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KTM 250 EXC RACING Motorcycle User Manual

Contents

1. Hexagon collar nut flywheel Hexagon collar screw spring hanger kickstarter M6 Loctite 243 10 Nm Hexagon collar screw cover E starter only SX M6 Loctite 243 8 Nm Hexagon collar screw hanger vent hose M6 Loctite 243 8 Nm Allan head screw kickstarter M8 Loctite 243 25 Nm Hexagon collar screw shift lever M6 Loctite 243 10 Nm Hexagon screw engine sprocket M10 Loctite 243 60 Nm Spark plug M10 10 12Nm Spark plug M12x1 25 20 Nm Engine oil Use only fully synthetic oil brands which meet quality requirements API SG SH Shell Advance Ultra 4 of API classes SG or SH information on bottles or higher TEMPERATURE CAUTION 0 C 32 F POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE WEAR 10W 40 15W 40 10W 50 15W 50 TECHNICAL DATA CHASSIS 250 450 525 SX MXC EXC RACING 2003 450 525 SX RACING 250 450 525 EXC RACING 450 525 MXC EXC USA Frame Central tube chrome moly steel frame Fork WP Up Side Down 4860 MXMA Wheel travel front rear 300 335 mm Front brake Disk brake with carbon steel brake disc 0 260 mm 10 2 in brake caliper floated Rear brake Disk brake with carbon steel brake disc 2 220 mm 8 7 in brake caliper floated 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 offro
2. 37 Checking setting distance of the magnetic sensor 38 Battery 39 Charging the battery 39 Fuse NEEN 40 Replacing the headlight parking lightlamp 40 Cooling system 41 Checking the coolant level 41 Bleeding the cooling system 41 Replacing the glassfiber yarn packing of the silencer 42 Cleaning the spark arrestor MXC EXC USA 42 Cleaning the air filter 43 Checking adjustment of the hand decompression release cable A7 Adjusting the throttle cables 43 Changing the original position of the clutch lever 44 Checking the oil level of the hydraulic clutch 44 Bleeding of the hydraulic clutch 44 Carburetor 45 Adjusting the mixture control screw 45 Checking the float level 45 Draining the float chamber of the carburetor 46 9 de ee e 46 Checking the engine oillevel 46 ea toa ade Mere Aw e es dud don cao 47 Changing the engine 47 TROUBLESHOOTING vats xem ER EUR 49 CEEANING EE 57 CONSERVATION FOR WINTER OPERATION 57 STORAGE ov nate aad di Do io er d E tcd REOR Ead 51 Using afte
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5. must be taut see illustration If necessary correct the chain tension A WARNING A EXCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE COMPO NENTS OF THE SECONDARY DRIVETRAIN CHAIN BEARINGS OF TRANSMISSION 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 loosen lock nuts and turn right and left adjusting screws 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 Tighten the counter nut of the adjusting screws Before tightening thr collar nut verify that the chain adjusters O are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut to 80 Nm A WARNING A F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE TIG
6. API SG SH TEMPERATURE 0 C 32 F 10W 40 15W 40 10W 50 15W 50 Engine oil Only use fully synthetic branded oils Shell Advance Ultra 4 meeting or sur passing the quality requirements of API classes SG or SH see specifications on the container 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 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 is accommodated in the hex socket plug 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 Dis mount the oil screen clean the components thoroughly and blow com pressed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and
7. Hand decompression lever 5 H nda Drake Jever Fipo teii nire e a a 5 Digital speedometer indicator lamps 6 Electronic speedometer 6 1 deeg Et Ee 7 Short circuit button SX MXC 11 Combination switch 11 Headlamp switch EXC USA 11 Flashiel 11 Emergency OFF button EXC 11 Emergency OFF switch EXC Australia 12 INCI CAO PC TP 12 EE een Kee 12 CHOKE uk Eege 12 FOL Stahl deViCe eate 13 SEIT 13 Die EE EE 13 FOOL Drake Pedal entere teuit waar a 13 Ile Te WEE 13 Compression damping of fork 14 Rebound damping of fork 14 Damping action during compression of shock absorber SX 24 Compression damping of shock absorber MXC EXC 15 Rebound damping of shock absorber SX MXC EXC 15 SLCC wl lee 15 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 5 ER pic Ene 16 DRIVING INSTRUCTIONS 17 PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE 20 MAINTENANCE WORK ON CHASSIS AND ENGINE 24 Checking and adjusting the steering head bearing 24 Breather plug front 25 Cleaning the dust sleeves of the telescopic fork 25 Adjus
8. connettore a 2 pol 32 connett ventilatore faro verde naran ja rojo negro violeta blanco JIA Go interm intermitente derecho delantero tacometro lampara aviso lampara aviso conector multiple boton de arr par de urg interruptor combinado Interr interr claxon conjunto del 00 phare feu de position clignoteur av gauche clignoteur av droit compteur vitesse temoin feu route temoin de clignoteur connect multiple 4 ba de dem arr d urg commodo contact de stop av contact Harr de stop k Laxon centrale clignot boitier CDI bougie bobine d allumage generateur generateur d regulateur relais de demarreur fusible 10A connect multiple clign arr gauche impuls 6 clign arr droite feu arr et de stop contact d clignoteur demrreur electrique connect multiple 3 batterie 12V 4Ah connect multiple 2 32 connect ventilateur luz de posicion zquierdo delantero luces largas intermitentes 4 luz de freno del Luz de fren tras intermintente unidad cdi bu r APPENDIX APENDICE LL a 2 a 9 2 lt I z LA bobina de encendido generador generado de impulsos regulador de tension rele de arranque fusible principal 10R conector multiple 6 intermitente izquierdo trasero intermitente derecho trasero luz de freno trasero Interup
9. 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 be 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 malfunction 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 at the carburetor bottom Press the tool slightly upward and turn the adjusting wheel Guntil 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
10. turning the adjusting screw clockwise will increase the backlash Tighten the counternut and check whether the throttle grip can be actuated smoothly Mount tank and seat Changing the original position of the clutch lever The adjusting screw 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 counterclock wise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN 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 and cover together with the rubber boot The oil level in the horizontal standing master cylin der should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50 CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO F
11. 49014120 1 OGOLCE IN UO cc 3724 24010 14048 NOILVSITILN G OSN d JIVANVW IWANVW S SYANMO ONANLITINVSONANAIGAY ONIDVY DXW 2X3 XS SZS OSP DXi OSZ IMPORTANT WE STRONGLY SUGGEST THAT YOU 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 A WARNING A IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE Please insert the serial numbers of your motorcycle in the boxes below 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 mainten ance 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 inoperative by any person KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY E
12. E starter do not work The battery is discharged 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 carburetor dirty Float leaks Air filter very dirty Exhaust system is not tight defor med or the silencer does not con tain enough glassfiber yarn Valve gap too small Loss of compression because hand decompressor 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 Hose of engine ventilation is bent Engine oil level too high Motor oil too thin viscosity 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 check 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 w
13. First disconnect the negative and then the positive pole of the battery Remove the filter box cover and unhitch both rubber bands Remove battery Install the battery with the terminals facing the front see illustration connecting the negative terminal post to the battery last A WARNING A F ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS N THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER N 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 EXPLOSIVE 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 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
14. 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 the axle shaft Mount the collar nut tighten the clamping screws on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm Loosen the clamp screws on the right fork leg Take the motorcycle down from its 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 165 A WARNING A F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KIM DEALER AS SOON AS POSSIBLE LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS 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 remove chain tensioner hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held Push
