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KTM 400 EXC Motorcycle User Manual

1. 20 Checking the engine oil level 48 20 49 Changing the engine oil 49 PERIODIC MAINTENANCE 21 Changing the oil filters 50 TROUBLESHOOTING 51 MAINTENANCE WORK CHASSIS AND ENGINE 27 Changing the spring preloading of the shock absorber 27 STORAGE mate 53 do ah 27 CONSERVATION FOR WINTER OPERATION 53 Basic suspension setup for the weight of the driver 28 Checking the shock absorber and spring 28 ud i 53 Determining the static sag of the shock absorber 28 CEEANING SR erdu Oa UR eta ROT eR 53 Determining the riding sag of the shock absorber 28 Checking the basic setup of the telescopic fork 29 oe Changing the spring preload on the telescopic fork TECHNICAL DATA CHASSIS 59 SX THOGGIS tears 29 HEAD WORK INDEX 22220200 61 Changing the spring preload on the telescopic fork Models oe donde ear dh at cae Sede tay lace ee anand 29 WIRING DIAGRAM appendix 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 th
2. AND ENGIN Mount the lower triple clamp upper steering head bearing protection ring O ring upper triple clamp and the blind screw Tighten the collar screw on the lower triple clamp to 60 Nm Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 stages Adjust the steering head bearing without clearance see Checking and adjust ing the steering head support and tighten the clamp screws on the upper triple clamp to 17 Nm in 3 stages Mount the front wheel fender and tighten the screws to 10 Nm Mount the hand brake cylinder and tighten the screws to 10 Nm Mount the staring number plate Mount the front wheel see Dismounting and mounting the front wheel 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 triple clamp 1 includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support 2 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 3 of the handlebar clamps and screws 4 of the handlebar support Position the handlebar support and tighten screws 4 to 40 Nm 30 ft lbs Mount the handlebar and handlebar clamps and tighten screws 3 to 20 Nm 15 155 The gap between the handlebar sup port and the
3. Reserve XC 3 01 0 8 US gallons Reserve EXC 1 01 0 3 US gallons Choke If you pull the choke button 2 out as far as possible a bore in the carbure tor will be opened through which the engine may take in additional fuel The result is a fat fuel air mixture of the type needed for cold starts To deactivate the choke push the choke button back into its basic position Hot start device 450 525 SX If you pull the hot start device 3 out as far as possible a bore in the carbu retor will be opened through which the engine may take in additional air The result is a lean fuel air mixture of the type needed for hot starts To deactivate the hot start device push the hot start button back Into its basic position Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled Foot pedal The foot brake pedal is located in front of the right footrest 115 basic position can be adjusted to your seat position see maintenance work Side stand Push the side stand to the ground with your foot and load it with the motor cycle Make sure that you put your bike on solid ground and in a secure posi tion For off road riding you can use the rubber
4. 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 motorcycle with air permeated tarpaulin or blanket Do not use airtight materials as a possible humidity might not be able to escape and could cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING
5. Mixture control screw open Slide 15 15 15 15 Performance restrictor Slide stop Slide stop Slide stop Stop pump membrane Hot start device BASIC CARBURATOR SETTING Type 858 2 15 mm 450 EXC G XC G RACING USA Keihin FCR MX 3900E 858 2 15 mm 450 EXC RACING SIXDAYS EU Keihin FCR MX 3900 898 2 15 mm 450 SX RACING Keihin FCR MX 4122B 898 2 15 mm 925 EXC XC RACING DESERT EU Keihin FCR MX 3900F Main jet 1 Jet needle OBDVR OBDTR OBDTP OBDVT 78 182 185 178 Idling jet 42 42 40 42 Main air jet 200 200 200 200 00 100 100 100 Idling air jet 1 Needle position 3 from top 4 from top 4 from top 3 from top starting jet 85 85 85 85 Mixture control screw open 1 25 2 0 1 5 1 29 Slide Performance restrictor 15 15 15 15 Slide stop Stop pump membrane Hot start device BASIC CARBURATOR SETTING Type 858 2 15 mm 898 2 15 mm 925 XC G EXC G RACING USA Keihin FCR MX 3900F 925 EXC RACING SIXDAYS EU Keihin FCR MX 3900F 898 2 15 mm 2 2 mm 525 SX RACING Keihin FCR MX 4125C Main jet Jet needle 178 OBDVT 182 OBDTR 185 OBDTP Idling jet 42 42 Main air jet 200 200 200 100 100 100 Idling air jet 42 Needle position Starting jet 3 from top 5 from top 4 from top Mixture control screw open Slide Performance r
6. cold engine Close the fuel tap and put one end of the hose 1 into a collecting vessel Open the drain plug 2 turning it counterclockwise by serval turns and drain the fuel from the float chamber Then retighten the drain plug and open the fuel tap WARNING FUEL IS EASILY FLAMMABLE AND TOXIC WHEN HANDLING FUEL BE SURE TO EXERCISE THE UTMOST CAUTION NEVER PERFORM ANY WORK ON THE FUEL SYSTEM NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE OF THE FUEL PROPERLY Oil circuit SX XC EXC Via the long oil screen 4 the oil pump 3 draws engine oil from the oil sump of the transmission This engine oil flows through an oil line 5 into the cylin der head for camshaft lubrication 6 the oil quantity is controlled by the jet screw 7 An oil duct branches off to the long oil filter 8 where the coarser particles contained in the engine oil are filtered away Then the engine oil arrives at the short oil filter 9 which also filters the fine particles Now the purified engine oil is pumped past the bypass valve 10 to the conrod bear ing 11 and sprayed from below onto the piston through a nozzle 12 The second oil pump 13 draws the engine oil via the short o
7. 1 compression ring 1 oil scraper ring pressure circulation lubrication with 2 rotor pumps Engine oil full synthetic oil Motorex Power Synt 4T 10W 50 Quantity of engine oil Primary drive 1 1 liters Transmission claw shifted lst gear 2 gear 3rd gear Ath gear 5th gear 6th gear Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator Spark plug no generator NGK CR 9 EBK Cooling system Cooling liquid liquid cooled permanent rotation of cooling liquid through mechanically driven water pump 1 2 liters 50 antifreeze 50 destilled water at least 25 13 F JASO T903 TEMPERATUR 0 C 32 F 9W 40 Engine oil Only use fully synthetic engine oils that meet the JASO MA quality require ments see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for tem peratures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F CAUTION POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE WEAR 10W 50 TIGHTENING TORQUES ENGINE 250 5 Hexagon collar screw engine case clutch cover ignition cover water pump cover 6 Oil drain plug 12 1 5 Allen head plug oil screen short 16 1 5 Oil 10 Nm Hexagon plug oil screen long M20x1 5 15 Nm Collar screw for oil filter cover M5 6 Nm Plug pressure valve M12x1 5 20 Nm Screws oil pump co
8. button button briefly press O button hold O button 3 secs Starts and stops the stop watch no function changes to the next display mode clears the 52 figure Kilometers or miles The unit kilometers or miles can also be changed The ODO figure will be retained and converted accordingly TR1 1 51 TR2 and A2 figures will be cleared To select the unit select the SPEED H mode and hold the O button for 3 sec onds to access the SETUP menu Press the O button until the KMH MPH function blinks Press the button briefly to move to the options Press the button for KMH or the button for MPH To set briefly press the O button 1 x and hold for 3 seconds until the dis play returns to the SPEED H mode If no button is pressed for 20 seconds the setting will be stored automati cally and the display will return to the SPEED H mode button to access the menu to activate the KMH display button to activate the MPH display changes to the next mode changes from the menu to the SETUP menu stores and closes the SETUP menu briefly press O button hold O button 3 secs es Le Setting the clock To set the clock switch the ignition off and select the SPEED CLK mode Press and hold the button for 3 seconds The blinking digits be changed using the and buttons Press the button to move to the next digit 0 12 will show the time in the 12 hour mode 0 24 in the 24 hour mode Press and
9. 6 Nm Hexagon collar screw shift roller Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 6 Nm Hexagon collar screw clip Hexagon collar screw chain adjuster M Loctite 243 6 Nm Hexagon collar screw stator XC EXC Hexagon collar screw stator SX Hexagon collar screw pulser coil 5 M6 10 Nm M5 Loctite 243 6 Nm Hexagon collar nut flywheel Hexagon collar screw bump part kickstarter 12 1 60 Hexagon collar screw spring hanger kickstarter Hexagon collar screw cover E starter only SX Hexagon collar screw hanger vent hose M6 Loctite 243 10 Nm M6 Loctite 243 10 Nm M6 Loctite 243 10 Nm Allan head screw kickstarter Hexagon collar screw shift lever M6 Loctite 243 10 Nm M8 Loctite 243 25 Nm M6 Loctite 243 10 Nm Hexagon screw engine sprocket 10 Loctite 243 60 Nm Spark plug Spark plug 10 10 12 Nm M12x1 25 20 Nm CHASSIS 250 SX F 450 525 SX 250 400 450 525 XC EXC 450 525 XC EXC USA Frame Central tube chrome moly steel frame Fork Wheel travel front rear WP 4860 MA PA WP 4860 MA 450 525 XC USA WP 4860 MA PA 300 335 mm Rear suspension Front brake WP Progressive Damping System shock absorber aluminium swing arm Disk brake with carbon steel brake disc 0 260 mm 10 2 brake caliper floated Rear brake Disk brake with carbon steel brake disc 0 220
10. NO LUBRICATION IS ALLOWED TO REACH THE REAR OR THE BRAKE DISKS OTHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL CAUTION WHEN MOUNTING THE CHAIN MASTERLINK CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary Chain wear To check the chain wear observe the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 Kilograms 33 10 upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space 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 AND ENGIN General information about 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
11. WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the front brake pads The brake pads can be Inspected from below The linings must be at least 1 mm 0 04 in thick WARNING OOOO AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC AND ENGIN Replacing the front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips 1 and pull out bolt 2 Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage
12. black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple rw VIAGKAIV FRANCAIS Batterie Ventilateur temoin feu route Relais de clignotants temoin de clignoteur Contacteur de frein avant Alternateur Contacteur au guidon pour ordinateur de bord Phare Contacteur code phare Avertisseur sonore Bobine d allumage Contacteur d allumage Clignotant avant gauche Clignotant arri re gauche Ordinateur de bord Capteur d allumage feu de position Contacteur de frein arri re Feu rouge stop R gulateur redresseur Clignotant avant droit Clignotant arri re droit Capteur de vitesse bouton de d marrage Relais de d marreur D marreur bouton d arr t d urgence Capteur d ouverture de carburateur COULEUR DE CABLE bl noir ye jaune bu bleu vert re rouge wh blanc br brun orange pi rose gr gris pu violet ESPANOL Bateria Motor del ventilador lampara aviso luces largas Rel de la luz intermitente lampara aviso intermitentes Interruptor de luz del freno delantero Generador Interruptor de manillar para instrumento combinado Faro Interruptor de encender apagar la luz larga Claxon Bobina de encendido Cerradura de encendido Luz intermitente izquierda delantera Luz intermitente izquierda trasera Veloc metro digital multifuncional Generador de impulsos luz de posicion Interruptor de luz del freno trasero Luces de parqueo traseras
13. BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the rear brake pads Push the brake caliper 1 toward the chain wheel in order to move the brake piston into its basic position Remove the clips 2 pull out the bolt 3 and remove the brake pads Thoroughly clean the brake caliper with compressed air and check the sleeves of the 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 3 into the brake caliper up to the stop Reattach clips 2 WARNING Oe IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CLIPS HAVE BEEN FITTED CORRECTLY AFTER WORKING ON THE BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on Its frame so that the fron
14. DAMAGE AND INCREASED WEAR DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL TER IS NOT MOUNTED CORRECTLY Thoroughly wash the air filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Also clean the air filter box Check the carburetor collar for damage and that it is filled correctly Mount the air filter on the filter support Insert the air filter and filter support in the throttle cap and mount them in the filter box aligning in a central posi tion and fix with the filter retaining 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 back lash until said thumping should be approx 10mm measured at the lever s outer end If necessary correct this backlash To adjust move back the protective cover 6 loosen the counter nut 7 and correct the adjustment screw 8 accordingly Tighten counter nut and push back protective cover CAUTION THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE CHECKED REGULARY IF THERE IS NO PLAY IN THE DEKO LEVER THIS CAN RESULT IN ENGINE DAMAGE NOTE No adjustment need be made to the automatic decompressor Adjusting the throttle cables The throttle grip should always provid
15. Faro anteriore Commutatore abbagliante anabbagliante Avvisatore acustico Bobina d accensione Interruttore d accensione Indicatore ant sx Indicatore post sx Tachimetro digitale multifunzione Pick up Luce di posizione Interruttore luce post di stop Luce post di posizione stop Regolatore raddrizzatore Indicatore ant dx Indicatore post dx sensore velocit Pulsante d avviamento Rel d avviamento Motorino d avviamento Interrutore di aresto d mergenza Potenziometro carburatore sensore TPS CAVO COLORATO bl nero ye giallo bu blu gn verde re rosso wh bianco br marrone or arancione pi rosa gr grigio pu violetto z ANHANG APPENDICE LA LA ct gt lt LA ct Ol P 4 39IdN3ddV 9NVHNV J gt ne ne E gt lt I gt C o ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Front brake switch Generator Handle bar switch for multi func digital speedometer Headlight High low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button Throttle position sensor TPS CABLE COLOURS bl
16. OPERATION RELATED NOISE STOP IMME DIATELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Always finish braking before you enter a curve Also change down to lower gears depending on your speed When driving down hill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat AN WARNING IN CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF ROAD TRACKS HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAK ING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN RIDES ON SALT STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRAK ING EFFECT 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 WEAKER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH PLAY THIS IS AN INDICA TION THAT SOMETHING IS WRONG WI
17. THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST USE AFTER A PERIOD OF STORAGE Mount the charged battery regard polarity Set the time in the speedometer 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 005 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 250 5 Design Liquid cooled single cylinder 4 stroke engine Displacement 249 51 ccm Bore Stroke 76 55 mm Ratio 12 8 1 Fuel unleaded fuel with at least RON 95 Valve timing 4 valves controlled by finger levers and 2 camshafts driven by a pair of spur gears and a tooth type chain Camshaft 05 Valve diameter Intake 30 9 mm Valve diameter Exhaust 26 5 mm Valve clearence cold Intake 0 10 0 20 mm 0 004 0 008 in Valve clearence cold Exhaust Crank shaft bearing 0 12 0 22 mm 0 005 0 009 in 2 cylinder roller bearings Connecting rod bearing needle bearing Top end bearing Piston bronze bushing alluminium alloy forged Piston rings Engine lubrication
18. adjusting screws Clean and grease the adjusting screws regularly Motorex Long Term Grease 2000 Before tightening the collar nut verify that the chain adjusters 4 are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut 1 to 80 Nm WARNING IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE NOTE The large adjusting range of the chain adjusters 32mm allows you to use different secondary ratios combination with the same chain length The chain adjusters 4 can be rotated by 180 CC 69 69 max 272 mm L2 3 16 17 18 AND ENGIN 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 Motorex Chainlube 622 X ring chains on the other hand are very simple to clean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry you can use a special X ring chain spray e g Motorex Chainlube 622 WARNING
19. btums 12187 05 2 5 turns WP 12187B26 1 5 turns WARNING THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 6 24MM Compression damping of shock absorber XC EXC The compression damping during compression be adjusted for the XC and EXC shock absorbers Mono Compression Control The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver Turning in a clockwise direction will increase the damping turn ing in a counterclockwise direction will decrease the damping STANDARD ADJUSTMENT turn the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber WP 12187 06 15 clicks WARNING THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 2 24MM Rebound damping of shock absorber SX XC EXC By using the adjusting screw the degree of damping of the rebound be adjusted Turn the knob clockwise to increase damping turn it counter
20. 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 Place the motorcycle on the ground again Ask a helper to hold 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 A 600 mm Motorcycle on ground unloaded dimension B 565 mm A oda Be ma E hee ee oe ee 35 mm If the static sag is lower the spring preload of the shock absorber must be reduced if the static sag is higher the spring preload must be increased See chapter Changing the spring preload of the shock absorber Determining the riding sag of the shock absorber Have a helper hold the motorcycle while you sit on the bike in a normal seating position feet on the footrests wearing full protective clothing and bounce up and down a few times to allow the rear wheel suspension to become level Stay on the bike and have another person measure the distance between the same two points and write it down as dimension C riding sag 1
21. conflicts with others These problems or conflicts can be avoided if the motorcycle is used responsibly To safeguard the future of motorcycle sports make sure that you use the motorcycle in accordance with the law show that you are environmentally conscious and respect the rights of others We wish you a lot of fun when driving KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments 1 spare parts manual chassis amp engine AN J V AND LIN J GQUARAN NFURIVIA Be Le gt g Be KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions The motorcycles comply with the regulations and categories currently in effect with the leading interna tional motorcycle associations Observance of the service maintenance and tuning instructions for the engine and chassis specified in the Owner s Manual is a prerequisite for faultless operation and the avoidance of premature wear improperly tuned chassis can lead to damage and breakage of the chassis components see chapter on checking the basic chassis setting The service work specified in the Lubrication and Maintenance Schedule must be performed and serv ice records must be kept for warranty documentation Lack of proper service and maintenance records or documentation could void warranty The fuels and lubricants specified in the Owner s Manual or fluids with equivalent specifications must be used in accord
22. 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 TOYO B 143 FF sintered lining at the back These linings provide an opti mal combination of dosing brake performance and life cycle The lining type is stated on the back of the brake pad and also recorded the homologation papers Other brake pads are available for competition sports FRONT TOSHIBA 38 SINTERED harder to dose good brake per formance long life for wet slippery terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price REAR FERODO 4424 organic better controllability shorter service life for dry terrain TOSHIBA H38 Sinter longer service life than FERODO 4424 higher braking performance BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases The brake disk must be at least 2 80 mm thick at the thinnest point A Check the thickness of the brake disk at several points WARNING BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTITUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMMEDI ATELY AS SOON AS THEY REACH THE WEAR LIMIT HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID RESERVOIRS The brake fluid reservoirs on t
23. digital speedometer Remove the headlight mask and disassemble the electronic speedometer Remove the screw connection 3 insert the battery type CR 2430 with the writing facing up and reinstall the screw connection AND ENGIN Battery XC EXC The battery is located under the seat and 15 maintenance free Maintenance free means you will not need to check the acid level Clean the battery terminals regularly and grease with acid free grease if necessary The charge condition and type of charge are very important for the battery s serv ice life TO REMOVE THE BATTERY First disconnect the negative pole then the positive pole from the battery Remove the filter box cover and detach both rubber bands 1 Remove the battery Install the battery as described for the specific type of battery see illustra tion Connect the minus pole to the battery last ABW WT SOLLTE AUS IRGEND EINEM GRUND ELEKTROLYT SCHWEFELSAURE AUS DER BATTERIE AUSTRETEN IST HOCHSTE VORSICHT GEBOTEN ELEKTROLYT KANN SCHWERE VERBRENNUNGEN VERURSACHEN BEI HAUTKONTAKT MIT REICHLICH WASSER ABSPULEN FALLS ELEKTROLYT IN DIE AUGEN GELANGT MINDESTENS 15 MINUTEN LANG MIT WASSER AUSSPULEN UND SOFORT EINEN ARZT AUFSUCHEN OBWOHL ES SICH UM EINE VERSCHLOSSENE BATTERIE HANDELT KONNEN DENNOCH EXPLOSIVE GASE AUSTRETEN FUNKEN ODER OFFENE FLAMMEN VON DER BATTERIE FERNHALTEN DEFEKTE BATTERIEN AUSSER REICHWEITE VON KINDERN HALTEN UND ORD NUNGSGEMA
