN atest aah 46 Operation instruments 6 Overview of the electronic speedometer functions 12 P rodi mialntaliee uuo ox ea hx Jaden Cae at ue 21 EE 25 Rebound damping of fork 15 Rebound damping of shock absorber SX MXC EXC 16 Refilling the front brake fluid reservoir 34 Refilling the rear brake fluid reservoir 35 Replacing fork springs 27 Replacing headlight lamp parking light lamp 40 Replacing the battery of the digital speedometer 38 Replacing the front brake pads 35 Replacing the glassfiber yarn packing of the silencer 42 Replacing the rear brake pads 36 Running in the Racing models 17 Serial number locations
52. e axle shaft Mount the collar nut 5 tighten the clamping screws 6 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm 30ft Ib Loosen the clamp screws on the right fork leg Take the motorcycle down from 115 stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 10 Nm 7 ft Ibs IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Loosen the collar nut 1 remove chain tensioner 2 hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION DO NOT OPERATE
53. e selected Naturally in cases of jet changes you have to start your adjusting work from the beginning 5 Then use the adjusting wheel to set the desired idle speed 6 In cases of greater changes in the outside temperature and extremely different altitudes the idling speed should be readjusted Basic information on carburetor wear As a result of engine vibrations the throttle valve jet needle and needle jet are subjected to Increased wear This wear may cause the carburetor to mal function e g overly rich mixture Therefore these parts should be replaced after 200 hours Adjusting the mixture control screw Especially on the EXC models accessing the mixture control screw Is diffi cult For this reasons we have created an appropriate special tool Introduce the special tool on the mixture control screw 2 at the carburetor bottom Press the tool slightly upward and turn the adjusting wheel 3 until the tool engages the slot of the mixture control screw Now you can go about adjusting the screw Marks were provided on the adjusting wheel making it easier to keep track of the turns Checking the float level float height For this purpose dismount the carburetor and remove the float chamber Hold the carburetor in a slanted position such that the float will abut the float nee dle valve but not compress it In this position the edge of the float should be parallel with the float cham ber sealing surface see illus
54. e 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 The clutch lever 1 is located on the left side of the handlebar The adjust ing screw A is used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hand decompression lever The hand decompression lever 2 is needed only if the carburetor overflows after a fall To pump the engine free pull the hand decompression lever during the starting procedure The outer end of the lever must provide for a backlash of approx 10mm 0 4 in at all times Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompression lever encounters Hand brake lever The hand brake lever 3 is mounted on the handlebars on the right and actuates the front wheel brake The adjusting screw B can be used to change the basic position of the hand brake lever see Maintenance Short circuit button SX MXC The short circuit button 4 turns off the engine When pressing this button the ignition circuit is short circuited Combination switch EXC The light switch has 2 respectively 3 switch positions A Light off this functi
55. ent of adjusting screws on carburetor Defective spark plug Defective ignition system Disassemble the carburetor and clean the jets Have the carburetor adjusted Replace the spark plug Have the ignition system checked TROUBLE CAUSE REMEDY Engine does not rev high Engine will not reach full power Engine stops or splutters in carburetor Engine gets too hot Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition timing faulty Fuel supply partially interrupted or carbu retor dirty Float leaks Air filter very dirty Exhaust system 15 not tight deformed or the silencer does not contain enough glass fiber yarn Valve gap too small Loss of compression because hand decom pressor has no play Electronic ignition timing faulty Insuffient fuel Engine takes air out of control Insufficient cooling liquid Not enough air stream Cooling system has not been bled Radiators very dirty Foam formation in cooling system Bent cooling hose Thermostat defective Dismount carburetor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor Replace the float Clean or replace air filter Check if exhaust is damaged replace glasfiber yarn in exhaust silencer Adjust valve gap Check setting of the hand decompression cable Have ignition system checked Clean and chec
56. f 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different places on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets CAUTION SECURE THE SCREWS OF THE CHAIN WHEEL BY APPLYING LOCTITE AND FASTEN THEM IN A CROSSWISE ORDER TIGHTENING TORQUE FOR NUTS 35 NM TIGHTENING TORQUE FOR SCREWS 50 NM AND ENGIN 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 25 Nm BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front and TOSHIBA H 38 sintered lining at the back These linings provide an opti mal combination of dosing brake performance and life cycle The lining type is stated on the back of the brake pad and also recorded in the homologation papers Other brake pads are available for competition sports FRONT TOSHIBA H 38 SINTERED harder to dose good brake per formance long life for wet slippery terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price REAR FERODO 4424 organic better controll
57. f with water WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER AND ENGIN Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in WARNING AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the rear brake pads Push the brake caliper 1 toward the chain wheel in order to move the brake piston into its basic position Remove the clips 2 pull out the bolt 3 and remove the brake pads Thoroughly clean the brake caliper with compressed air and check the sleeves of the g