15. collar for damage and that it is filled correctly Mount the air filter on the filter support Mount the filter together with the filter support in the filter box making sure to center them properly and fix them with the filter holding bracket 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 backlash 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 loosen the counter nut and correct the adjustment screw 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 a 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 Loosen the counternut and turn the adjusting screw accordingly Turning the adjusting screw counterclockwise will reduce the backlash
16. 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 limited guarantee information specific to your KTM model and region In accordance with the international quality management ISO 9001 standard KTM uses quality assurance processes that lead to the highest possible product quality REG NO 12 100 6061 TABLE OF CONTENTS Page SERIAL NUMBER LOCATIONS 5 le 5 Engine number engine type 5 OPERATION INSTRUMENTS 5 I UE eer 5
17. correctly The idle speed is controlled by means of the adjusting wheel and the mixture control screw The adjusting wheel is used to adjust the basic setting of the slide The mixture control screw is used to control the idle mixture which arrives at the engine by 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 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 to set the normal idle speed 1400 1500 rpm 4 Turn mixture control screw 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
18. 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 brake pedal The foot brake pedal is located in front of the right footrest Its 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 motorcycle Make sure that you put your bike on solid ground and in a secure position For off road riding you can use the rubber band to additionally secure the center stand in its folded up position Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap Turn the adjusting screws 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 1418X727 18 clicks SX Typ White Power 1418X737 21 clicks EXC MXC Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw REB the degree of damping of the rebound can be adjus
19. inspected by a KTM dealer The fuse capacity is 10 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO INSTALLED OR A FUSE ALLOWED TO BE REPAIRED AN IMPROPER TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with holder O carefully out of the reflector Pull connector off the headlamp and remove rubber cap Disengage retaining clip and take bulb out of reflector When changing the parking light lamp simply pull it out of the holder Insert the new lamp such that the noses engage in the recesses When doing so do not touch the glass body of the lamp so that it remains free from fat Engage retaining clip mount rubber cap and connector If the parking light lamp is to be replaced simply insert it in the holder Reinsert the parking light lamp together with the holder Engage the bottom end of the headlamp mask at the retaining pins and fix the mask by means of the rubber bands 10mm when engine is cold Cooling system Coolant is circulated a water pump 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 C 158 F the thermostat opens and the coolant is also pumped through both aluminum radiators Air
20. its basic position Remove the clips pull out the bolt 6 and remove the brake pads Thoroughly clean the brake caliper with compressed air and check the sleeves of the guide 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 into the brake caliper up to the stop Reattach clips A WARNING A 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 O on the left side of the fork fists Loosen and remove the collar nut loosen the clamping screews on the right side of the fork fist Hold the front wheel pull out the wheel spindle 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
21. 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 complete 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 6 CABLES Check correct setting and easy running of all control cables 7 COOLING FLUID Check the level of the cooling fluid when the engine is cold 8 ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights indicators control lamps and horn while the engine is running 9 LUGGAGE If you are taking luggage with you check that this is securely fastened 4 2 e T m Starting when the engine is cold Open the fuel tap Swing up the side stand or center stand Put the gear in neutral Operate the choke Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter A WARNING A F YOU WANT TO START THE ENGINE MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MIGHT SLIP OFF THE KICK STARTER 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 THROTTLE GRIP THE KICK BACK HAZARD WILL BE HIG
22. remove the float chamber Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it In this position the edge of the float should be parallel with the float chamber sealing surface see illustration 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 o k you can adjust the float height by bending the float lever O Mount the float chamber install the carburetor and adjust the idle speed 3 2 2 T I Ul 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 a cold engine Close the fuel tap and put one end of the hose into a collecting vessel Open the drain plug turning it counterclockwise by serval turns and drain the fuel from the float chamber Then retighten the drain plug and open the fuel tap A WARNING A 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 AR
23. the SPEED H mode The setting can be stored immediately by holding the MODE button for a few seconds until the display returns to the SPEED H mode BUTTON to access the menu to activate the KMH setting BUTTON to activate the MPH setting press the MODE to change to the next mode press and hold the MODE BUTTON 3 sECONDS to store the setting and return to the SETUP menu NOTE If you retrofit this Tripmaster on another motorcycle the power can also be supplied by the 12 V vehicle electric system You will need an additional cable harness spare part no 583 14 069 210 which you can order from your KTM dealer ual 7 e 37 Check set distance of the magnetic sensor The distance between magnet and sensor 0 must be 2 4 0 08 0 16 in otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing in or off the sensor KMH WS mm x 3 14 MPH WS mm x 3 14 1 61 Wheel circumference with standard tires 2205 mm Battery MXC EXC The battery is located under the seat and is 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
24. the motorcycle 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 600 mm Motorcycle on ground unloaded dimension B 565 mm 512 2 2 0 AC T u n 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 600 mm Motorcycle on ground loaded dimension C 510 mm RIGING GAS 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 riding sag is more than 105 mm the spring is to
25. the periodical mainte nance service 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 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 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 silicone spray or engine oil Then push the dust protection bellows into the outer tubes by hand Adjusting the spring preload on the fork SX The spring preload on the SX models can be adjusted changed by 9 mm by turning adjusting screw Turning in a clockwise direction will increase the prestress turning in a counterclockwise direction will decrease the prestress Changing the spring preload will not affect the rebound damping adjustment Generally if the spring preload is higher the rebound damping should also be set higher lt lt G 5 PDS 1218 760 450 525 5 81 99 260 76 95 260 71 90 260 60 65 70 75 80 85 90 RIDE
26. wheel has stopped The TRP1 AVS1 and STP1 figures are automatically reset to O after passing 999 9 BUTTON function BUTTON no function press the MODE to change to the next mode press and hold the MODE 3 5 to automatically reset the TRP1 AVS1 and STP1 figures to O SPEED AVS1 average speed 1 display mode AVS1 is always active and shows the average speed based on the TRP1 and STP1 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 function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1 AVS1 and STP1 figures to O SPEED STP1 stop 1 display mode STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor 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 function BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset the TRP1 AVS1 and STP1 figures to O SPEED TRP2 trip 2 display mode The TRP2 trip meter is always active and counts to 999 9 Contrary to TRP1 the displayed figure can be changed using and buttons Thi
27. 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 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 A WARNING A HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL 2 1 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw In this way the position of the point of pressure e g 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 CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 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 PRO VIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking the brake fluid level front