24. glass fiber yarn filling in the silencer SX Replace the glass fiber yarn filling in the silencer Enduro Replace the sealing cup for the foot brake cylinder SX Replace the sealing cup for the foot brake cylinder Enduro Fes ete NOTE If the inspection establishes that permissible tolerances are exceeded the respective components must be replaced MAINTENANCE AND ADJUSTING WORK MARKED WITH 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 SERV ICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION IF USING A POWER WASHER DO NOT POINT THE WATER JET AT THE ELECTRIC COMPONENTS PLUGS CABLES BEARINGS CARBURE TOR ETC THE HIGH PRESSURE WILL CAUSE WATER TO PENETRATE INTO THE COMPONENTS AND CAN CAUSE THEM TO MALFUNCTION OR LEAD TO PREMATURE WEAR WHEN TRANSPORTING YOUR KTM ENSURE THAT IT 15 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 TO
25. handlebar clamps should be the same size in the front and in the rear A THE SCREWS 4 MUST BE SECURED WITH LOCTITE 243 AND ENGIN Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Press the chain upward at the end of the chain sliding component The distance between the chain and the swing arm should be approx 8 10 mm 0 31 0 39 in In the course of this procedure the upper chain portion A must be taut see drawing If necessary correct the chain tension WARNING EXCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE COMPONENTS OF THE SECONDARY DRIVETRAIN CHAIN BEARINGS OF TRANS MISSION AND REAR WHEEL ASIDE FROM RESULTING PREMATURE WEAR IF WORST COMES TO WORST THE CHAIN MAY RUPTURE OR THE COUNTERSHAFT OF THE TRANSMISSION MAY BREAK TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks B Tighten the counter nut of the
26. hold the button for 3 seconds to store the settings If no button 15 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 briefly press O button changes to the next digit hold button 3 secs starts the SETUP menu stores the time and changes to the SPEED CLK dis play mode OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS Motorcycle is driving display briefly press button briefly press button briefly press O button hold O button 3 secs SPEED H no function no function next display mode displays the SETUP menu gt lt gt lt Motorcycle is standing SPEED CLK no function no function next display mode setting the clock menu starts stops LAP without stops LAP stores SERA clearing LAP figure figure resets LAP to O next display mode clears all LAP figures LAP LAP next figure no function next display mode next display mode X SPEED no function no function next display mode clears MAX X SPEED ODO no function no function next display mode next display mode SPEED TRI no function no function next display mode clears TRI 51 Al SPEED TR2 increases the TR2 figure reduces the TR2 figure next display mode clears TR2 SPEED 1 no function no function next display mode clears TRI 51 Al SPEED A2 no function no function next display mode next display mode SPE
27. is always active and counts to 999 9 It is used to meas ure the length of a trip or the distance between 2 refueling stops 15 linked to Al average speed 1 The calculation of these figures Is acti vated by the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The Al and 51 figures are automatically cleared after passing 999 9 button no function button no function briefly press button changes to the next display mode hold button 3 secs clears the TRI 51 Al figures SPEED TR2 display mode tripmaster 2 The tripmaster 2 is always active and counts to 999 9 Contrary to TRI the displayed figure can be changed using the and buttons This is a very use ful function for trips taken according to a roadbook button increases the TR2 figure button decreases the TR2 figure briefly press O button changes to the next display mode hold button 3 secs clears the TR2 figure SPEED A1 display mode average speed 1 Al shows the average speed based on the TRI tripmaster 1 and SI stop watch 1 figures The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse Is received button no function button no function briefly press O button changes to the next display mode hold O button 3 s
28. luces de freno Regulador rectificador Luz intermitente derecha delantera Luz intermitente derecha trasera sensor de velocidad bot n de arranque Rel del arranque Motor de arranque el ctrico interruptor de parada de emergencia Potenci metro del carburador COLOR DE CABLE bl negro ye amarillo bu azul gn verde re rojo wh blanco br marron or naranja pi rosado gr gris pu violeta 900 9 3 0103 DU at Group Partner
29. 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 system with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regularly 250 400 450 525 SX XC EXC 2006 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED WORKSHOP FOR RACING ADDITIONAL ORDER FOR THE KTM WORKSHOP every 30 100 liter fuel consumption is equivalent to approx 15 operating hours hours 200 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 eccentricity of the crankshaft journal Check piston pin bearing Check the entire transmission the roller bearings for wear Replace
30. the foot brake pedal 37 dome Biden 7 Checking the rear brake fluid level 37 Electronic speedometer 8 Refilling the rear brake fluid reservoir 37 the Clock Aug an Anne 12 Checking tne teal Drake pads as 38 E CAME dese AN 12 Replacing ne rear Drake pads 38 Fuel a aah an tae meee tem TED 13 Dismounting and mounting the front wheel 38 EE 13 Dismounting and mounting the rear wheel 39 Hot start device 450 525 SX 13 Checking spoke tension os e ue Porch Bw e ca 39 SEINE sege rra 14 Tires e aves 2 gu ok powwow 40 Kickstarter 14 Check set distance of the magnetic sensor 40 ROSE 14 Replacing the battery of the digital speedometer 40 Side Stand RE 14 Battery XC EXC 41 Steering lOCK ai ete oie im ees 14 Charging the battery 41 Compression damping of fork 15 USS CK Ardet uU gc ot ee ce 42 Rebound damping of fork 15 Replacing headlight lamp parking light lamp 42 Damping action during compression of shock absorber SX 15 Cooling System 43 C
31. wheel starts turning SPEED displays the speed H displays the engine s service hours The service hour counter starts to count as soon as you Start the engine The displayed figure cannot be changed Service intervals are indicated service hours for some KTM offroad motor cycles making the service hour counter a very practical function SPEED ODO display mode odometer The SPEED ODO mode displays the speed and the total distance traveled The display automatically changes to the SPEED H display mode when the front wheel stops turning no function no function changes to the next display mode changes to the next display mode button button briefly press O button hold O button 3 secs The electronic speedometer has a number of display modes functions that you can also activate reveal see Activating and deactivating display modes TRI TR Al A2 9 52 Kmh Mph SE CLK H Lu I CU 2 3 SPEED Kmh CLK FWMxic Wi CBC LESC EC DE LD I LAP Activating and deactivating display modes In the display mode SPEED H press and hold the O button for 3 seconds to access the SETUP menu The active functions will be displayed The blink ing function can be activated by pressing the button and deactivated by pressing the button Press and hold the button 3 seconds to store the settings If no button is pressed for 20 seconds the setting will be stored automati cally and t
32. yarn packing of the silencer Aluminum silencers are filled with glassfiber yarn to muffle noise Have the filling checked regularly by an authorized KTM workshop see Lubrication and Service Chart The insulating material fibers escape through the holes in the perforated pipe with time causing the silencer to burn out In addition to causing a higher noise level it will also affect the power characteristic The insulating material suitable for your exhaust is available from your authorized KTM workshop By experience the front glassfiber yarn packing 3 needs to be replaced more often than the rear silencing mat 4 For this purpose remove the silencer from the vehicle and dismount the front cap 5 Pull the front glassfiber yarn packing together with the inner exhaust pipe 6 out of the silencer Clean the front inner exhaust pipe To facilitate the mounting procedure you can make a mounting tool 7 out of wood plastic or metal Insert the mounting tool into the Inner pipe and mount the glassfiber packing Push the inner pipe containing the packing into the silencer such that the slot engages the web A Use a blunt ended object to stuff the glassfiber yarn packing all the way into the silencer and mount the front cap To change the rear silencing mat start by removing the front packing and the inner exhaust pipe Then drill open the rivets and remove the end cap C NOTE In every exhaust repair procedure the O rings mu
33. 2006 250 5 250 EXC RACING 400 EXC RACING 450 SX XC EXC RACING 925 SX XC EXC RACING ART NR 3 211 73EN IMPORTANT gt Please read this manual carefully and completely before going on your first ride It contains a great deal of information and advice which will help you use and handle your bike properly In your own interest please pay particular attention to notices that are marked as follows Si WARNING IGNORING THESE INSTRUCTIONS DANGEROUS TO LIFE AND LIMB CAUTION IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR CYCLE S TRAFFIC SAFETY Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inopera tive by any person All information contained is without obligation KTM Sportmotorcycle AG particularly reserves the
34. 3 WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRES SURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS IN CASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN IN CASE COOLANT IS INGESTED CONSULT A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDI ATELY AND CONSULT DOCTOR A mixture of 50 antifreeze liquid and 50 destilled water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mix ture offers antifreeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION THE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQ UID OR AFTER ADDING MORE THAN 0 25 L 0 06 US GALLONS COOLING LIQUID SEE BELOW FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZE E G MOTOREX ANTI FREEZE USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING EXTREME CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVER HEATING PROBLEMS TO AVOID THIS AN ELECTRIC BLOWER 4 IS OFFERED FOR MODELS WITH ELECTRIC STARTERS ASK YOUR KTM DEALER Checking the coolant level The coolant should be 10 mm 0 4 in above the rad
35. 4860MA PA WP4860MA PA 14187B03 WP4860MA PA 14187 05 Compression adjuster Rebound adjuster Spring 20 18 4 4 N mm 20 20 4 6 N mm Spring preload Air chamber length 5 mm 100 mm 5 mm 100 mm 4 2 N mm 4 4 N mm 5 mm 3 mm Fork oil STANADARD ADJUSTMENT 110 mm 110 mm SAE 5 SAE 5 SAE 5 SAE 5 SHOCK ABSORBER 250 SX F 450 525 SX 250 400 450 525 XC EXC WP 5018 PDS MCC 12187 06 450 525 XC USA 525 EXC SIXDAYS WP 5018 PDS DCC 12187 26 WP 5018 PDS DCC 12187 03 WP 5018 PDS DCC 12187 05 Compression adjuster 15 LS low speed 15 LS low speed 15 15 LS low speed 2 5 HS high speed 2 5 HS high speed 1 5 HS high speed Rebound adjuster 22 22 22 22 Spring Spring preload 76 250 5 mm 80 250 5 mm 80 250 80 250 TIGHTENING TORQUES CHASSIS Collar screw front wheel spindle M24x1 5 40 Nm Brake caliper front 8 Loctite 243 25 Nm Brake caliper FTE radial front M10x1 25 Loctite 243 40 Nm Clamping screws upper fork bridge EXC 8 20 Clamping screws lower fork bridge EXC 8 15 Nm Clamping screws upper fork bridge SX 8 17 Nm Clamping screws lower fork bridge SX 8 12 Nm Hexagon collar screw handlebar clamp 8 20 Allan head srew handlebar support 10 Loctite 243 40 Nm Shock absorber top M12 70 Nm Shock absorber bottom Collar nut swing arm bolt Sprocket Screws 8 35 Nm Engine mounting bol