58. fiber yarn packing 1 needs to be replaced more often than the rear silenc ing mat 2 For this purpose remove the silencer from the vehicle and dismount the front cap 3 Pull the front glassfiber yarn packing together with the inner exhaust pipe 4 out of the silencer Clean the front inner exhaust pipe To facilitate the mounting procedure you can make a mounting tool 5 out of wood plastic or metal Insert the mounting tool into the inner pipe and mount the glassfiber packing Push the inner pipe containing the packing into the silencer such that the slot engages the web A Use a blunt ended object to stuff the glassfiber yarn packing all the way into the silencer and mount the front cap To change the rear silencing mat start by removing the front packing and the inner exhaust pipe Then drill open the rivets and remove the end cap NOTE In every exhaust repair procedure the O rings must be replaced by new ones Glass fiber yarn packings are available from your licensed KTM mechanic WARNING Oe THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN NING TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN Cleaning the spark arrester MXC EXC USA The spark arrester should be cleaned every time the glassfiber yarn filling is changed or at least once annually For this purpose dismount the silencer cap and remove any deposits that might exist regio
59. four stroke motorcycles the JASO T903 MA standard Whereas car engines require long changing inter TEMPERATUR vals motorcycle engines require a higher power output at higher speeds Most E motorcycle engines also use the same oil to lubricate the transmission and 0 C the clutch The JASO MA standard responds to these special requirements 32 F Only use fully synthetic engine oils that meet the JASO MA quality require ments see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for tem 5W 40 10W 50 peratures over O C 32 F or 5W 40 for temperatures under O C 32 F CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE Changing the engine oil Note When changing the engine oil it is necessary to clean the short and long oil screens and to replace both oil filters Engine oil has be changed with the engine at an operating temperature CAUTION AN ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE VERY HOT DO NOT BURN OR SCALD YOURSELF Place the motorcycle on a horizontal surface remove the plug 1 and allow the oil to drain into a receptacle Clean plug with magnet thoroughly Once the entire oil has been drained clean the sealing surface mount the plug together with the sealing ring and tighten it to 20 Nm CLEANING THE SHORT OIL SCREEN The short oil screen 2 is accommodated in the hex socket
60. ging the basic position of the foot brake pedal 35 Digital speedometer indicator lamps 7 Checking the rear brake fluid level 35 Electronic speedometer 8 Refilling the rear brake fluid reservoir 35 setting the clock 12 Checking the rear brake pads 36 2 35 15 eatis Nar are 13 Replacing the rear brake pads 36 PC AID MT ae da ae 13 Dismounting and mounting the front wheel 36 CORSA ET die ed 13 Dismounting and mounting the rear wheel 37 Hot start device 450 525 SX 13 Checking spoke tension 37 SNIT lever Sas Mat es GEM EEG p 14 Tires air pressure 38 VC K SHAUL EE 14 Check set distance of the magnetic sensor 38 Foot Drake pedal 14 Replacing the battery of the digital speedometer 38 Side M a a 14 Battery MACIEXC suis mars trie 39 SECON MOCK duse uma e WX dr Sets does n 14 Charging the battery 39 Compression damping of fork 15 Fuse EUREN 40 Rebound damping of fork 15 Replacing headlight lamp parking light lamp A0 Damping action during compression of shock absorber SX 15 ss Ras Dre To o 2 3009 Ba t Gee 41 Compressi
61. gnoteur Contacteur de frein avant Alternateur Contacteur au guidon pour ordinateur de bord Phare Contacteur code phare Avertisseur sonore Bobine d allumage Contacteur d allumage Clignotant avant gauche Clignotant arri re gauche Ordinateur de bord Capteur d allumage feu de position Contacteur de frein arri re Feu rouge stop R gulateur redresseur Clignotant avant droit Clignotant arri re droit Capteur de vitesse bouton de d marrage Relais de d marreur D marreur bouton d arr t d urgence Capteur d ouverture de carburateur COULEUR DE CABLE bl noir ye jaune bu bleu gn vert re rouge wh blanc br brun orange rose gr gris pu violet ESPANIOL Bateria Motor del ventilador lampara aviso luces largas Rel de la luz intermitente lampara aviso intermitentes Interruptor de luz del freno delantero Generador Interruptor de manillar para instrumento combinado Faro Interruptor de encender apagar la luz larga Claxon Bobina de encendido Cerradura de encendido Luz intermitente izquierda delantera Luz intermitente izquierda trasera Veloc metro digital multifuncional Generador de impulsos luz de posicion Interruptor de luz del freno trasero Luces de parqueo traseras luces de freno Regulador rectificador Luz intermitente derecha delantera Luz intermitente derecha trasera sensor de velocidad bot n de arranque Rel del arranque Motor de arranque el ctrico interruptor de parad
62. he fuse capacity is 10 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED OR A FUSE ALLOWED TO BE REPAIRED AN IMPROPER TREATMENT COULD DAM AGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the park ing light lamp with holder 4 carefully out of the reflector Pull connector 5 off the headlamp and remove rubber cap 6 Disengage retaining clip and take bulb out of reflector When changing the parking light lamp simply pull it out of the holder Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above when engine is cold AND ENGIN Cooling system Coolant is circulated by a water pump 1 located in the engine When the engine is cold the coolant only circulates through the cylinder and the cylin der head After the engine has reached its operating temperature about 70 158 F the thermostat 2 opens and the coolant is also pumped through both aluminum radiators Air blowing in through the radiators cools the coolant The slower the speed of the motorcycle the less the coolant is cooled down Dirty radiators also reduce the cooling efficiency Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 3 a water temperature rising up to 120
63. he next gear Let clutch lever go slowly and open the throttle or shift down again JN gt 4 Jn NG IN NOTE Dedicated to nothing but offroad racing 250 400 450 525 SX MXC EXC Racing models make no compromises in their design As such they do not include any radiator fan and the size of the radiator is dimensioned for optimum ergonomics In normal racing the cooling system is sufficient If you use your motorbike in other conditions please note that the E starter allows you to start MXC EXC Racing models again at any time Therefore turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time more than 2 minutes Avoid letting the clutch slip frequently and for extended periods This would cause the engine oil to heat up thereby heating up the cooling system You should drive at low speeds 4 stroke style letting the engine pull you and not at high speeds not by letting the clutch slip 2 stroke style WARNING AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED DO NOT ADJUST THE HANDLEBAR IT WILL LOSE STABILITY CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIV ING IT ACHANCE TO WARM UP AFTER THAT NO FURTHER PRE