28. CEEDED THE RESPECTIVE COMPONENTS MUST BE REPLACED RECOMMENDED INSPECTION OF THE 250 450 525 EXC ENGINE USED FOR HOBBY ENDURO COMPETITIONS BY YOUR KTM wORKSHOP ADDITIONAL ORDER FOR THE KTM wORKSHOP a 100 liter fuel consumption is equivalent to approx 15 operating hours 60 hours 400 liter 90 hours 600 liter 120 hours 800 liter 180 hours 1200 liter 240 hours 1600 liter 270 hours 1800 liter Check the clutch disks for wear Check the length of the clutch springs 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 Check the eccentricity of the valve disk 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 damage visual check Check the eccentricity of the crankshaft journal Replace the conrod bearings Check piston pin bearing E qe Replace the balancer shaft bearings Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear Check the length of the bypass valve spring lo NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED THE RESPECTIVE COMPONENTS MUST BE RE
29. E 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 O the oil pump draws engine from the sump of the transmission This engine oil flows through an oil line into the cylinder head for camshaft lubrication the oil quantity is controlled by the jet screw An oil duct branches off to the long oil filter where the coarser particles contained in the engine oil are filtered away Then the engine oil arrives at the short oil filter which also filters the fine particles Now the purified engine oil is pumped past the bypass valve to the conrod bearing and sprayed from below onto the piston through a nozzle The second oil pump draws the engine oil via the short oil screen out of the crankcase thereby lubricating the transmission gears 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 Q If the engine is warm the engine oil must be visible up to the upper edge of the inspection glass Replenish the engine oil if necessary CAUTION INSUFFICIENT AMOUNTS OF OR LOW GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE ENGINE
30. EXC RACING 11 kW Keihin FCR MX 37 Keihin FCR MX 37 3700A 450 EXC RACING 450 SX RACING 12 kW Keihin FCR MX 39 3900A Keihin FCR MX 41 4122A Carburator setting number Main jet 160 160 178 185 Jet needle OBETP OBEKT OBDVR OBDTP Needle position 3 rd from top 3 rd from top 3 rd from top 4 rd from top Starting jet 85 85 Mixture control screw open 1 25 0 75 15 Idling air jet 100 100 100 100 Slide 15 Performance restrictor Idling jet 42 42 42 40 Main air jet 200 200 200 200 85 85 1 15 15 Slide stop Slide stop Stop pump membrane 858 2 15 mm 858 2 15 mm 858 2 15 mm 858 2 15 mm BASIC CARBURATOR SETTING 525 EXC RACING Six Days 525 EXC RACING 525 MXC RACING 12 kW FCR MX 39 Keihin FCR MX 39 3900B 525 SX RACING Keihin FCR MX 41 Carburator setting number 3900A Main jet 178 178 4125A 185 Jet needle OBDTN OBDVT OBDTP Idling jet 42 42 Main air jet 200 200 2 idling air jet 100 100 Mixture control screw open 1 5 1 25 15 Slide 15 Performance restrictor 42 00 Starting jet 85 85 85 1 5 15 Stop pump membrane 858 2 15 mm 858 2 15 mm Slide stop 858 2 15 mm TIGHTENING TORQUES Hexagon collar screw engine case clutch cover ignition cover M6 10 Nm Oil drain plug M12x1 5 20 Nm 10 Nm Hexagon plug oil screen long M20x1 5 15 Nm Allan head plug oil screen short 16 1 5 Col
31. HAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK 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 The free play at the foot brake pedal must then be adjusted by means of the piston rod 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 cylinder to be recognised from the resistance on the foot brake pedal CAUTION 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 disc brake is located on the engine in the vicinity of the oil filters The brake fluid level must not drop below the MIN marking when the vehicle is in an upright position A WARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AUTHORIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir When the brake fluid level has dropped to the MIN mark you need to refill the brake fluid reservoir For this purpose it is recommended to remove screw and to pull the brake fluid reservoir outwards Unscrewing the ca
32. HER DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS 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 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 MW A Starting when the engine is warm 1 Open the fuel tap 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 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 NOTE The carburetor has an accelerator pump Every time you open the throttle fuel will be injected into the intake
33. HTEN 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 you to use different secondary ratios in combination with the same chain length The chain adjusters can be rotated by 180 max 272 mm 16 17 18 KO OVO o Chain maintenance For a long chain life good maintenance is very important Chains without X rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray e g Shell Advance Bio Chain 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 Shell Advance Bio Chain AN WARNING AN NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS OTHER WISE 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 on
34. ILL UP THE MASTER CYLINDER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Bleeding of the hydraulic clutch To bleed the cover of the master cylinder of the clutch needs to be removed For this purpose remove screws and take off cover together with rubber bellows 6 At the slave cylinder of the clutch remove the bleeder nipple In its place mount the bleeder syringe which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubble free state Make sure that the oil does not overflow The bleeder syringe can be purchased from your KTM dealer Having completed the bleeding procedure you have to verify that the oil level in the master cylinder is correct If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID CARBURETOR Adjust idling Keihin FCRMX 37 39 41 Idling adjustment of the carburetor strongly affects the engine s starting behavior That is an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted
35. ILLING SEE BELOW FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZE E G SHELL ADVANCE COOLANT USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING EXTREME CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVERHEATING PROBLEMS TO AVOID THIS AN ELECTRIC BLOWER 15 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 THE COOLANT HAS BEEN DRAINED IT WILL BE ABSOLUTELY NECESSARY TO BLEED THE COOLING SYSTEM DURING FILLING SEE BELOW Bleeding the cooling system By removing the screw at the front end of the cylinder you can drain the coolant To bleed the cooling system fill in approx 0 8 liters 0 2 US gallons of coolant and remove the bleeder screw 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 3 2 2 T I E 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 si
36. LO II 065 9484 8501 0398 34 00 SO 80 60 20 10 DXW 629 099 0862 331426 118poy 44584449 187 161840 gt gt Modell 2003 5 N M a Land Datum Name Dateiname SERV LCE 250 450 525 EXC Racing EEN q RACOSAUS 2 2 lt gt C gt 5 SN mz 2 9 Q 2 5 o Ll COO 14 ook O 2 5 0 5 H HERE 1200 ED 5 0 0 5 11 ra i EZ 5 2 REES ES og EES SR 1 1L 0 ge ge ToT I gg d o HH SSS EN E HH 23 ee 45 a 01 1 1 ge r d ge r d rri HEN 1 4 4 3E UL BEEN 1 Eger zn KOKUSAN H 1 3 0 1 Tj o p 56131 29 530 310 0054 AUS cee EXC RACING 2003 EU 19 03 2002 Scheinwerfer Standl icht Blinker li vo Blinker re vo Tacho Fernlichtkontrolle Blinkerkontrolle 4 pol Stecker Start Not Rus zum Kombischalter Bremslichtsch vo Bremslichtsch hi Horn Bl inkgeber CDI Einheit Ziindkerze Ziindspule Generator Impulsgeber Spannungsregler Startrelais Stecksicherung 10A 6 Stecker Blinker li hi Blinker re hi Brems SchluBlicht Blinkerschalter Startermotor 3 pol Stecker Batterie 12V 4Ah 2 pol Stecker 2 L fteranschluss bl blue br broun gelb ge yellow grau g
37. LY GET OUT OF CONTROL F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIATELY 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 A WARNING A 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 BRAKING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN RIDES ON SALT STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRAKING EFFECT THE 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 WEA KER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL F THE RESI
38. PLACED MAINTENANCE WORK ON CHASSIS AND ENGINE A MA ARN ING A MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK REQUIRES EXPERT SKILLS AND TECHNICAL KNOW HOW FOR YOUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CAR BURETOR 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 COUNTRY
39. QUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI TUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT IN THE EVENT OF SUCH MODIFICATIONS PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION Introduction 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 against 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
40. RROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER CAUTION AFTER RIDES SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL STORAGE 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 compression 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 m