36. 5 the difference between dimensions A EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground loaded dimension C 510 mm 1 2 AR de ol dee ce Sea esta 90 mm GG EGG RGAE RG GEG 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 high If the ridi Des 12187 03 250 5 4 sag is more than 105 mm the spring is too soft the WP12187B05 450 525 SX The spring rate is written on the outside of the spring e g 80 250 The type 80 250 number of the shock absorber is embossed on the bottom of the tank 84 250 The illustrations show which spring should be installed The standard spring Is shown in bold print 76 250 After installing a different spring readjust the static sag to 35 mm 2 mm 80 250 72 250 76 250 SPRING RATE 60 65 70 15 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM WP12187B06 250 400 450 525XC EXC WP12187B26 450 925 XC USA 84 250 80 250 76 250 SPRING RATE 60 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 1 2 2 WP14187B03 WP14187B05 250 SX F 450 525 SX 4 6 N mm 4 8 N mm SPRING RATE 65 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KIL
37. 6 speed 6 speed 4 speed Gear ratio lst Gear 2nd Gear 3rd Gear Ath Gear 22 26 22 26 22 26 22 26 oth Gear 24 23 24 24 24 23 6th Gear 22 25 21 18 Ignition system Generator 12V 150W 12V 150W 12V 150W Spark plug DCPR 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 50 antifreeze 5096 destilled water at least 25 13 F Starting equipment kick electric starter kickstarter kick electric starter kickstarter kick electric starter Engine oil Only use fully synthetic engine oils that meet the JASO MA quality require JASO T903 MA ments see information on the can KTM recommends Motorex Power Synt 4T in the 10W 5O viscosity for tem peratures over 0 C 32 F or 5W 40 for temperatures under 0 C 32 F TEMPERATUR CAUTION aor POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE WEAR 9W 40 10W 50 BASIC CARBURATOR SETTING 250 EXC RACING EU 400 EXC RACING EU 400 EXC G RACING USA 450 EXC RACING EU Main jet Jet needle Keihin FCR MX 3700B Keihin FCR MX 39000 Keihin FCR MX 39000 Keihin FCR MX 3900E Idling jet Main air jet 200 200 200 200 Idling air jet 100 100 100 100 Needle position Starting jet 3 from top 1 from top 1 from top 3 from top
38. C Racing models again at any time Therefore turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time more than 2 minutes Avoid letting the clutch slip frequently and for extended periods This would cause the engine oil to heat up thereby heating up the cooling system You should drive at low speeds 4 stroke style letting the engine pull you and not at high speeds not by letting the clutch slip 2 stroke style WARNING AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED DO NOT ADJUST THE HANDLEBAR IT WILL LOSE STABILITY CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIV ING IT ACHANCE TO WARM UP AFTER THAT NO FURTHER PRE CAUTIONS IN THIS RESPECT NEED TO BE TAKEN THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADI ATORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVER REV DAMAGING THE VALVES IN ADDITION THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL
39. CAN BE RECOGNIZED AS EARLY AS POSSIBLE ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDI TIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRIALS WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SEC OND MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE REPLACE THE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR DAMAGED IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR LENS THE OPERATOR WILL BE BLINDED NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING THE SX SXS XC MODELS ARE NOT APPROVED FOR USE ON PUB LIC ROADS AND FREEWAYS WHEN RIDING YOUR MOTORCYCLE PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE Check the following before each start When you start off the motorcycle must be in perfect technical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks CHAIN A loose chain can fall from the chain wheels an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear to the chain and chain wheels Exc
40. D AVOID DAMAGE TO THE ON BOARD ELECTRONIC SYSTEM ALWAYS DISCON NECT THE MINUS POLE BEFORE YOU CHARGE THE BATTERY TOCHARGE CONNECT THE BATTERY TO THE BATTERY CHARGER BEFORE YOU SWITCH ON THE BATTERY CHARGER WHEN THE BATTERY IS CHARGED SWITCH OFF THE BATTERY CHARGER BEFORE YOU DISCONNECT THE BATTERY PROVIDE ADEQUATE VENTILATION WHEN CHARGING THE BATTERY IN A CLOSED ROOM THE BATTERY EMITS EXPLOSIVE GASES WHEN CHARGING ELECTROLYTES WILL ESCAPE THROUGH THE SAFETY VALVES IF THE BATTERY IS CHARGED TOO LONG OR AT AN EXCESSIVE VOLTAGE OR AMPERAGE THIS WILL REDUCE BATTERY CAPACITY TRY TO AVOID QUICK CHARGES m AND ENGIN Fuse The fuse 1 is located in the starter relay of the E starter 2 underneath the left side paneling Having removed the left side paneling the air box cover and the protection cover A you will be able to see the fuse The following loads are connected to it E starter system horn flasher lights electronic speedometer The starter relay also contains a 10 amp spare fuse 3 Replace a blown fuse only with an equivalent one If a new fuse that has just been installed gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 10 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED OR A FUSE ALLOWED BE REPAIRED AN IMPROPER TREATMENT COULD DAM AGE
41. E WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING ADDITIONAL ORDER FOR THE KTM WORKSHOP every 60 A 100 liter fuel consumption is equivalent to approx 15 operating hours hours 400 liter Check the clutch disks for wear Check the length of the clutch springs Check the clutch drive for indentations Check the outer clutch hub for indentations 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 Check the valve guides for wear Replace the valve springs Replace the conrod bearings Replace the crankshaft main bearings Check the length of the bypass valve spring Replace the glass fiber yarn filling in the silencer Replace the sealing cup for the foot brake cylinder Replace the throttle slide jet needle and main jet holder every 200 hours NOTE If the inspection establishes that permissible tolerances are exceeded the respective components must be replaced 1st service every 250 400 450 525 SX XC EXC 2006 after 3 hours 15 hours A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY or or 20 fuel 100 fuel Change engine oil short and long oil filters Clean oil screen and drain plug magnet Check oil lines for damage or bends Replace spark plug after 30 hours Check and adjust valve clearance Check engine mounting bolts for tightness Clean the
42. ED 51 no function no function next display mode clears TRI 51 Al X X X X SPEED S2 starts stops S2 no function next display mode clears S2 If the CLK LAP MAX TRI TR2 Al A2 51 and 52 figures are suddenly cleared the battery in the electronic speedometer is empty and must be replaced see Replacing the battery in the electronic speedometer A tripmaster switch Is available as an accessory that lets you control the electronic speedometer functions from the handlebar Filler cap bayonet cap To open the filler cap Turn the filler cap 45 counter clockwise To close the filler cap Put the filler cap on and turn it 45 clockwise Filler screw To open the filler Turn the filler cap counter clockwise To close the filler cap Put the filler cap on and tighten it by turning it clockwise Install the tank breather hose 1 without kinks Fuel tap OFF In this position the fuel tap is closed No fuel can flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too
43. Idling jet 40 Main air Jet 200 Idling air jet 100 Needle position 5 from top starting jet Mixture control screw open slide Performance restrictor Stop pump membrane 898 2 15 mm Hot start device 2 5 mm 250 400EXC 4505 450 XC ope um me me Design Liquid cooled single cylinder 4 stroke engine with balancer shaft Bore Stroke 75 56 5mm 89 64 95 63 4 mm 95 63 4 mm 89 72 m 95 72 mm Fuel unleaded fuel with at least RON 95 USA Premium RON 91 Valve timing 4 valves over rocker arm and 1 overhead camshaft camshaft drive through single chain Camshaft 5532 595 0121 590 5521 590 5521 590 5521 590 5521 Valve diameter Intake 28 mm 35 mm 35 mm Titan Valve diameter Exhaust 24 mm 30 mm 30 mm Titan Valve clearence cold Intake 0 10 0 15 mm 0 004 0 006 Valve clearence cold Exhaust 0 10 0 15 mm 0 004 0 006 Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication pressure circulation lubrication with two rotor pumps Engine oil full synthetic oil Motorex Power Synt 4T 10W 50 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
44. L KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Remove the collar nut 1 remove the chain tensioner 2 and pull out the wheel spindle 3 until you can push the rear wheel forwards Take the chain off the rear sprocket pull out the wheel spindle and carefully remove the rear wheel from the swing arm 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 PRE VENT THE THREAD FROM JAMMING The rear wheel is remounted the reverse order Before tightening the col lar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws WARNING ee IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV IOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESS
45. NING 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 first gear refered to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Close throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and accelerate If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throt tle back to 3 4 the speed hardly decreases although the engine will use less gas Only give as much gas as the engine can handle Through quick and high revving of the throttle the fuel usage increases By shifting down use the brakes if necessary and close the throttle at the same time Pull the clutch lever and shift down to the next gear Let clutch lever go slowly and open the throttle or shift down again Le Jn NG IN NOTE Dedicated to nothing but offroad racing 250 400 450 525 SX XC EXC Racing models make no compromises in their design As such they do not include any radiator fan and the size of the radiator is dimensioned for optimum ergonomics In normal racing the cooling system is sufficient If you use your motorbike in other conditions please note that the E starter allows you to start XC EX