64. ing comfort and extends the life of your tires WARNING DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE HOMOLOGATED TIRES FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Check set distance of the magnetic sensor The distance between magnet 2 and sensor 1 must be 2 4 mm 0 08 0 16 in otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing in or off the sensor 1 Replacing the battery of the digital speedometer Remove the headlight mask and disassemble the electronic speedometer Remove the screw connection 3 insert the battery type CR 2430 with the writing facing up and reinstall the screw connection AND ENGIN Battery MXC EXC The battery is located under the seat and 15 maintenance free It is not necessary to check the electrolyte level or to refill water Simply keep the battery poles clean and slightly grease them with an acid free grease if necessary Removing the battery First disconnect the negative and then the positive pole of the battery Remove the filter
65. ion of these figures Is acti vated by the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The TRI Al and S1 figures are automatically cleared after passing 999 9 button no function button no function briefly press button changes to the next display mode hold O button 3 secs clears the TRI 51 1 figures SPEED TR2 display mode tripmaster 2 The tripmaster 2 is always active and counts to 999 9 Contrary to TRI the displayed figure can be changed using the and buttons This is a very use ful function for trips taken according to a roadbook button increases the TR2 figure button decreases the TR2 figure briefly press O button changes to the next display mode hold O button 3 secs clears the TR2 figure SPEED A1 display mode average speed 1 Al shows the average speed based on the TRI tripmaster 1 and SI stop watch 1 figures The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received button no function button no function briefly press O button changes to the next display mode hold O button 3 secs clears the TRI 51 Al figures d Wt gc CT AC 20 SPEED Km h TRI TR M A2 9 52 000 MAX LAP CLK H SPEED
66. itch short circuit button light switch and socket connectors with a contact spray In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent A KEEP THE ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER CAUTION AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL STORAGE gt gt Should you wish to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil short and long oil filters old engine oil contains aggressive contaminants Check antifreeze and amount of cooling liquid Warm up the engine once again close the fuel cock and wait until the engine dies Then open the drain plug of the float chamber to remove the remaining fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to c
67. ith the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer WARNING Oe SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOAD ING THE SPOKES MUST BE TENSIONED TO 5 NM TIRES AIR PRESSURE front rear Off road 1 0 bar 1 0 bar Road driver only 1 5 bar 2 0 bar AND ENGIN Tires air pressure Tire type tire condition and air pressure level affect the way your motor cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size be found in the technical specifications and the homolo gation certificate Tire condition has to be checked every time you want to ride your motor cycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Refer to the specific regulations in your country for minimum tire tread requirements We recommend you replace the tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pres Sure ensures optimum driv
68. k fuel system and carburettor Check rubber sleeve and carburetor for tight fit Refill cooling liquid see maintenace work check cooling system for leaks Drive on briskly electric fan can be retrofitted Bleed cooling system Clean radiators with water jet Replace cooling liquid use antifreeze liquid with brand name Shorten or replace cooling hose Dismount and check thermostat opening temperature 70 C 158 F or replace it High oil consumption All switched on lamps blown out Hose of engine ventilation is bent Engine oil level too high Motor oil too thin viscosity Capacitor or voltage regulator faulty Dislocate i e replace non buckling vetilation hose Check engine oil level and if necessary correct it Use thicker engine oil see chapter Engine oil Dismount seat and fuel tank and check connections have capacitor and voltage regulator checked Horn flasher lights and E starter do not work Blown fuse in the starter relay Dismount left side paneling and filter box cover replace fuse The battery is discharged The battery isn t charged by the generator because Remove seat and fuel tank and check voltage regulator con nections voltage regulator and generator should be checked by a KTM dealer CLEANING gt h Dh h h Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would
69. l the oil filter inserts 3 out of the housing Clean the oil filter cover the sealing surfaces of the O rings and the engine casing Check the O rings of the oil filter covers for damage and if necessary replace them Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil Fill oil filter with oil place the long oil filter in the front and the short filter in the back of the filter box Grease the O rings 4 of the oil filter covers and mount the covers Mount the screws and tighten them to 6 Nm Position the brake fluid container and tighten the screw to 8 Nm Return the motorcycle to an upright position Remove the oil dipstick 5 at the clutch cover and fill in 1 2 liters of fully synthetic engine oil Motorex Power Synt 4T 10W 50 Start the engine and check all screwed connections and the oil filter cover for leaks Finally check the engine oil level and if necessary correct it TROUBLESHOOTING gt If you had the specified maintenance work on your motorcycle carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the troubleshooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by yourself In case of uncertainty please contact a KTM dealer TROUBLE CAUSE REMEDY Engine doesn t crank E starter Operating errror Blown fuse Discharge
70. les The unit kilometers or miles can also be changed The ODO figure will be retained and converted accordingly The TRI 1 51 TR2 and A2 figures will be cleared To select the unit select the SPEED H mode and hold the O button for 3 sec onds to access the SETUP menu Press the O button until the KMH MPH function blinks Press the button briefly to move to the options Press the button for KMH or the button for MPH To set briefly press the O button 1 x and hold for 3 seconds until the dis play returns to the SPEED H mode If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode button to access the menu to activate the KMH display button to activate the MPH display changes to the next mode changes from the menu to the SETUP menu stores and closes the SETUP menu briefly press O button hold O button 3 secs Le Motorcycle is driving display Setting the clock To set the clock switch the ignition off and select the SPEED CLK mode Press and hold the button for 3 seconds The blinking digits be changed using the and buttons Press the button to move to the next digit 0 12 will show the time in the 12 hour mode 0 24 in the 24 hour mode Press and hold the button for 3 seconds to store the settings If no button is pressed for 20 seconds the settings will be stored automati cally and the displa