41. RS WEIGHT INCLUSIVE GEARS IN KILOGRAM LLI lt oi UO 2 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 wearing 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 accordingly 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 helper to hold
42. SIDE 1 LITER OF USED OIL CONTAMINATES 1 000 000 LITERS OF WATER Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcycle 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 of the top triple clamp and turn steering stem bolt 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 20 Nm A WARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTOR CYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS 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 Shell Advance Grease Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 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
43. STANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH PLAY THIS IS AN INDICATION 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 A WARNING A MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING 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 CARBURETTOR 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 FLAMMABLE 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 yo
44. SySLeETI e 41 Correct chain tenso susc nda tetti scares 29 Damping action during compression of shock absorber SX 14 Digital speedometer indicator lamps 6 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 Draining the float chamber of the carburetor 46 Page Divine leg De Le 17 Electronic sd 6 Emergency OFF button E 11 Emergency OFF switch EXC Australia 12 Engine number engine type 5 late 47 FECE EE 12 Flasher e EE 11 FOOL Drake ET EE 13 m 12 gr i2 Pm 40 General information about KTM disc brakes 31 General tips and warnings for starting the motorcycle 16 Hand Drake TEVET 5 Hand decompression 5 Headlamp switch EXC 11 Klee dE 13 How to change the handlebar position 28 Die EE 13 Kilometers ce 37 Maintenance work on chassis and engine 24 felt ane een ee eee eer nee o 46 Operation insi Umento ese u
45. THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES THE FRONT AND REAR WHEEL MAY ONLY BE FITTED WITH TIRES THAT HAVE THE SAME PROFILE TYPE BE SURE TO CHECK THE SPOKE TENSION AFTER MINUTES RUNNING TIME THE SPOKE TENSION WILL DECREASE QUICKLY ON NEW WHEELS IF YOU CONTINUE TO DRIVE WITH LOOSE SPOKES THE SPOKES MAY CRACK AND LEAD TO UNSTABLE HANDLING SEE CHECKING THE SPOKE TENSION THE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR 1 PER SON 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 CONDITIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SECOND 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 NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING A WARNING A THE SX MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS AND FREEWAYS WHEN RIDING YOUR MOTORCYCLE PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE DRIVING INSTRUCTIONS Check the following before each start When you sta
46. ad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 2 0 bar 28 psi 2 0 28 psi Fuel tank capacity 7 liters 2 US gallons EXC 8 liters 2 1 US gallons MXC 13 Liter 3 5 gallons Final drive ratio 450 14 50t 525 14 48t 250 12 52t 450 15 45t 525 15 40t 450 14 50t 525 14 48t Chain X Ring 5 8 x 1 4 Available final sprockets 38t 401 421 45t 481 50t 52t Bulbs headlight HS1 12V 35 35W parking light 12V 5W Sockel W2 1x9 5d brake rear light 12V 21 5W Sockel BaY15d flasher light 12V 10W Sockel 155 license plate illmination 12V 1 2W Sockel 1x4 6d Battery maintenance free battery 12V 8Ah Steering head angle 63 5 Wheel base 1481 x 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 TIGHTENING TORQUES CHASSIS WP4860MXMA WP4860MXMA Collar screw front wheel spindle M24x1 5 1418X727 1418X737 Brake caliper front Loctite 243 25 Nm Compression adjuster 18 Brake disk front Loctite 243 15 Nm Rebound adjuster 19 Brake disk rear Loctite 243 15 Nm Spring 4 4 N mm 4 2 N mm Clamping screws upper fork bridge Spring preload 5 mm 0 20 in 5 mm 0 20 in Clamping screws lower fork bridge Air chamber length 90 mm 3 6 in 4i Clamping screws fork stubs Fork oil Collar nut rear wheel spindle M20x1 5 Hexagon nut swing arm bolt M14x1 5 He
47. annually For this purpose dismount the silencer cap and remove any deposits that might exist in region Renew the O ring and mount the silencer cap 4 500069005 222222 AA EAS Cleaning the air filter A dirty air filter impairs the air flow rate reduces the engine performance and increases the fuel consumption In extreme cases dirt may even get into the engine and cause damage Therefore change the air filter in regular intervals For this purpose rotate the two quick release fasteners counter clock wise and pull them outward up to the stop pull the filter box cover forward and remove it Unhook the filter holding brackets at the bottom swing them sideways and take the air filter together with the filter support out of the filter box CAUTION DO NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY TWINAIR FOR AIR FILTER MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS OTHERWISE DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR 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
48. at regular intervals For checking tap on each spoke with 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 A WARNING A 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 OVERLOADING THE SPOKES MUST BE TENSIONED TO 5 NM Replacing the battery of the digital speedometer Remove the headlight mask and disassemble the electronic speedometer Remove the screw connection insert the battery type Duracell CR 2430 with the writing facing up and reinstall the screw connection N61 D UELS LAP DEI 00 MAX LAP Setting the clock To set the clock switch the ignition off and select the SPEED CLK mode Press and hold the MODE button for 3 seconds The blinking digits can be changed using and buttons Press the MODE button to move to the next digit If no button is pressed for 20 seconds the settings will be stored automati cally and the display will return to the SPEED CLK mode BUTTON time BUTTON time press the MODE to change to the next digit press and hold the MODE BUTTON 3 sECONDs to store the time and return to the SPEED CLK mode Activating deactiva
49. ating hour counter a very practical function SPEED ODO display mode The SPEED ODO mode shows the speed and the total kilometers traveled When the front wheel stops turning the display will automatically change to the SPEED H mode The information will disappear in the display when the front wheel stops turning for 1 minute NOTE A Tripmaster switch part no 583 14 069 244 is available as an accessory and enhances the electronic speedometer by providing the following functions 2x Tripmaster 2x chronometer for the lap time Average speed Maximum speed Clock Display in miles Tripmaster switch The switch has three buttons MODE plus and minus A WARNING A DO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT Electronic speedometer functions provided by the Tripmaster switch The display modes on the electronic speedometer will change in the following order If not please read the chapter ACTIVATING AND DEACTIVATING THE DISPLAY MODE SPEED ODO display mode SPEED displays the speed in KPH or MPH The displayed figure cannot be cleared ODO displays the kilometers or miles traveled The displayed figure cannot be cleared BUTTON function BUTTON function T 1 Li 1 press the MODE to change to the next mode press and hold the MODE BUTTON 3 SECONDS to change to the n
50. 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 a water temperature rising up to 120 C 248 F is admissible without fear of problems A WARNING A F POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE 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 F COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND CONSULT DOCTOR A mixture of 40 antifreeze liquid and 60 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 F THE COOLANT HAS BEEN DRAINED IT WILL BE ABSOLUTELY NECESSARY TO BLEED THE COOLING SYSTEM DURING F
51. brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir 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 A WARNING A THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws and remove lid 9 and membrane O Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING A NEVER USE DOTS 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 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 m
52. e OOOO Li Wo CI DIDI LI I SP ODO MAX LAP OK 1 SPEED Digital speedometer indicator lamps The green control lamp flashes in the same rhythm as the flashing indicator when the indicator is working The blue control lamp lights up when the high beam is on Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move The engine must be started in order for the speedometer to be supplied with electricity from the generator An impulse must be received from the wheel sensor to activate the display the front wheel must turn at least one time TEST All of the display elements will light up for 1 second for the function test WS wheel size The display will change and briefly show the diameter of the front wheel in millimeters If the front wheel does not turn the display will automatically change to the SPEED H mode If the front wheel turns the display will automatically change to the SPEED ODO mode SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display mode will automatically change from SPEED ODO to SPEED H H shows the operating hours The operating hour counter starts to count as soon as you start the engine The displayed figure cannot be cleared Service intervals are indicated in operating hours for some KTM offroad motorcycles making the oper