46. O Stops the stop watch stores the lap time and restarts the stop watch again The time is reset to O A total of 10 lap times can be stored If the lap time con tinues to run after you press the button all 10 mem ory locations are occupied To clear all of the stored lap times hold the O button for 3 seconds in the SPEED LAP mode Up to 10 lap times can be stored in this way Changes to the next display mode lf no lap time is stored or the motorcycle is driving the LAP LAP mode will be skipped Clears all LAP figures FWltrnic wi CAC LESC ETC DE ED I LAP LAP LAP display mode to view lap times The LAP LAP display mode will only be shown if lap times have been stored and the front wheel has stopped It will display the lap number and the stopped lap time in hours minutes and seconds Press the button to access the next lap time To clear all of the stored lap times hold the O button for 3 seconds the SPEED LAP mode button changes to the next lap time button no function briefly press O button changes to the next display mode hold O button 3 secs changes to the next display mode SPEED MAX display mode maximum speed MAX displays the maximum speed traveled and 15 always active button no function button no function briefly press O button changes to the next display mode hold button 3 secs clears the MAX figure SPEED TR1 display mode tripmaster 1 The TR1 tripmaster
47. O BEAR ONLY THE LOAD OF THE MOTORCYCLE THE SIDE STAND AND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR CYCLE THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND Fuel The racing engine needs unleaded fuel with at least RON 95 USA Premium RON 91 CAUTION USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE 95 OCTANES NEVER USE GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig 1st service after every 250 SX F 2006 3 hours 10 hours CLEAN MOTORCYCLE CHECKED MORE QUICKLY WHICH SAVES MONEY or or 20 fuel 70 fuel Change engine oil oil filter Clean oil screen drain plug magnet spark plug after 30 hours Check and adjust valve clearance ENGINE Check engine mounting bolts for tightness Clean the spark plug connector and check for a tight fit Check the screws on the kick starter and shif
48. OGRAM WP14187B06 250 400 450 525 XC EXC WP14187B29 490 525 XC USA 4 4 N mm 4 6 N mm SPRING RATE 5 70 75 80 85 90 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM AND ENGIN According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons Similar to the shock absorber smaller deviations in your weight can be compensated by adjusting the spring preload However if your telescopic fork bumps frequently hard end stop during compression you should install harder fork springs to avoid damaging the telescopic fork and frame Changing the spring preload on the telescopic fork SX models The telescopic forks of the SX models come with a preload adjuster for easy adjustment of the spring preload You can adjust the spring preload 9 mm by turning the adjusting screws basic position middle position NOTE Always turn the adjusting screws the same distance on both fork legs Different spring preloads on the fork legs will reduce the telescopic fork s response Changing the spring preload on the telescopic fork XC EXC models The telescopic forks for these models must be partly disassembled to adjust the spring preload see WP ma
49. OTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER OF USED OIL CONTAMINATES 1 000 000 LITERS OF WATER Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring 1 For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 1 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 2 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counterclock wise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw 2 tighten it to 8 Nm ADJUSTMENT VALUES SPRING PRELOAD WP 12187 03 5 mm 0 2 in WP 12187 05 5 mm 0 2 WP 12187 06 6 mm 0 24 in WP 12187 26 5 0 2 in Pivot bearing The pivot bearing 3 for PDS suspe
50. SES BIODEGRADABLE HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL ALWAYS USE ORIGINAL KTM HYDRAULIC OIL AVAILABLE FROM YOUR AUTHORIZED KTM WORK SHOP TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY NEVER REFILL WITH BRAKE FLUID AND ENGIN CARBURETOR Adjust idling Keihin FCRMX 37 39 41 Idling adjustment of the carburetor strongly affects the engine s starting behavior That 15 an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2 The adjusting wheel is used to adjust the basic set ting of the slide The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system Clockwise turning reduces the fuel quantity lean mixture counterclockwise turning increases the fuel quantity rich mixture TO ADJUST IDLING CORRECTLY PROCEED AS FOLLOWS 1 Turn in mixture control screw 2 up to the stop and turn it back out to the basic position see technical date engine 2 Warm up the engine 3 Use the adjusting wheel 1 to set the normal idle speed 1400 1500 rpm 4 Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease Memorize this position and turn mixture control screw slowly counterclockwise until the idling spee
51. SS ENTSORGEN CAUTION NEVER REMOVE THE CLOSURE 2 SINCE IT WILL BE DAMAGED PAY ATTENTION TO THE DIFFERENT INSTALLATION POSITION FOR THE DIF FERENT TYPES OF BATTERIES TOPLITE BATTERY POLES FACE THE FRONT EXIDE BATTERY POLES FACE THE REAR STORAGE If the motorcycle is being immobilized for longer periods of time remove and charge the battery Storage temperature O 35 C avoid direct sunlight Charge the battery every 3 months Charging the battery The battery discharges every day even if it is not used Always disconnect the battery when charging Charge the battery as described in the instructions 3 on the battery housing Do not exceed the amperage and charging time Quick charging at a high amperage has an adverse effect on the service life Always use special charging devices to charge maintenance free batteries e g the KTM charging device item no 58429074000 You can also use this charging device to test the off load voltage and startability of the battery and generator It is impossible to overcharge the battery with this device Charge the battery immediately if it is empty when you start the motorcycle If left to stand in an uncharged condition for a longer period of time the bat tery will run down and sulfatize destroying the battery Recharge the battery every 3 months if it is being stored for a longer period of time CAUTION NEVER REMOVE THE CLOSURE 2 SINCE IT WILL BE DAMAGE
52. TED WARRANTY AND Replacing fork springs 29 LIMITED GUARANTEE INFORMATION 3 Breather plug front fork 30 Cleaning the dust sleeves of the telescopic fork 30 SERIAL NUMBER LOCATIONS 5 Checking and adjusting the steering head bearing 30 Chassis HulnbeF EE 5 Changing the fork offset caster SX 31 Engine number engine type 5 Checking and adjusting the steering head bearing 32 Check chain tension exu 4 284 4484 33 OPERATION INSTRUMENTS 5 Correct chain 33 lee USSR ee s qc Pari xu aes 5 Chain maintenance 34 Hot start lever 250 SX F 6 8181 Tc TERTIO 34 Hand decompression lever 450 525 SX 6 General information about KTM disc brakes 35 Hand brake 6 Adjusting the free travel at the hand brake lever 36 Short circuit button SX XC 6 Checking the brake fluid level front brake 36 Combination switch EXC 6 Refilling the front brake fluid reservoir 36 RSI 7 Checking the front brake pads 36 Starter button EXC 7 Replacing the front brake pads 37 Emergency OFF switch EXC Australia 7 Changing the basic position of
53. TH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Stopping and parking Apply the brakes fully and put the engine into neutral To turn off the engine push the short circuit button or the emergency OFF button with the engine at idling speed until the engine stops Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle WARNING Oe MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN NING THE ENGINE EXHAUST PIPE MUFFLER BRAKE ROTORS AND SHOCK ABSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED CAUTION NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE USE THE SHORT CIRCUIT BUTTON OR THE EMERGENCY OFF BUTTON INSTEAD CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE 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 FLAMMA BLE MATERIALS NOTE REGARDING THE SIDE STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground Is solid and that your motorcycle is standing securely Just case you can shift into first gear CAUTION THE SIDE STAND IS DESIGNED T
54. THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the park ing light lamp with holder 4 carefully out of the reflector Pull connector 5 off the headlamp and remove rubber cap 6 Disengage retaining clip and take bulb out of reflector When changing the parking light lamp simply pull it out of the holder Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above AND ENGIN ru Bee geg Cooling system Sak Coolant is circulated by a water pump 1 located in the engine When the engine is cold the coolant only circulates through the cylinder and the cylin der head After the engine has reached its operating temperature about 70 158 F the thermostat 2 opens and the coolant is also pumped through both aluminum radiators Air blowing in through the radiators cools the coolant The slower the speed of the motorcycle the less the coolant is cooled down Dirty radiators also reduce the cooling efficiency Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap 3 a water temperature rising up to 120 C 248 F is admissible without fear of problems WARNING IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP
55. URE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose Check spoke tension espe cially on a new motorcycle at regular intervals For checking tap on each spoke 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 WARNING Oe SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOAD ING THE SPOKES MUST BE TENSIONED TO 5 NM TIRES AIR PRESSURE front rear Off road 1 0 bar 1 0 bar Road driver only 1 5 bar 2 0 bar AND ENGIN Tires air pressure Tire type tire condition and air pressure level affect the way your motor cycle rides and must therefore be checked whenever you are gett
56. WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE NOTE If you have trouble starting the motorcycle this could be due to old fuel in the float chamber The easily inflammable components of the new fuels evaporate during longer periods of standstill When the motorcycle has been out of operation for more than a week It is there fore recommended to drain the old fuel from the float chamber The engine will immediately start off when the float chamber is filled with new fuel Starting when the engine is warm Open the fuel tap 1 Swing up the side stand Put the gear in neutral Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter NH 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 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 WAR
57. ance with the maintenance schedule No claims can be filed under the warranty for damage or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than average wear on components such as the drive train or the brakes In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached The SX SXS XC and other competition only labeled models are prohibited on public roads the road approved models are only allowed on public roads the original homologated throttled version Without this performance restriction i e de throttled these models are only allowed to be driven off road and not on public roads The EXC models are designed for off road sports endurance competitions enduro and not suitable for predominant motocross use Note The above is a general statement Specific limited warranty and limited guarantee information may vary depending upon distribution Please check with your local KTM dealer for limited warranty and lim ited guarantee Information specific to your KTM model and region In accordance with the international quality management ISO 9001 standard KTM uses REG NO 12 100 6061 quality assurance processes that lead to the highest possible product quality JN IMPORTANT LIMI