71. llar screw hanger vent hose 6 Loctite 243 8 Nm 8 Allan head screw kickstarter Hexagon collar screw shift lever 10 Loctite 243 60 Nm Spark plug 10 10 12 Spark plug 12 1 25 20 Hexagon screw engine sprocket Engine oil Only use fully synthetic engine oils that meet the JASO MA quality require JASO T903 MA ments see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for tem peratures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F TEMPERATUR E CAUTION aor POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE WEAR 9W 40 10W 50 CHASSIS 450 525 SX 250 400 450 525 EXC MXC DESERT 450 525 MXC G EXC G USA Frame Central tube chrome moly steel frame Fork 4860 WP Up Side Down 4860 Wheel travel front rear 300 335 mm Rear suspension WP Progressive Damping System shock absorber aluminium swing arm Front brake Disk brake with carbon steel brake disc 260 mm 10 2 in brake caliper floated Rear brake Disk brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake disc Wear limit max 2 5 mm front and 3 5 mm rear Front tires 80 100 21 90 90 21 80 100 21 Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 1 5 bar 1 5 bar 21 psi Rear tires 110 90 19 140 80 18 110 100 18 Air pressure offroad 1 0 bar
72. located behind it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them downward Clean the dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with Universal oil spray Motorex Joker 440 or engine oil Then push the dust protection bellows into the outer tubes by hand NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcy cle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward For readjusting loosen the five pinch bolts 3 of the top triple clamp and turn steering stem bolt clockwise 4 until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly tap on the triple clamp to release tension Retighten the five pinch bolts to 20 Nm EXC and 15 Nm SX AN WARNING eee IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI ODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED
73. low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button Throttle position sensor TPS CABLE COLOURS bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple HEI CA DEUTSCH Batterie L ftermotor Fernlichtkontrolle Blinkerkontrolle Blinkerrelais vorderer Bremslichtschalter Generator Lenkerschalter f r Kombiinstrument Scheinwerfer Auf Abblendschalter Hupe Z ndspule Z ndschloss linker vorderer Blinker linker hinterer Blinker Multifunktionsdigitaltacho Impulsgeber Standlicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Starttaster Startrelais Startermotor Not Aus Schalter Vergaserpotentiometer KABELFARBEN bl blau gelb bu blau gn gr n re rot wh wei br braun or orange rosa gr grau pu violett ITALIANO Batteria Motorino ventola Spia abbagliante spia lampeggiatori Rel indicatori Interruttore luce ant di stop Generatore Interruttore sul manubrio per tachimetro multifunzione Faro anteriore Commutatore abbagliante ana
74. lter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust system with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly RECOMMENDED INSPECTION OF THE 250 400 450 525 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP 100 liter fuel consumption is equivalent to approx 15 operating hours Check the clutch disks for wear Check the erem ln spams eee Le Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear visual check Check the camshaft for wear visual check Replace the camshaft bearings Check the length of the valve springs Check the spring cap for wear Seng Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for eames visual check Gt 220 1207 5 Replace the conrod bearings the conrod bearings Check piston pin bearing C Replace the crankshaft main Pa memes e Check the Check the length of the byp
75. n B Renew the O ring and mount the silencer cap AND ENGIN Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accu mulated To clean lift the filter box cover 1 see illustration and pull off towards the front Detach the bottom of the filter retaining bracket 2 tilt aside and remove the throttle cap 3 and the air filter 4 and filter support 5 from the filter box The SX models do not have a throttle cap CAUTION DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM AGE THE FOAM KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE BIO DIRT REMOVER AND LIQUID BIO POWER NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS OTHERWISE DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL TER IS NOT MOUNTED CORRECTLY Thoroughly wash the air filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Mount the air filter on the filter support Insert the air filter and filter support in the throttle cap and mount them in the filter box aligning in a central posi tion and fix with the filter retaining b
76. n This engine oil flows through an oil line 5 into the cylin der head for camshaft lubrication 6 the oil quantity is controlled by the jet screw 7 An oil duct branches off to the long oil filter 8 where the coarser particles contained in the engine oil are filtered away Then the engine oil arrives at the short oil filter 9 which also filters the fine particles Now the purified engine oil is pumped past the bypass valve 10 to the conrod bear ing 11 and sprayed from below onto the piston through a nozzle 12 The second oil pump 13 draws the engine oil via the short oil screen 14 out of the crankcase thereby lubricating the transmission gears 15 Checking the engine oil level The engine oil level can be checked with the engine either warm or cold Place the motorcycle in an upright position and on a horizontal surface not on the Side stand If the engine is cold the engine oil must be visible at the lower edge of the inspection glass A If the engine is warm the engine oil must be visible up to the upper edge of the inspection glass B Replenish the engine oil if necessary CAUTION INSUFFICIENT AMOUNTS OF OR LOW GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE ENGINE Engine oil Automobile engine oil used to be used for four stroke motorcycles before there JASO T903 MA were separate motorcycle specifications Different technical developments made it necessary to a separate specification for