53. e can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 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 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 optimal 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 homo logation 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 slippe
54. e 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 3 01 0 8 US gallons Reserve EXC 52222552655 1 01 0 3 US gallons Choke If you pull the choke button O out as far as possible a bore in the carburetor will be opened through which the engine may take in additional fuel The result is fat fuel air mixture of the type needed for cold starts To deactivate the choke push the choke button back into its basic position n S 2 3 4 5 6 Hot start device 450 525 SX If you pull the hot start device out as far as possible a bore in the carburetor will be opened through which the engine may take in additional air The result is a 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
55. eck oil lines for damage or bends Replace spark plug after 30 hours Check and adjust valve clearance Check engine mounting bolts for tightness NER D z gt 2 Check and adjust valve clearance Check carburetor connection boot for cracks and leaks Check idle speed setting Check vent hoses for damage or bends Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation and bends CARBURETOR adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting 7 cc lt 2 lt Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake lines for damage and leaks Check function smooth operation and adjust free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs Check swing arm bearings Check adjust steering head bearings Check tightness of chassis screws CHASSIS BRAKES triple clamps fork leg axle passage Check spoke tension and rim joint Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wea
56. egree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side 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 1218X760 26 clicks Type White Power 1218X761 26 clicks A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTE NANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 15mm 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 CAUTION NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK IF YOU TURN THE HANDLEBAR TO THE LEFT THE KEY COULD GET DAMAGED GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE 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 lev
57. ench unscrew the respective number of turns for the specific type of shock absorber in a clockwise direction Typ White Power 1218X760 2 turns A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTE NANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 24mm Compression damping of shock absorber MXC EXC The compression damping during compression can be adjusted for the MXC and EXC shock absorbers Mono Compression Control The degree of damping can be adjusted by turning adjusting screw with a screwdriver Turning in a clockwise direction will increase the damping turning 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 1218X761 17 clicks AN WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTE NANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 24mm Rebound damping of shock absorber SX MXC EXC By using the adjusting screw the d
58. ention to start start E starter ing information see driving instructions Engine will not start Kick starter The motorcycle has been out of The easily inflammable components of the new fuels evaporate operation for a longer period of during longer periods of standing still time Therefore old fuel has accu When the motorcycle has been out of operation for more than mulated in the float chamber a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start when the float chamber is filled with new fuel Fuel supply interrupted Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if fuel leaks out the carburetor may need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap Flooded engine 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 Sooty or wet spark plug Clean and dry the spark plug or exchange it respectively Electrode gap too large Adjust spark plug electrode gap to 0 6 mm Spark plug connector or spark plug Dismount spark plug connect ignition cable hold to ground faulty blank place on engine and actuate starter a strong spark must be produced at the spark plu
59. er the handbrake lever and 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 a 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 abitily 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 If the foot brake lever is not released the brake pads rub continuously and the braking system is over heated 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 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 dis tribute 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 precise
60. etting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications and in the homolo gation certificate Tire condition has to be checked every time you want to ride your motorcycle 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 driving comfort and extends the life of your tires A WARNING A DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY 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 F AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT 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 especially on a new motorcycle
61. ext mode ALI ICI nn 30 LILI ual 7 e 7 SPEED MAX display mode MAX displays the maximum speed It is always active BUTTON function BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON 3 SECONDs to reset the MAX figure to 0 SPEED LAP display mode LAP displays the stopped lap time in hours minutes and seconds BUTTON Starts and stops the stop watch The lap time is not reset to O BUTTON Stops the running stop watch stores the lap time and restarts the stop watch The time is reset to O A total of 10 lap times can be stored and read in the SPEED LAP display mode To clear all of the stored lap times hold the MODE button for 3 seconds in the SPEED LAP mode press the MODE to change to the next mode If no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped press and hold the MODE BUTTON 3 SECONDS to reset the LAP figure and all stored lap times to O LAP LAP display mode The lap number is shown at the top and the lap time in hours minutes and seconds at the bottom of the display If no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped Hold the MODE button for 3 seconds in the SPEED LAP mode to clear the stored lap times BUTTON changes to the next lap time E 1 BUTTON function press the MODE BurroN to change to the nex
62. g f no spark is created replace the spark plug f the new spark plug doesn t produce a spark either dis connect the spark plug connector from the ignition cable hold it a distance of approx 5 mm from ground and start If a spark now occurs replace spark plug cap If no spark is produced control ignition system Short circuit cable scored in wiring Dismount the fuel tank disconnect the black yellow cable from harness emergency OFF switch or the cable of the emergency OFF switch and the short circuit short circuit button faulty button respectively and check the ignition spark If a spark is generated look for the problem in the short circuit circuit The plug connection of the CDI Remove the seat and the fuel tank Clean the plug connection unit the pulse generator or the and treat it with contact spray ignition coil has oxydized Water in carburetor or jets blocked Dismount and clean the carburetor Engine fails to idle Glogged idling jet Disassemble the carburetor and clean the jets Incorrect adjustment of adjusting Have the carburetor adjusted screws on carburetor Defective spark plug Replace the spark plug Defective ignition system 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 High oil consumption All switched on lamps blown out Horn flasher lights
63. g 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 ual 7 e 27 How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar in the position that is the most convenient for you The upper tri ple clamp includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support are offset from the cen ter by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws of the handlebar clamps and screws of the handlebar support Position the handlebar support and tighten screws to 40 Nm Mount handlebar and handlebar clamps and tighten screws to 20 Nm The gap between the handlebar support and the handlebar clamps should be the same in the front and in the rear A WARNING A THE SCREWS MUST BE SECURED WITH LOCTITE 243 Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring For this purpose you should dismoun