58. and grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the Sliding metal sheet 3 in the caliper support and of the leaf spring 41 WARNING eee IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY AFTER WORKING ON THE BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw 5 The free play at the foot brake pedal must then be adjusted by means of the piston rod 6 Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston the brake cylin der to be recognised from the resistance on the foot brake pedal IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking the rear brake fluid level The reservoir
59. band 1 to additionally secure the center stand in its folded up position Steering lock The handlebar can be locked by means of the lock located on the steering head To lock it turn handlebar all the way to the right insert key turn it to left press it in turn it to right and remove it CAUTION NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK IF YOU TURN THE HAN DLEBAR TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com pressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap 1 Turn the adjusting screws 2 clockwise to increase damping turn it counter clockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork WP 14187 20 clicks WP 14187 05 20 clicks WP 14187 06 20 clicks 14187B29 20 clicks Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw 3 REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding SIANDARD ADJUSTMENT turn adjusting screw clockwise as far as it wil
60. cessary correct it Use thicker engine oil see chapter Engine oil Dismount seat and fuel tank and check connections have capacitor and voltage regulator checked Dismount left side paneling and filter box cover replace fuse The battery is discharged The battery isn t charged by the generator because Remove seat and fuel tank and check voltage regulator con nections voltage regulator and generator should be checked by a KTM dealer CLEANING gt 7 7 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 IF USING A POWER WASHER DO NOT POINT THE WATER JET AT THE ELECTRIC COMPONENTS PLUGS CABLES BEARINGS CARBURETOR ETC THE HIGH PRESSURE WILL CAUSE WATER TO PENETRATE INTO THE COMPONENTS AND CAN CAUSE THEM TO MALFUNCTION OR LEAD TO PREMATURE WEAR You should use normal brand name detergents to clean the motorcycle Especially dirty parts should also be cleaned with the help of a paint brush Before cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Drain the float chamber of the carburetor Then take a sho
61. clockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn the adjusting screw clockwise to the stop then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber WP 12187 22 clicks WP1218 BO5 22 clicks WP 12187 06 22 clicks WP 1218 26 22 clicks WARNING THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRES SION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 4 15MM AND Instructions for initial operation Make sure the work for the pre delivery inspection was formed by your authorized KTM workshop The DELIVERY CERTIFICATE and SERVICE MANUAL will be handed over when you pick up your vehicle Read these operating instructions carefully before your first ride Familiarize yourself with the operating elements Set the clutch lever 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 abit
62. cycles before there JASO T903 MA were separate motorcycle specifications Different technical developments made it necessary to a separate specification for four stroke motorcycles the JASO T903 MA standard Whereas car engines require long changing inter TEMPERATUR vals motorcycle engines require a higher power output at higher speeds Most E motorcycle engines also use the same oil to lubricate the transmission and 0 C the clutch The JASO MA standard responds to these special requirements 32 F Only use fully synthetic engine oils that meet the JASO MA quality require ments see information on the can KTM recommends Motorex Power Synt 4T in the 10W 50 viscosity for tem 5W 40 10 50 peratures over O C 32 F or 5W 40 for temperatures under O C 32 F CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE Changing the engine oil Note When changing the engine oil it is necessary to clean the short and long oil screens and to replace both oil filters 250 SX F only one oil filter Engine oil has be changed with the engine at an operating temperature CAUTION AN ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE VERY HOT DO NOT BURN OR SCALD YOURSELF Place the motorcycle on a horizontal surface remove the plug 1 and allow the oil to drain into a receptacle Clean plug with magnet thoroughly Once the entire oil has been drained c
63. d decreases again Adjust the point of the highest idling speed between these two positions If in the course of this procedure the speed undergoes a relatively high increase reduce the idle speed to a normal level and repeat the procedure specified in 4 serious competitive racers will choose a setting approx 1 4 turn clock wise leaner than this ideal value because their engine will heat up more when used in competitions NOTE If you fail to obtain a satisfying result by following the procedure described above an incorrectly dimensioned idling nozzle may be the cause If a the mixture control screw has been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to 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 mal function e g overly rich mixture Therefore these parts should be replaced after approx 200 hours Adjusting th
64. e engine type are stamped into the left side of the engine below the engine sprocket Enter this number on page 1 Clutch lever The clutch lever 1 is located on the left side of the handlebar The adjust ing screw A 15 used to change the original position of the clutch lever see maintenance work on chassis and engine The clutch is hydraulically actuated and adjusts itself automatically Hot start lever 250 5 If you pull the red hot start lever 1 during the starting procedure backward a bore in the carburetor will be opened through which the engine may take additional air The result is a lean fuel air mixture of the type needed for hot starts Hand decompression lever 450 525 SX The hand decompression lever 2 is needed only if the carburetor overflows after a fall To pump the engine free pull the hand decompression lever during the starting procedure The outer end of the lever must provide for a backlash of approx 10mm 0 4 in at all times Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompression lever encounters Hand brake lever The hand brake lever 3 is mounted on the handlebars on the right and actuates the front wheel brake The adjusting screw B can be used to change the basic position of the hand brake lever see Maintenance Short circuit button SX XC The short circuit button 4 turns off the engine When
65. e for backlash of 3 5mm Besides with the engine running the idling speed must not change if you turn the handlebar all the way to the left or right To adjust the throttle cables dismount the seat and the tank together with spoilers Slide back the protection cover 9 Loosen the counternut 10 and turn the adjusting screw 11 accordingly Turning the adjusting screw counterclockwise will reduce the backlash turning the adjusting screw clock wise will increase the backlash Tighten the counternut and check whether the throttle grip can be actuated smoothly Mount tank and seat AND ENGIN Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw counterclockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw clockwise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER TAIN LIMITS ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE Checking the oil level of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws 2 and cover 3 together with the rubber boot 4 The oil level in the horizon
66. e mixture control screw Especially on the EXC models accessing the mixture control screw Is diffi cult For this reasons we have created an appropriate special tool Introduce the special tool on the mixture control screw 2 at the carburetor bottom Press the tool slightly upward and turn the adjusting wheel 3 until the tool engages the slot of the mixture control screw Now you can go about adjusting the screw Marks were provided on the adjusting wheel making it easier to keep track of the turns Checking the float level float height For this purpose dismount the carburetor and remove the float chamber Hold the carburetor in a slanted position such that the float will abut the float nee dle valve but not compress 11 In this position the edge of the float should be parallel with the float cham ber sealing surface see illustration If the float height does not correspond to the desired value check the float needle valve and necessary replace it If the float needle valve is you can adjust the float height by bending the float lever 141 Mount the float chamber install the carburetor and adjust the idle speed AND ENGIN Draining the float chamber of the carburetor Following every wet cleaning procedure the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it Water in the float chamber causes malfunctioning Perform this task on
67. ecs clears the TR1 51 Al figures d gc CT AC 20 SPEED Km h TRI TR M A2 9 52 Mhz 000 MAX LAP CLK H SPEED A2 display mode average speed 2 A2 shows the average speed based on the TR2 tripmaster 2 and S2 stop watch 2 figures The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip no function no function changes to the next display mode changes to the next display mode button button briefly press O button hold O button 3 secs SPEED 51 display mode stop watch 1 51 shows the traveling time based on and continues to run whenever it receives impulses from the wheel sensor The calculation of this figure is acti vated by the first impulse received from the wheel sensor and stops 3 sec onds after the last impulse is received no function no function changes to the next display mode clears the TR1 51 Al figures button button briefly press O button hold O button 3 secs SPEED S2 display mode stop watch 2 52 15 a manual stop watch Start the stop watch by pressing the button press again to hold Press again to continue timing Press the O button to change to the next mode The S2 display will blink in the other modes if S2 continues to run in the background To stop 52 return to the SPEED S2 mode and press the button