77. n synchronize the compression damping 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 high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compres sion rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping STANDARD LOW SPEED SETTING turn the adjusting screw 4 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absor ber in a counterclockwise direction Typ White Power 12187 05 15 clicks STANDARD HIGH SPEED SETTING turn the adjusting screw 5 to the limit in a clockwise direction using a box wrench unscrew the respective number of turns for the specific type of shock absor ber in a counterclockwise direction Typ White Power 12187 05 2 turns AN WARNING ee THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 6 24MM Compression damping of shock absorber MXC EXC
78. ng ring 1 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 1 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm ADJUSTMENT VALUES SPRING PRELOAD A minimum preload 4 mm 0 15 in STANDARD PRELOAD 7 mm maximum preload 10 mm 0 4 in Pivot bearing The pivot bearing 3 for PDS suspension struts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubricants Grease and other lubricants cause the Teflon coat to dissolve whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing ce 99 9 04 GUD EU V Q A RS KT ay r x gt D IS GS W ASS PDS 12187A05 450 525 SX SPRING RATE 84 250 80 250 76 250 60 65 70
79. nly be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring off load voltage charging level charging time charging voltage Volt 0 4 A gt 12 7 12 5 12 2 If the battery is empty it can be recharged for a maximum period of 10 hours at 0 4 and a maximum of 14 4 V CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT VENTILATION EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES AVOID QUICK CHARGING IF POSSIBLE inp JSL AND ENGIN Fuse MXC EXC The fuse 1 is located in the starter relay of the E starter 2 underneath the left side paneling Having removed the left side paneling the air box cover and the protection cover A you will be able to see the fuse The following loads are connected to it E starter system horn flasher lights electronic speedometer The starter relay also contains a 10 amp spare fuse 3 Replace a blown fuse only with an equivalent one If a new fuse that has just been installed gets blown again you are strongly advised to have it inspected by a KTM dealer T
80. ompression so that the valves will be closed slowly operate the kickstarter until you can hear the automatic decompressor click release Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate pivot points of the control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see chapter BATTERY The storage place should be dry and not subjected to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use airtight materials as a possible humidity might not be able to escape and could cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST USE AFTER A PERIOD OF STORAGE Mount the charged battery regard polarity Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you should check all parts for their function and wear Should any service jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoi
81. on damping of shock absorber MXC EXC 16 Checking the coolant level 41 Rebound damping of shock absorber SX MXC EXC 16 Bleeding the cooling system 41 Replacing the glassfiber yarn packing of the silencer 42 GENERAL TIPS AND WARNINGS FOR STARTING THE Cleaning the spark arrester MXC EXC USA 42 MOTOREVOLE ondes miam 17 Cleaning the air filter 43 Instructions for initial operation 17 Checking the adjustment of the hand decompression Running in the Racing models 17 release cable 43 Adjusting the throttle cables 43 DRIVING INSTRUCTIONS 18 Changing the original position of the clutch lever 44 Check the following before each start 18 Checking the oil level of the hydraulic clutch 44 Starting when the engine is cold 19 Bleeding of the hydraulic clutch 44 Starting when the engine is warm 19 CARBURETOR Adjust idling Keihin FCRMX 37 39 41 45 What to do when the engine is flooded 19 Adjusting the mixture control screw 45 LATINE ON desear ah ce aed em RUE a ee 19 Checking the float level float height 45 sta cR d Re de 19 Draining the float chamber of the carburetor 46 BAR INR
82. on is not available in all models B Low beam on C High beam on You may use button 5 to actuate the horn The red short circuit button 6 serves to switch off the engine Leave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch 1 Flasher switch The flasher switch is a Separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dismount the entire turn indicator system without affecting the function of the remaining electrical system a Flasher left gt Flasher right Starter button EXC G Pushing the black starter button 2 will actuate the E starter Emergency OFF switch EXC Australia The red emergency OFF switch 3 15 arranged adjacent to the throttle grip C mL In this position the E starter is operational and the engine can be started Gi In this position the E starter and ignition circuits are interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter Pushing the black starter button 4 will actuate the E starter Digital speedometer indicator lamps ing indicator when the indicator is working The blue control lamp 6 lights up when the high beam is on green control lamp 5 flashes in the same rhythm
83. orcycle in vertical position Measure the distance between the rear axle and the fixed point again to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm Ape oda Be ma dee eae hee ee eee oe ee 35 mm If the static sag is lower the spring preload of the shock absorber must be reduced if the static sag is higher the spring preload must be increased See chapter Changing the spring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C The riding sag is the difference between dimensions A and C EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 510 mm enl AR Ra aa iv gt ol dee de Sea esta 90 mm The riding sag should lie between 90 and 105 mm If the riding sag is less than 90 mm the spring is too hard the spring rate is too high If the
84. p cover M5 Loctite 222 6 Nm Hexagon collar screw cylinder head top section 6 10 Hex collar screw cylinder head top section water pump cover M6 8 Nm Hexagon collar screw exhaust flange 6 Loctite 243 8 Nm Cylinder head screw 10 40 50 Allan head screw camshaft gear 8 Loctite 243 28 Nm Stop screw autodecompression M5 Loctite 222 8 Nm Allan head screw cap rocker arm M5 5 Nm Counter nuts valve adjustment screw M6x0 75 11 Nm Allan head screw primary gear free wheel 6 Loctite 648 16 Nm Hexagon nut primary gear M20x1 5 Loctite 243 150 Nm Allan head screw balancer shaft gear M6 Loctite 243 8 Nm Nut for inner clutch hub M18x1 5 Loctite 243 150 Nm Hexagon collar screw clutch spring 6 8 Nm Allan head screw shift roller locking piece 6 Loctite 243 10 Nm Hexagon collar screw locking lever M5 Loctite 243 6 Nm Hexagon collar screw shift roller M5 Loctite 243 6 Nm Hexagon collar screw securing guide chain guide chain tensioner M Loctite 243 8 Nm 6 Hexagon collar screw clip M5 Loctite 243 6 Nm Hexagon collar screw chain adjuster M6 8 Nm Hexagon collar screw stator SX M5 Loctite 243 6 Nm Hexagon collar nut flywheel 12 1 60 6 Hexagon collar screw spring hanger kickstarter M Loctite 243 10 Nm Loctite 243 25 Nm 6 Loctite 243 10 Nm Hexagon collar screw cover E starter only SX M6 Loctite 243 8 Nm Hexagon co