64. ing preload of the shock absorber 28 Charging the battery 39 Chassis EES 5 CHECK chain EE 29 Checking adjustment of the hand decompression release el 43 Checking and adjusting the steering head bearing 24 Checking the brake fluid level front brake 32 Checking the coolant level 41 Checking the engine oil level ent testet 46 Checking the float te 45 Checking the front brake 32 Checking the oil level of the hydraulic clutch 44 Checking the rear brake fluid 33 Checking the rear brake 34 Checking estre te etn 36 Checking setting distance of the magnetic 38 iso TET 12 e FE 57 Cleamng tie air TILED du a EI S 43 Cleaning the dust sleeves of the telescopic fork 25 Cleaning the spark arrestor MXC EXC 05 42 EE 5 Combination switch 0 0 0000 11 Compression damping of 14 Compression damping of shock absorber MXC EXC 15 Conservation for winter operation 51 Coolihe
65. ith 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 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 Capacitor or voltage regulator Dismount seat and fuel tank and check connections have faulty capacitor and voltage regulator checked The battery isn t charged by the generator because and Blown fuse in the starter relay Dismount left side paneling and filter box cover replace fuse Remove seat and fuel tank and check voltage regulator connections voltage regulator and generator should be checked by a KTM dealer CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft 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 PREMATURE DESTRUCTION OF THESE PARTS You should use normal brand name detergents to clean the motorcycle Especially di
66. iving KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL by KTM SPORTMOTORCYCLE AG AUSTRIA Al rights reserved IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION 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 international 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 An 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 service 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 specifications 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
67. l filter in the front and the short filter in the back of the filter box Grease the O rings O 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 at the clutch cover and fill in 1 2 liters of fully synthetic engine oil Shell Advance Ultra 4 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 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 Operating errror Turn on the emergency OFF switch Australia only E starter Blown fuse Dismount the left paneling and the filter box cover and replace the fuse in the starter relay Discharged battery Recharge the battery and investigate the causes for discharg ing contact a KTM dealer Low outside temperature Start the engine with the kickstarter Engine cranks but doesn t Operating error Open fuel tap tank fuel actuate choke Pay att
68. lar screw for oil filter cover M5 6 Nm 20 Nm Jet screw and hollow screw oil line M8 10 Nm Plug pressure valve M12x1 5 Screws oil pump cover M5 Loctite 222 6 Nm 10 Nm Hex collar screw cylinder head top section water pump cover M6 8 Nm OY Hexagon collar screw cylinder head top section Hexagon collar screw exhaust flange M6 Loctite 243 8 Nm Cylinder head screw 40 50 Nm Allan head screw camshaft gear M8 Loctite 243 28 Nm Stop screw autodecompression M5 Loctite 222 8 Nm 5 O 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 M6 Loctite 648 16 Nm Loctite 243 150 Nm Allan head screw balancer shaft gear M6 Loctite 243 8 Nm Hexagon nut primary gear M20x1 5 Hexagon collar screw clutch spring M6 8 Nm Loctite 243 10 Nm Hexagon collar screw locking lever M5 Loctite 243 6 Nm Allan head screw shift roller locking piece Hexagon collar screw shift roller M5 Loctite 243 6 Nm Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 8 Nm Hexagon collar screw clip M5 Loctite 243 6 Nm Hexagon collar screw chain adjuster M6 8 Nm Hexagon collar screw stator MXC EXC M6 Loctite 243 8 Nm Hexagon collar screw stator SX M5 Loctite 243 6 Nm Hexagon collar screw pulser coil M5 Loctite 243 6 Nm 60 Nm Hexagon collar screw bump part kickstarter M6 Loctite 243 8 Nm
69. lencer s muffling power By experience the front glassfiber yarn packing needs to be replaced more often than the rear silencing mat For this purpose remove the silencer from the vehicle and dismount the front cap Pull the front glassfiber yarn packing together with the inner exhaust pipe O out of the silencer Clean the front inner exhaust pipe To facilitate the mounting procedure you can make a mounting tool 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 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 A WARNING A THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN 42 Cleaning spark arrester MXC EXC USA The spark arrester should be cleaned every time the glassfiber yarn filling is changed or at least once
70. ly 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 250 450 525 5 RACING MODELS WERE UNCOM PROMISINGLY DESIGNED FOR OFF ROAD COMPETITION PURPOSES ONLY EVEN THOUGH THE EXC MODELS ARE APPROVED FOR USE ON PUBLIC ROADS THEIR USE ON ROADS IS RECOMMENDED ONLY TO A VERY LIMITED EXTENT AVOID EXTENDED ON ROAD RIDES AT FULL THROTTLE A WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KIM 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 COL ORED 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 EXAMPLE FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER
71. o soft the spring rate is too low The spring rate is written on the outside of the spring e g 76 95 260 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 1218X761 250 400 450 525 MXC MXC Desert EXC EXC G 76 95 260 71 90 260 66 86 260 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE L LE LL 1418X727 450 525 SX 4 6 N mm 4 4 N mm 4 2 N mm 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM SPRING RATE 1418X737 250 400 450 525 MXC MXC Desert EXC EXC G 4 4 N mm 4 2 N mm 4 0 N mm SPRING RATE 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 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 if your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs
72. otorcycle 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 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 avoid the long waiting times at your mechanic at the beginning of the next biking season TECHNICAL DATA ENGINE 250 450 525 SX MXC EXC RACING 2003 Type 250 EXC 450 Sx 450 MXC 450 EXC 525 SX 525 MXC 525 EXC Design Liquid cooled single cylinder 4 stroke engine with balancer shaft Displacement 448 cc 510 cc Bore Stroke 75 56 5 95 63 4 mm 89 72 mm 95 72 mm Ratio Fuel unleaded premium gasoline with at least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft camshaf
73. p and rubber bellows Add brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 until it reaches the MAX mark then screw rubber bellows and cap back on Rinse off spilled or overflowing brake fluid with water A WARNING A 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 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 A WARNING A 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 toward the chain wheel in order to move the brake piston into
74. 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 A WARNING A BEFORE 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 throttle 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 rewving 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 the next gear Let clutch lever go slowly and open the throttle or shift down again NOTE Dedicated to nothing but offroad racing 250 450 525 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 radia
75. r fit and tension WHEELS Lubricate chain Check clearance of wheel bearings at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact spray Change brake fluid 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 Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain check tension and adjust if necessary Clean air filter 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 s
76. r 5 51 TECHNICAL SPECIFICATIONS ENGINE 52 TECHNICAL SPECIFICATIONS CHASSIS 55 INDEX rr 56 WIRING DIAGRAM Appendix SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube Enter this number in the field on page no 1 Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever is located on the left side of the handlebar The adjust ing screw is used to change the original position of the clutch lever see maintenance work on chassis and engine Hand decompression lever The hand decompression lever 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 is mounted on the handlebars on the right and actuates the front wheel brake The adjusting screw can be used to change the basic position of the hand brake lever see Maintenance
77. r grey gr n g green orange orange rot red schwarz black violett violet wei white blau braun Start Notaus Schalter bl blu br marrone ge giallo gr grigio verde arancione rosso nero violetto bianco 9 1 P 02 N headlight position light indic left fr indic right fr speedometer turn turn high beam indicator turn indicator multip cont plug 4 startsu run off to combinat switch stoplight switch f stoplight switch r horn turn indicator CDI spark plug unit ignition coil generator pulser coil voltage regulator starter relay fuse multip cont plug 6 blinker left rear blinker right rear rear stoplight blink switch starter engine multip cont plug 3 battery 12V 4Ah Manaus cont plug 2 fan connection bleu brun Jaune gris vert orange rouge noir violet blanc bl azul br marron ge amarillo gr gris 9 faro luce di posizione lampegg ant sn lampegg ant dx tachimetro spia abbagliante spia lampeggiator connettore a 4 pol disinteritor partire ulti comando int luce arresto ant int luce arresto pos clacson trasmett di lampeg LUI candela seatola bobina d accens dinamo Impuls regol di tens rele d avviamento fusibile 10A connettore a 6 poli trasmett d lampegg post sn Lampegg post dx fanal post di freno int lampeggiatori mot d avviamento connettore a 3 pol batteria 12V 4Ah