68. ectively and check the ignition spark If a spark is generated look for the problem in the short circuit circuit Remove the seat and the fuel tank Clean the plug con nection and treat it with contact spray Dismount and clean the carburetor Engine fails to idle Glogged idling jet Incorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Disassemble the carburetor and clean the jets Have the carburetor adjusted Replace the spark plug Have the ignition system checked TROUBLE CAUSE REMEDY Engine does not rev high Engine will not reach full power Engine stops or splutters in carburetor Engine gets too hot Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition timing faulty Fuel supply partially interrupted or carbu retor dirty Float leaks Air filter very dirty Exhaust system 15 not tight deformed or the silencer does not contain enough glass fiber yarn Valve gap too small Loss of compression because hand decom pressor has no play Electronic ignition timing faulty Insuffient fuel Engine takes air out of control Insufficient cooling liquid Not enough air stream Cooling system has not been bled Radiators very dirty Foam formation in cooling system Bent cooling hose Thermostat defective Blown fan fuse XC Desert Defect thermoswitch XC D
69. esert Fan defective XC Desert 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 with water jet Replace cooling liquid use antifreeze liquid with brand name Shorten or replace cooling hose Dismount and check thermostat opening temperature 70 C 158 F or replace it Replace fuse and check if fan operates properly see below Contact a KTM dealer Check if fan operates properly To do this start the engine then bypass the connections to the thermoswitch bottom right radiator contact a KTM dealer High oil consumption All switched on lamps blown out Horn flasher lights and E starter do not work Hose of engine ventilation is bent Engine oil level too high Motor oil too thin viscosity Capacitor or voltage regulator faulty Blown fuse the starter relay Dislocate i e replace non buckling vetilation hose Check engine oil level and if ne
70. essive tensioning of the chain will put additional load on the components of the secondary drivetrain chain bearings of transmission and rear wheel Aside from resulting in premature wear If worst comes to worst the chain may rupture or the countershaft of the transmission may break TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indicates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as com plete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at the hand brake lever and foot brake lever CABLES Check correct setting and easy running of all control cables COOLING FLUID Check the level of the cooling fluid when the engine Is cold ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights indica tors control lamps and horn while the eng
71. estrictor Stop pump membrane Hot start device 898 2 15 mm 898 2 15 mm 858 2 15 mm 2 5 858 2 15 mm TIGHTENING TORQUES ENGINE 250 400 450 525 SX XC EXC Hexagon collar screw engine case clutch cover ignition cover Oil drain plug 12 1 5 Allan head plug oil screen short 16 1 5 Oil 10 Nm Hexagon plug oil screen long Collar screw for oil filter cover M20x1 5 15 Nm M5 Plug pressure valve 12 1 5 Jet screw hollow screw oil line Screws oil pump cover M8 Hexagon collar screw cylinder head top section Hex collar screw cylinder head top section water pump cover Hexagon collar screw exhaust flange M5 Loctite 222 6 Nm 6 M Loctite 243 10 Nm Cylinder head screw Allan head screw camshaft gear 10 Oil 40 50 Nm Allan head screw cap rocker arm Counter nuts valve adjustment screw Allan head screw primary gear free wheel M8 Loctite 243 28 Nm M5 6 Nm 75 11 Nm 6 Loctite 648 16 Nm Allan head screw balancer shaft gear Hexagon nut primary gear M20x1 5 left Loctite 243 150 Nm M6 Loctite 243 10 Nm Nut for inner clutch hub M18x1 5 Loctite 243 120 Nm Hexagon collar screw clutch spring M6 Loctite 243 8 Nm Allan head screw shift roller locking piece M6 Loctite 243 10 Nm Hexagon collar screw locking lever M5 Loctite 243 6 Nm M5 Loctite 243
72. ever when the brake pads are pressed against the brake disc can be adjusted for any hand size When you press the hand brake lever forwards you should have at least 3 mm free travel Turn the adjusting screw 1 if necessary CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 3 MM 0 1 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking the brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handle bar and the reservoir 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 WARNING eee IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reser voir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e g Motorex Brake Fluid DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water
73. for the rear brake disk is located on the right side of the motor cycle on the rear brake cylinder No air bubble should be visible in inspection glass A when the vehicle is parked a vertical position IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir Add brake fluid as soon as a bubble is visible in inspection glass A To top up remove screw 7 Fill DOT5 1 brake fluid e g Motorex Brake Fluid DOT 5 1 up to the mark B on the inside of the reservoir and remount the screw Spilled brake fluid must be rinsed off with water WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IS AN EFFECTIVE PAINT REMOVER USEONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER AND ENGIN Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in WARNING AT THEIR MOST WORN POINT
74. g indicator when the indicator is working The blue control lamp 6 lights up when the high beam is on green control lamp 5 flashes the same rhythm as the flash SPEED SPEED L 99 Km TR2 M A2 515 00 WS Km h Mph Mies 000 MAX LAP CLK H ri LI Km h rice LILI D ZI CI 000 Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sen sor The display lights up when the engine is running The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor The O button is used to change between display modes The and buttons are used to control various functions TEST All of the display segments briefly light up for the display function test WS wheel size The display changes and the circumference of the front wheel 15 briefly dis played in millimeters 2205 mm corresponds to a front wheel circumference of 21 with production tires Afterwards the display will return to the previous display mode SPEED display mode H service hours Only the SPEED and SPEED ODO display modes are activated in the condition at delivery SPEED H is displayed whenever the display 15 activated and the front wheel is not turning It automatically changes to the SPEED ODO display mode as soon as the front
75. h stop button start button flasher switch start relay battery handle bar switch MN optional starter motor flasher relay E Le BEA RENI multi func digital speedometer regulator rectifier cooling fan 004 7 E e brake switch a a pu bl flasher control lamp bu right rear flasher br driving light lamp front brake switch left rear flasher headlight generator 2 ick u QE i ignition coil left front flasher EXC Racing 2006 pre wiring diagramm main harness 594 11 075 150 05 03 2005 rear light brakelight XL handle bar switch optional il __ 9 a 5 S mz H bi B speed sensor 5 LL j wh 3 1 l a stop switch e bl ignition coil EXC Racing USA 2005 06 ANHANG APPENDICE APPENDIX APENDICE 250 450 525 light switch q wh start button wiring diagramm start relay starter motor PT ey SPI L wh re cooling fan BS generator main harness 594 11 075 100 regulator rectifier br lt 25 02 2005 light brakelight gt y D 18 AIN ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Front brake switch Generator Handle switch for mult
76. he display will return to the SPEED H mode button button briefly press O button hold O button 3 secs activates the blinking display deactivates the blinking display changes to the next display without changing any settings Starts the SETUP stores the settings and changes to the SPEED H mode The following display modes can be activated TRI tripmaster 1 2 tripmaster 2 1 average speed 1 A2 average speed 2 51 stop watch 1 S2 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH MPH display in kilometers or miles see Kilometers or miles If you have activated all of the display modes they will be displayed in the following order SPEED H SPEED CLK SPEED LAP LAP LAP SPEED MAX SPEED ODO SPEED TR1 SPEED TR2 SPEED A1 SPEED A2 SPEED S1 SPEED S2 SPEED CLK time display mode CLK displays the time in hours minutes and seconds button button briefly press O button hold O button 3 secs no function no function changes to the next display mode set the clock menu To set the clock see Setting the clock SPEED LAP lap time display mode You can use the manual stop watch to stop and store up to 10 lap times which you can view in the LAP LAP display mode see below LAP displays the lap times in hours minutes and seconds button button briefly press O button hold O button 3 secs starts and stops the stop watch lap time is not reset to
77. he front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces sary to top up the brake fluid If the brake fluid level drops below the mini mum level either the brake system has a leak or the brake pads are completely worn in this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake systems with Motorex Brake Fluid DOT 5 1 brake fluid one of the best brake currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible with DOT 5 1 Never use brake fluid DOT 5 The color of this silicon oil based product is purple red The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid WARNING HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE QUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCK ETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL AND ENGIN Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 In this way the position of the point of pressure 1 6 the resis tance you feel on the hand brake l
78. i func digital speedometer Headlight High low beam switch Horn Ignition coll Ignition switch Left front flasher Left rear flasher Multi func digital speedometer Pick up Position light Rear brake switch Rear light brakelight Regulator rectifier Right front flasher Right rear flasher Speed sensor Start button Start relay Starter motor Stop button Throttle position sensor TPS CABLE COLOURS bl black ye yellow bu blue gn green re red wh white br brown or orange pi pink gr grey pu purple VIAGKAIV DEUTSCH Batterie ftermotor Fernlichtkontrolle Blinkerkontrolle Blinkerrelais vorderer Bremslichtschalter Generator Lenkerschalter f r Kombiinstrument Scheinwerfer Auf Abblendschalter Hupe Z ndspule Z ndschloss linker vorderer Blinker linker hinterer Blinker Multifunktionsdigitaltacho Impulsgeber Standlicht hinterer Bremslichtschalter hinteres Begrenzungslicht Bremslicht Regelgleichrichter rechter vorderer Blinker Rechter hinterer Blinker Geschwindigkeitssensor Starttaster Startrelais Startermotor Not Aus Schalter Vergaserpotentiometer KABELFARBEN bl blau ye gelb bu blau gn gr n re rot wh weif br braun or orange pi rosa gr grau pu violett ITALIANO Batteria Motorino ventola spia abbagliante spia lampeggiatori Rel indicatori Interruttore luce ant di stop Generatore Interruttore sul manubrio per tachimetro multifunzione