85. pecifications must be used in accordance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached The SX SXS MXC and other competition only labeled models are prohibited on public roads On the road approved models are only allowed on public roads in the original homologated throttled version Without this performance restriction i e de throttled these models are only allowed to be driven off road and not on public roads The EXC models are designed for off road sports endurance competitions enduro and not suitable for predominant motocross use Note The above is a general statement Specific limited warranty and limited guarantee information may vary depending upon distribution Please check with your local KTM dealer for limited warranty and lim ited guarantee Information specific to your KTM model and region In accordance with the international quality management ISO 9001 standard KTM uses REG NO 12 100 6061 quality assurance processes that lead to the highest possible product quali
86. problems for the environment or lead to conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others We wish you a lot of fun when driving KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments 1 spare parts manual chassis amp engine AN J V AND LIN J GQUARAN NFURIVIA Be Le gt g Be 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 Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The service work specified in the Lubrication and Maintenance Schedule must be performed and serv ice records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty The fuels and lubricants specified in the Owner s Manual or fluids with equivalent s
87. racket Checking the adjustment of the hand decompression release cable Start the engine and at idling speed slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever The back lash until said thumping should be approx 10mm measured at the lever s outer end If necessary correct this backlash To adjust move back the protective cover 6 loosen the counter nut 7 and correct the adjustment screw 8 accordingly Tighten counter nut and push back protective cover CAUTION THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE CHECKED REGULARY IF THERE IS NO PLAY IN THE DEKO LEVER THIS CAN RESULT IN ENGINE DAMAGE note No adjustment need be made to the automatic decompressor Adjusting the throttle cables The throttle grip should always provide for backlash of 3 5mm Besides with the engine running the idling speed must not change if you turn the handlebar all the way to the left or right To adjust the throttle cables dismount the seat and the tank together with spoilers Slide back the protection cover 9 Loosen the counternut 10 and turn the adjusting screw 11 accordingly Turning the adjusting screw counterclockwise will reduce the backlash turning the adjusting screw clock wise will increase the backlash Tighten the counternut and check whether the throttle grip can be actuated smoothly Mount tank and seat AND ENGIN Changing the original position
88. relay battery starter motor aa e E regulator rectifier cooling fan E rear 5 brake switch a bl 5 cS right rear flasher Le e re rear light brakelight i E left rear flasher pick up generator wiring diag ramm main harness 594 11 075 050 05 03 2004 dh A VLV multi func digital speedometer Lo i re bl speed sensor il ANHANG APPENDICE APPENDIX APENDICE N stop switch handle bar switch e bl ignition coil Racing USA 2005 250 450 525 start button light switch wh wiring diagramm start relay starter motor ge E p i o 5 cooling fan br main harness battery 594 11 075 100 regulator rectifier H lt 25 02 2004 rear light brakelight dh A VLV JIIONJdY XIGN4iddV 1910N dd SNVHNV stop button black ellow black brown blue white 6 GC ignition coil SX 450 525 2005 9 enerator red white red black green CDI harness 594 39 032 000 pick Up 20 02 2004 P 4 JOIGNAddV 9NVHNV J gt ne ne lt gt lt I mv 2 A ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Front brake switch Generator Handle bar switch for multi func digital speedometer Headlight High
89. riding sag is more than 105 mm the spring 15 too soft the Spring rate is too low The spring rate is written on the outside of the spring e g 88 250 The type number of the shock absorber is embossed on the bottom of the tank The illustrations show which spring should be installed The standard spring is shown in bold print After installing a different spring readjust the static sag to 35 mm 2 mm PDS 12187A06 250 400 450 525 MXC MXC Desert EXC EXC G 84 250 80 250 76 250 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE 1 14187 05 450 525 5 4 8 4 6 N mm 4 2 SPRING RATE 60 65 70 15 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 250 400 450 525 MXC MXC Desert EXC EXC G 14187 06 4 4 N mm 4 2 N mm 4 0 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE AND ENGIN According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder Spring Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons Similar to the shock absorber smaller deviations in your weight can be compensated by adjusting the spring preload However
90. riorate the driving performance BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as com plete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at the hand brake lever and foot brake lever CABLES Check correct setting and easy running of all control cables COOLING FLUID Check the level of the cooling fluid when the engine Is cold ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights indica tors control lamps and horn while the engine Is running LUGGAGE If you are taking luggage with you check that this is securely fastened Starting when the engine is cold 1 Open the fuel tap 1 2 Swing up the side stand or center stand 3 Putthe gear in neutral 4 Operate the choke 2 5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actu ate the E starter WARNING OOO IF YOU WANT TO START THE ENGINE MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU
91. splay changes to the next display without changing any settings Starts the SETUP stores the settings and changes to the SPEED H mode The following display modes can be activated TRI tripmaster 1 2 tripmaster 2 AI average speed 1 A2 average speed 2 51 stop watch 1 S2 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH MPH display in kilometers or miles see Kilometers or miles If you have activated all of the display modes they will be displayed in the following order SPEED H SPEED CLK SPEED LAP LAP LAP SPEED MAX SPEED ODO SPEED TR1 SPEED TR2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK time display mode CLK displays the time in hours minutes and seconds button button briefly press O button hold O button 3 secs no function no function changes to the next display mode set the clock menu To set the clock see Setting the clock SPEED LAP lap time display mode You can use the manual stop watch to stop and store up to 10 lap times which you can view in the LAP LAP display mode see below LAP displays the lap times in hours minutes and seconds button button briefly press O button hold O button 3 secs starts and stops the stop watch lap time is not reset to O Stops the stop watch stores the lap time and restarts the stop watch again The time is reset to O A total of 10 lap times can be stored If the lap time con tinues to run
92. spring 26 CROKE rain A 13 CEINE SNS RE can PRIE MIEL e or d 51 Cleaning the air filter 43 Cleaning the dust sleeves of the telescopic fork 28 Cleaning the spark arrester MXC EXC USA 42 tren WEE 6 Combination switch EXC 6 Compression damping of fork 15 Compression damping of shock absorber MXC EXC 16 Conservation for winter operation 51 Cooling a ooh Pata ei Rack KC 41 Correct chain tension 31 Damping action during compression of shock absorber SX 15 Determining the riding sag of the shock absorber 26 Determining the static sag of the shock absorber 26 Digital speedometer indicator lamps 7 Dismounting and mounting the front wheel 36 Dismounting and mounting the rear wheel 37 HEAD WORD INDEX gt Draining the float chamber of the carburetor 46 Driving instructions 18 Electronic speedometer 8 Emergency OFF switch EXC Australia y Engine number engine 5 DIT Geste Ses Seg dut 54 EOC ON ES eal Gn aaa E anita 47 PAW OR OD ee e 13 Flasher e Re enr 7 Foot Drake pedal a 3 deo Boro ae 14 gi ie e CPP 20 FUGIT Boars
93. t injury Besides this manual contains important information on motorcycle maintenance At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual is an important part of your motor cycle and should be passed on to any subsequent owner in case you decide to sell it We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chas sis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer For your own safety use KTM approved parts and accessories only KTM is not liable for damage that arises in connection with the use of other products Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle To ensure that all work to your KTM is performed properly and to avoid warranty conflicts KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer Off road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full It may however involve potential
94. the type needed for cold starts To deactivate the choke push the choke button back into its basic position Hot start device 450 525 SX If you pull the hot start device 3 out as far as possible a bore in the carbu retor will be opened through which the engine may take in additional air The result is a lean fuel air mixture of the type needed for hot starts To deactivate the hot start device push the hot start button back Into its basic position 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 Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled Foot pedal The foot brake pedal is located in front of the right footrest 115 basic position can be adjusted to your seat position see maintenance work Side stand Push the side stand to the ground with your foot and load it with the motor cycle Make sure that you put your bike on solid ground and in a secure posi tion For off road riding you can use the rubber band 1 to additionally secure the center stand in its folded up position Steering lock The handlebar can be locked by means of the lock located on the steering head To lock it turn handlebar all the way to the right insert key turn it to left press it in turn it to right and remove it
95. tration If the float height does not correspond to the desired value check the float needle valve and if necessary replace it If the float needle valve is you can adjust the float height by bending the float lever 4 Mount the float chamber install the carburetor and adjust the idle speed AND ENGIN 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 Water in the float chamber causes malfunctioning Perform this task on cold engine Close the fuel tap and put one end of the hose 1 into a collecting vessel Open the drain plug 2 turning it counterclockwise by serval turns and drain the fuel from the float chamber Then retighten the drain plug and open the fuel tap WARNING FUEL IS EASILY FLAMMABLE AND TOXIC WHEN HANDLING FUEL BE SURE TO EXERCISE THE UTMOST CAUTION NEVER PERFORM ANY WORK ON THE FUEL SYSTEM NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF THE FUEL PROPERLY Oil circuit Via the long oil screen 4 the oil pump 3 draws engine oil from the oil sump of the transmissio
96. tuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it NOTE The carburetor has an accelerator pump Every time you open the throttle fuel will be injected into the intake passage When starting be sure that you open the throttle completely only once Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and open the throttle at the same time WARNING YOU START OFF CHECK THAT THE SIDE STAND HAS BEEN SWUNG UP FULLY IF THE STAND DRAGS ON THE GROUND THE MOTORCYCLE CAN GO OUT OF CONTROL Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Close throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and accelerate If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throt tle back to 3 4 the speed hardly decreases although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of the throttle the fuel usage increases By shifting down use the brakes if necessary and close the throttle at the same time Pull the clutch lever and shift down to t
97. ty JN Page Page IMPORTANT LIMITED WARRANTY AND LIMITED GUARAN Breather plug front fork 28 TEEJTNEORMALTFION 5 3 3 3 3 3 UR ROC RE ns 3 Cleaning the dust sleeves of the telescopic fork 28 Checking and adjusting the steering head bearing 28 SERIAL NUMBER LOCATIONS 5 Changing the fork offset caster SX 29 Chassis NUMDEF wa kee law aes 5 Checking adjusting the steering head bearing 30 Engine number engine type 5 Check chain tension 31 Correct chain 5 31 OPERATION INSTRUMENTS 6 Chain maintenance 32 CHURCH GV PEN x 6 Chain wear 32 Hand decompression lever 6 General information about KTM disc brakes 33 Hand brake 6 Adjusting the free travel at the hand brake lever 34 Short circuit button 5 6 Checking the brake fluid level front brake 34 Combination switch EXC 6 Refilling the front brake fluid reservoir 34 BE e s tito e SCR ee ar Checking the front brake pads 34 Starter button EXC 7 Replacing the front brake pads 35 Emergency OFF switch EXC Australia 7 Chan