78. rt 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 2 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 3 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 prema ture wear if worst comes to worst the chain may rupture or the coun tershaft of the transmission may break 4 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 deteriorate the driving performance 5 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
79. rty 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 warming 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 switch short circuit button light switch and socket connectors with a contact spray CONSERVATION FOR WINTER OPERATION 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 WARNING A KEEP THE ANTI CO
80. ry terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price REAR FERRIT 222 ORGANIC can be dosed better short life cycle for dry terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face of the brake pads decreases At their thinnest point the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location outside the contact face Check wear in several locations A WARNING A BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMMEDIATELY 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 necessary to top up the brake fluid If the brake fluid level drops below the minimum 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 SHELL ADVANCE BRAKE DOT 5 1 brake fluid one of the best brake currently available We recommend that
81. s is a very useful function for trips taken according to a roadbook TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received BUTTON increases the TRP2 figure BUTTON decreases the TRP2 figure press the MODE BurroN to change to the next mode press and hold the MODE BUTTON 3 to reset TRP2 to 0 SPEED AVS2 average speed 2 display mode AVS2 shows the average speed based on the TRP2 and STP2 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 The displayed figure will deviate from the actual average speed if TRP2 was changed manually or if STP2 was not stopped after the trip BUTTON no function BUTTON no function press the MODE to change to the next mode press and hold the MODE BUTTON 3 to change to the next mode SPEED STP2 stop 2 display mode STP2 is a manual stop watch Start the stop watch by pressing the but ton press again to hold Press again to continue timing Press the MODE button to change to the next mode The STP2 display will blink in the other modes if STP2 continues to run in the background To stop STP2 return to the SPEED STP2 mode and press the button BUTTON starts and stops the stop watch BUTTON no function press the MODE to change to the nex
82. t drive through single chain Camshaft 594 55 590 5521 590 5521 Valve diameter Intake 35 mm Titan 35 mm Valve diameter Exhaust 30 mm Titan 30 mm Valve clearence cold Intake 0 12 mm 0 0047 in Valve clearence cold Exhaust 0 12 mm 0 0047 in Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy cast alluminium alloy forged Piston rings 1 compression ring 1 oil scraper ring Engine lubrication pressure circulation lubrication with two rotor pumps Engine oil full synthetic oil Shell Advance Ultra 4 SAE 10W40 Quantity of engine oil 1 25 liters Primary ratio straight geared spur wheels 33 76 Z Clutch multi disc clutch in oil bath Transmission claw shifted Gear ratio 1 Gear 2 Gear 6 Gear 22 25 21 18 26 21 Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator 12V 150W 12V 40W 12V 150W 12V 40W 12V 150W Spark plug NGK DCPR 8E Spark plug gap 0 6 mm 0 02367 in Cooling system liquid cooled permanent rotation of cooling liquid through mechanically driven water pump Cooling liquid 1 liter 4096 antifreeze 6096 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 Six Days Type 3700A 250
83. t mode press and hold the MODE BUTTON 3 sECONDs to reset STP2 figures to O OVERVIEW OF TRIPMASTER FUNCTIONS SPEED MAX no function next display mode resets MAX to O P starts stops LAP stops LAP stores LAP next display mode clears all LAP figures Standing motorcycle Driving motorcycle next display mode no function figure LAP remains figure resets LAP to O X LAP LAP no function next display mode next display mode X SPEED CLK no function next display mode set clock menu m SPEED H no function next display mode display setup menu next display mode resets TRP1 STP1 and AVS1 to O SPEED 2 increases TRP2 figure decreases TRP2 figure next display mode resets TRP2 100 SPEED AVS2 no function next display mode next display mode SPEED STP2 starts stops STP2 no function next display mode sets STP2 to O next display mode resets TRP1 STP1 and AVS1 to 0 next display mode resets TRP1 STP1 and AVS1 to 0 Short circuit button SX MXC The short circuit button 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 Light off this function is not available in all models Low beam on Q High beam on You may use button O to actuate the horn The red short circuit button serves to switch off the engine Leave the swi
84. t mode press and hold the MODE BUTTON 3 SECONDS to change to the next mode SPEED CLK clock display mode CLK will display time in hours minutes and seconds BUTTON function BUTTON function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 stECONDs to set the time in the menu see SETTING THE CLOCK SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display mode will automatically change from SPEED ODO to SPEED H H shows the operating hours The operating hour counter starts to count as soon as you start the engine The displayed figure cannot be cleared Service intervals are indicated in operating hours for some KTM offroad motorcycles making the operating hour counter a very practical function BUTTON function BUTTON no function press the MODE to change to the next mode press and hold the MODE 3 to change to the SETUP mode see REVEALING CONCEALING functions SPEED TRP1 trip 1 display mode The TRP1 trip meter is always active and counts to 999 9 It is used to measure the length of a trip or the distance between 2 refueling stops TRP1 is linked to AVS1 and STP1 The calculation of these figures is activated 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
85. t 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 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counter clockwise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw Q tighten it to 8 Nm ADJUSTMENT VALUES SPRING PRELOAD minimum preload 4 mm 0 15 in STANDARD PRELOAD 6 mm SX 8 mm EXC MXC maximum Dreload a nn an anaana 10 mm 0 4 in Pivot bearing The pivot bearing for PDS suspension struts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubri cants 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 Check chain tension To check the chain tension park the motorcycle Press the chain upward at the end of the chain sliding component The distance between the chain and the swing arm should be approx 15 mm 0 6 in In the course of this procedure the upper chain portion
86. tch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch O 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 Flasher left gt Flasher right Emergency OFF button EXC The red emergency OFF button 6 is arranged adjacent to the throttle grip To turn off the engine push the button until the engine comes to a standstill 9 Pushing the black starter button will actuate the E starter Emergency OFF switch EXC Australia The red emergency OFF switch is arranged adjacent to the throttle grip C m In this position the E starter is operational and the engine can be started In this position the E starter and ignition circuits are interrup Gi ted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter G Pushing the black starter button will actuate the E starter 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 without kinks Fuel tap OFF In this position th
87. ted 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 1418X727 19 clicks SX Typ White Power 1418X737 20 clicks EXC MXC Damping action during compression of shock absorber SX The shock absorber on the SX models can 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 compression 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 compression 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 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Typ White Power 1218X760 15 clicks Standard high speed setting turn the adjusting screw to the limit in a counterclockwise direction using a box wr
88. 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 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 PREVENT THE THREAD FROM JAMMING The rear wheel is remounted in the reverse order Before tightening the collar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws A WARNING A F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KIM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS 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 TIRES AIR PRESSURE 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 g
89. tighten the plug to 10 Nm CLEANING THE LONG OIL SCREEN The long oil screen is accommodated in the hexagon plug O adjacent to the engine number Dismount the plug together with the oil screen clean the components thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them To mount the long oil screen 6 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 4 2 e T 4 bel CHANGING THE OIL FILTERS Remove the screw and swing the brake fluid container sideward Place receptacle underneath the engine to collect the drained oil Remove the 4 screws and dismount the two oil filter covers Using circlip pliers pull the oil filter inserts 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 neces sary 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 oi
90. ting the display modes It may not be necessary to display all of the display modes functions at the same time It is possible to conceal any information not currently required By deactivating certain functions the MODE button will only allow you to select from the activated modes In the SPEED H mode press and hold the MODE button for 3 seconds to access the SETUP menu The blinking function can be activated by pressing the button and deactivated by pressing the button 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 activates the blinking display BUTTON deactivates the blinking display press the MODE BurTON to change to the next display without changing any settings press and hold the MODE 3 5 to store the settings and change to the SPEED H mode Kilometers or miles The unit kilometers or miles can also be changed The ODO figure will be retained and converted accordingly The TRP1 AVS1 STP1 TRP2 and AVS2 figures will be cleared To select the unit select the SPEED H mode and hold the MODE button for 3 seconds to access the SETUP menu Press the MODE button 10 times until the KMH MPH function blinks Press the button to move to the options Press the button for KMH or the button for MPH If no button is pressed for 20 seconds the setting will be stored automatically and the display will return to
91. ting the spring preload on the fork SX 25 Basic suspension setup for the weight of the driver 26 How to change the handlebar position 28 Changing the spring preload of the shock absorber 28 PIVOL DEANING e habt orae bo DAP d 28 CHECK CHAN TENSION Seti o t eds 29 Correct Chain tension ox even e Cac ac anie s 29 Chain maintenance 30 PAU WEI sods Stet dy peas Ree 30 General information about KTM disc brakes 31 Adjusting the free travel at the hand brake lever 32 Page Checking the brake fluid level front brake 32 Refilling the front brake fluid reservoir 32 Checking the front brake pads 32 Replacing the front brake pads 33 Changing the basic position of the brake pedal 33 Checking the rear brake fluid 39 Refilling the rear brake fluid reservoir 33 Checking the rear brake 34 Replacing the rear brake pads 34 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 111 1 25 1 pIeSS UE EE 36 Checking the spoke tension 36 Replacing the battery of the digital speedometer 36 Setting tne ere aet 37 Kilometers
92. 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 various 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 you should install the respective fork springs The correct spring rate is shown in the illustrations The standard sprin
93. tor clignoteur motor de arrranque conector multiple batteria 12V 4Ah conector multiple conector 2 Lichtschalter Typ CEV 9610 Lights LO beam gt Blinkerschalter tet tc bo 2 ventilador ANHANG APPENDICE APPENDIX APENDICE Je Un 110 31242HO010W 45 JINVAGY uojougmew 0606 27177 5 EFT 557 DV 1 1 134 45 WLI OGOLCE
94. tor 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 A WARNING A 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 GIVING IT A CHANCE TO WARM UP AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED TO BE TAKEN THE ENGINE HAS REACHED ITS OPE RATING TEMPERATURE AS SOON AS THE RADIATORS 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 EASI
95. tu Dd 5 Periodic lubrication and maintenance schedule 20 WU 28 Rebound damping of TOM sxc erben cs 14 Rebound damping of shock absorber SX MXC EXC 15 Refilling the front brake fluid 32 Refilling the rear brake fluid 33 Replacing the battery of the digital speedometer 36 Replacing the front brake pads 33 Replacing the glassfiber yarn packing of the silencer 42 Replacing the headlight parking light lamp 40 Replacing the rear brake E 34 Serial lan ele eg e 5 Setting ClOCK EE 37 SEI EE 13 Short circuit button SX MXC WE 11 SIGS SLAG EE 13 Goer net ttre fpa M S ern REED utut af 15 DONA 2 51 Technical specifications 5 55 Technical specifications engine 52 Tires AI DRESS UE 36 7 ee te eler EE 49 Using after ee 51 Winna dias Appendix ADIGNAdV XIGNdddV JOIGNAddV ONVHNV 02u01 q 0131014 ouBau OI Oo DI upupu 51 16 46 0111 4040 0 q 1120 19 2 81d 31nu uoisuaj
96. ur motorcycle is standing securely Just in case you can shift into first gear CAUTION THE SIDE STAND IS DESIGNED 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 premium gasoline with an octane number of 95 or higher CAUTION USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE 95 OCTANES NEVER USE GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE A WARNING A 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 PERIODIC MAINTENANCE SCHEDULE 2003 250 450 525 SX MXC EXC RACING after every 15 hours or 100 fuel SPORTMOTORCYCLES 1 service after 3 hours or 20 fuel A clean motorcycle can be checked more quickly which saves money Change engine oil short and long oil filters Clean oil screen and drain plug magnet Ch
97. ust be at least 1 mm 0 04 in thick A WARNING A 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 front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips and pull out bolt 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 in the caliper support and of the leaf spring A WARNING A 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 T
98. voltage between the battery poles off load voltage Accurate results can only 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 76 0 5 A 100 75 4h 50 7h 25 11h A 14h If the battery is empty it can be recharged for a maximum period of 10 hours at 0 5 A 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 VENTI LATION 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 Fuse MXC EXC The fuse is located in the starter relay of the E starter underneath the left side paneling Having removed the left side paneling the air box cover and the protection cover Q you will be able to see the fuse The following loads are connected to it E starter system horn flasher lights The starter relay also contains a 10 amp spare fuse 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
99. xagon collar screw handlebar clamp M8 Allan head screw handlebar support Loctite 243 40 Nm Shock absorber top 60 Nm Shock absorber bottom Sprocket screws Ball joint for push rod Loctite 243 10 Nm Engine mounting bolt WP 5018 PDS WP 5018 PDS Engine brace M8 DCC MCC Screw adjusting ring spring preload shock abs M6 1218X760 1218X761 Spoke nipple 4 5 5 Compression adjuster 15 LS low speed TZ Other screws on chassis 2 HS high speed NN Rebound adjuster 26 26 Spring 76 95 260 71 90 260 Other collar nuts on chassis Spring preload 6 mm 0 24 in HEAD WORD INDEX Page Adjusting the free travel at the hand brake lever 32 Adjusting the mixture control screw 45 Adjusting the spring preload on the fork SX 25 Adjusting the throttle cables 43 Basic suspension setup for the weight of the driver 26 Battery ee 39 Bleeding of the hydraulic clutch 44 Bleeding the cooling system 41 Breather plUS Ont TOL base 25 Carburetor adjustment 45 Chain maintenance E 30 WEA Uc 30 Changing the basic position of the brake pedal 33 Changing the engine OU i Rer eed 47 Changing the original position of the clutch lever 44 Changing the spr
100. your motorcycle 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 chassis 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 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 dr
101. ystem 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 250 450 525 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ADDITIONAL ORDER FOR THE KTM WORKSHOP a 100 liter fuel consumption is equivalent to approx 15 operating hours 200 liter 45 hours 300 liter 60 hours 400 liter 90 hours 600 liter 120 hours 800 liter 135 hours 900 liter Check the clutch disks for wear Check the length of the clutch springs 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 Check the eccentricity of the valve disk 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 damage visual check Check the eccentricity of the crankshaft journal Replace the conrod bearings Check piston pin bearing Replace the balancer shaft bearings Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear Check the length of the bypass valve spring NOTE IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EX

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