98. u should install the respec tive fork springs The correct spring rate is shown in the illustrations The stan dard spring is shown in bold print The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork If you are uncertain which spring to use contact your KTM workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder Spring AND ENGIN Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on the road it will suffice to have this job performed in the course of the periodical maintenance serv ice CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK IF YOUR FORK IS LEAKING IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE SEALS REPLACED Cleaning the dust sleeves of the telescopic fork The dust protection bellows 2 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings
99. u to use different secondary ratios in combination with the same chain length The chain adjusters 4 can be rotated by 180 max 272 mm HS 3 16 17 18 AND ENGIN Chain maintenance For 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 X ring chains on the other hand are very simple to clean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry you can use a special X ring chain spray e g Motorex Chainlube 622 WARNING NO LUBRICATION 15 ALLOWED TO REACH THE OR THE DISKS OTHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL CAUTION WHEN MOUNTING THE CHAIN MASTERLINK CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary Chain wear To check the chain wear observe the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 Kilograms 33 Ib upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space o
100. uide bolts for damage Insert the left brake pad into the brake caliper and secure it with the bolt Insert the right brake pad and push the bolt 3 into the brake caliper up to the stop Reattach clips 2 WARNING Oe IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CLIPS HAVE BEEN FITTED CORRECTLY AFTER WORKING ON THE BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on Its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 4 on the left side of the fork fists Loosen and remove the collar nut 5 loosen the clamping screews 6 on the right side of the fork fist Hold the front wheel pull out the wheel spindle 7 NOTE The wheel spindle can be easily removed if you slightly revolve it with a ring spanner SW 27 mm Carefully remove the front wheel from the fork CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED To install the front wheel lift it into the fork position and mount th
101. use brake fluid DOT 5 The color of this silicon oil based product is purple red The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid WARNING HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE QUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCK ETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL AND ENGIN 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 can be adjusted for any hand size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 3 MM 0 1 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking the brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handle bar and the reservoir
102. way of the idle system Clockwise turning reduces the fuel quantity lean mixture counterclockwise turning increases the fuel quantity rich mixture TO ADJUST IDLING CORRECTLY PROCEED AS FOLLOWS 1 Turn in mixture control screw 2 up to the stop and turn it back out to the basic position see technical date engine 2 Warm up the engine 3 Use the adjusting wheel 1 to set the normal idle speed 1400 1500 rpm 4 Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease Memorize this position and turn mixture control screw slowly counterclockwise until the idling speed decreases again Adjust the point of the highest idling speed between these two positions If in the course of this procedure the speed undergoes a relatively high increase reduce the idle speed to a normal level and repeat the procedure specified in 4 serious competitive racers will choose a setting approx 1 4 turn clock wise leaner than this ideal value because their engine will heat up more when used in competitions NOTE If you fail to obtain a satisfying result by following the procedure described above an incorrectly dimensioned idling nozzle may be the cause If a the mixture control screw has been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to b
103. y will return to the SPEED CLK mode button button briefly press O button hold O button 3 secs time time changes to the next digit starts the SETUP menu stores the time and changes to the SPEED CLK dis play mode OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS briefly press button briefly press button briefly press O button hold O button 3 secs SPEED H no function no function next display mode displays the SETUP menu gt lt gt lt Motorcycle is standing SPEED CLK SPEED LAP no function starts stops LAP without clearing LAP figure no function stops LAP stores LAP figure resets LAP to O next display mode setting the clock menu next display mode clears all LAP figures X X LAP LAP next figure no function next display mode next display mode SPEED MAX no function no function next display mode clears MAX SPEED ODO no function no function SPEED TR1 no function no function next display mode clears TR1 S1 A1 next display mode next display mode SPEED TR2 increases the TR2 figure reduces the TR2 figure next display mode clears TR2 X X X X SPEED A1 SPEED S1 no function no function no function SPEED A2 no function no function no function next display mode clears TR1 S1 A1 next display mode next display mode next display mode clears TR1 S1 A1 SPEED S2
104. yed figure cannot be changed Service intervals are indicated in service hours for some KTM offroad motor cycles making the service hour counter a very practical function SPEED ODO display mode odometer The SPEED ODO mode displays the speed and the total distance traveled The display automatically changes to the SPEED H display mode when the front wheel stops turning no function no function changes to the next display mode changes to the next display mode button button briefly press O button hold O button 3 secs The electronic speedometer has a number of display modes functions that you can also activate reveal see Activating and deactivating display modes TRI TR Al A2 9 52 Km h Mph SE CLK H Lu I CU 2 3 SPEED Kmh CLK FWMxic Wi CBC LESC EC DE LD I LAP Activating and deactivating display modes In the display mode SPEED H press and hold the O button for 3 seconds to access the SETUP menu The active functions will be displayed The blink ing function can be activated by pressing the button and deactivated by pressing the button Press and hold the button 3 seconds to store the settings If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode button button briefly press O button hold O button 3 secs activates the blinking display deactivates the blinking di

KTM 400 EXC RACING Motorcycle User Manual

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