79. iator fins when the engine is cold see diagram In the event of the coolant being drained always fill and bleed the system CAUTION when engine is cold IF POSSIBLE ALWAYS CHECK THE LEVEL OF COOLING LIQUID WHEN THE ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Bleeding the cooling system SX XC EXC By removing the screw 5 at the front end of the cylinder you can drain the coolant To bleed the cooling system fill in approx 0 8 liters 0 2 US gallons of coolant and remove the bleeder screw 6 Do not reinstall the bleeder screw until coolant escapes at the bore without any bubbles Then fill in the coolant until it reaches a level about 10 mm above the radiator fins After a short ride check the coolant level once more AND ENGIN Bleeding the cooling system 250 SX F By removing the screw 1 at the water pump cover you can drain the coolant To bleed the cooling system fill in approx 1 0 liter 0 25 US gallons of coolant and remove the bleeder screw 2 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 10 mm above the radiator fins After a short ride check the coolant level once more Replacing the glassfiber
80. il screen 14 out of the crankcase thereby lubricating the transmission gears 15 Oil circuit 250 SX F The oil pump 20 sucks engine oil from the transmission oil sump through the long oil screen 21 and conveys it to the oil filter 22 where any con tamination 15 filtered out The cleaned engine oil is pumped past the bypass valve 23 to the conrod bearing 24 and sprayed onto the pistons from below through a jet 25 Two other oil ducts lead into the cylinder head One duct supplies the hydraulic chain tensioner 26 the other duct leads to the camshaft bearing support 27 where the camshaft bearings and the cam lever are supplied with oil via spraying nozzles The second oil pump 28 sucks the engine oil out of the crankcase through the short oil screen 29 and uses it to grease the transmission gears 30 Checking the engine oil level The engine oil level can be checked with the engine either warm or cold Place the motorcycle in an upright position and on a horizontal surface not on the Side stand If the engine is cold the engine oil must be visible at the lower edge of the inspection glass A If the engine is warm the engine oil must be visible up to the upper edge of the inspection glass B Replenish the engine oil if necessary CAUTION INSUFFICIENT AMOUNTS OF OR LOW GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE ENGINE Engine oil Automobile engine oil used to be used for four stroke motor
81. ill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start when the float chamber 15 filled with new fuel Close fuel tap loosen fuel hose at carburetor lead into a basin and open fuel tap if fuel leaks out the carburetor may need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap In order to pump the engine free pull the hand decompres Sion lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it Clean and dry the spark plug or exchange It respectively Adjust spark plug electrode gap to 0 6 mm Dismount spark plug connect ignition cable hold to ground blank place on engine and actuate starter a strong spark must be produced at the spark plug If no spark is created replace the spark plug Ifthe new spark plug doesn t produce a spark either disconnect the spark plug connector from the ignition cable hold it a distance of approx 5 mm from ground and start Ifa spark now occurs replace spark plug cap f no spark is produced control ignition system Dismount the fuel tank disconnect the black yellow cable from the cable of the emergency OFF switch and the short circuit button resp
82. ily and experience Hold the handlebars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking the foot brake lever is not released the brake pads rub continuously and the braking system 15 overheated Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you this should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is comprised of the following components Motorcycle ready for operation and tank full Luggage Driver with protective clothing and helmet Pay attention to the running in procedure Running in the Racing models Even very precisely machined sections of engine components have rougher surfaces than components which have been slid ing across one another for quite some time Therefore every engine needs to be broken in For this reason do not load the engine more than 50 of its capacity during the first 3 operating hours Besides the engine speed must not exceed 000 rpm Avoid going full throttle In the fol
83. ine Is running LUGGAGE If you are taking luggage with you check that this is securely fastened Starting when the engine is cold 1 2 3 4 Open the fuel tap 1 Swing up the side stand or center stand Put the gear in neutral Operate the choke 2 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actu ate the E starter WARNING Oe IF 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 KICKSTARTER OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT FORCE 2 WARNING ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE IF YOU DO NOT KICK HARD ENOUGHT WITH AN OPEN THROT TLE GRIP THE KICK BACK HAZARD WILL BE HIGHER DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS NESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE WILL MOVE FORWARD CAUTION MAXIMAL PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV UP THE ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE
84. ing ready to go anywhere on your motorcycle Tire size be found in the technical specifications and the homolo gation certificate Tire condition has to be checked every time you want to ride your motor cycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded 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 Tire pressure should be checked regularly on a cold tire Proper pres Sure ensures optimum driving comfort and extends the life of your tires WARNING DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE HOMOLOGATED TIRES FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Check set distance of the magnetic sensor The distance between magnet 2 and sensor 1 must be 2 4 mm 0 08 0 16 otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing in or off the sensor 1 Replacing the battery of the
85. is setting will deliver better handling in curves The offset is set to 20 mm in the condition at delivery To adjust the offset dismount the front wheel and remove the front wheel fender Remove the screw on the starting number plate Remove the clamp screws on the hand brake cylinder and fasten the hand brake cylinder to the left fork leg with a cable tie to keep the brake line from kinking see illustration Loosen the clamp screws and take the fork legs out of the triple clamps Loosen the collar screw 2 on the lower triple clamp 2 turns Remove the blind screw 1 from the upper triple clamp loosen the clamp screw and upper triple clamp on the seat Remove the O ring 3 and the pro tection ring 4 Tap gently on the lower triple clamp with a rubber hammer to loosen the steer ing stem 5 out of the bearing seat Take the lower triple clamp with the steer ing stem out of the steering head Remove the collar screw from the lower triple clamp and pull out the steer ing stem Thoroughly clean all parts Turn the steering stem 180 and insert it in the triple clamp tighten the collar screw all the way to the stop WARNING PLASTIC INSERT IN THE COLLAR SCREW THREAD MAKES THE COLLAR SCREW SELF LOCKING REPLACE IF THE COLLAR SCREW CAN BE SCREWED IN BY HAND DO NOT CONFUSE THE COLLAR SCREW WITH THE BLIND SCREW THE COL LAR SCREW IS SELF LOCKING Grease the steering head bearing and sealing elements
86. l go turn it back by as many clicks as are specified for the relevant type of fork WP 14187 18 clicks WP 14187BO05 20 clicks WP 14187 06 21 clicks WP 14187B29 20 clicks Damping action during compression of shock absorber SX XC USA 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 com pression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber compres sion rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counterclockwise will decrease the damping SIANDARD LOW SPEED SETTING turn the adjusting screw 4 to the limit in a clockwise direction using a screwdriver unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction WP 12187 15 clicks WP 12187BO05 15 clicks WP 12187B26 15 clicks SIANDARD HIGH SPEED SETTING turn the adjusting screw 5 to the limit in a clockwise direction using a box wrench unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction WP 12187B03 2
87. lean the sealing surface mount the plug together with the sealing ring and tighten it to 20 Nm CLEANING THE SHORT OIL SCREEN The short oil screen 2 is accommodated in the hex socket plug 3 at the engine bottom Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dismount the oil screen clean the components thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and tighten the plug to 10 Nm CLEANING THE LONG OIL SCREEN The long oil screen is accommodated in the hexagon plug 4 adjacent to the engine number Dismount the plug together with the oil screen clean the com ponents thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them To mount the long oil screen 5 place it on an approx 300 mm 12 in long pin type key or a similar tool Insert the pin type key through the opening into the bore of the opposite engine casing wall Then push the oil screen into the engine casing as far as possible Remove the pin type key mount the plug and tighten it to 15 Nm CAUTION THE OIL SCREEN 15 MOUNTED SLIGHTLY DOWNWARDS INCORRECTLY FITTED THE SCREEN LOOSES ITS FUNCTION AND THIS CAN CAUSE INCREASED ENGINE WEAR VAIN AN UN AND ENGIN Changing the oil filters Rem
88. lowing 12 operating hours you may load the engine up to 75 of its capacity Use the motorcycle on various types of terrain road easy off road trails CAUTION THE 250 400 450 525 SX XC EXC RACING MODELS WERE UNCOM PROMISINGLY DESIGNED FOR OFF ROAD COMPETITION PURPOSES ONLY ON THE ROAD APPROVED MODELS ARE ONLY ALLOWED ON PUBLIC ROADS IN THE ORIGINAL HOMOLOGATED THROTTLED VERSION AVOID EXTENDED ON ROAD RIDES AT FULL THROTTLE LS Fu 9 m WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER VEHICLES CAN SEE YOU AS EARLY AS POSSIBLE ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORIES RECOMMENDED BY KTM FOR EXAM PLE FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHI CLES DRIVING PROPERTIES THEFRONT AND REAR WHEEL MAY ONLY BE FITTED WITH TIRES THAT HAVE THE SAME PROFILE TYPE THE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR 1 PERSON ONLY NEVER TAKE ANOTHER RIDER ALONG OBSERVE THE TRAFFIC REGULATIONS DRIVE DEFENSIVELY AND TRY TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS
89. mm 8 7 in brake caliper floated Brake disc Front tires Air pressure offroad Air pressure road driver only Rear tires Air pressure offroad Air pressure road driver only Fuel tank capacity Wear limit max 2 5 mm front and 3 5 mm rear 80 100 21 90 90 21 1 0 bar 14 psi 1 0 bar 14 psi 1 5 bar 110 90 19 140 80 18 250 EXC 120 90 18 1 0 bar 14 psi 1 0 bar 14 psi 2 0 bar 28 psi 2 0 bar 28 psi 7 liters 2 US gallons EXC 8 liters 2 1 US gall XC USA 9 liters 2 4 gall XC 13 liters 3 5 gall 80 100 21 1 0 bar 14 psi 1 5 bar 21 psi 110 100 18 1 0 bar 14 psi Final drive ratio Chain 250 13 48 450 14 52 525 14 48 EU 15 45 USA 14 50 X Ring 5 8 x 174 Available final sprockets 38 40 42 45 48 49 50 51 52 Bulbs headlight parking light brake rear light flasher light 12V 35 35W socket 200 12V 5W socket W2 1x9 5d 12V 21 5W socket 15 12V 10W socket 155 Battery Steering head angle maintenance free battery 12V 8Ah 63 5 Wheel base Seat height unloaded 1481 10 mm 58 3 0 4 in 925 mm 36 5 in Ground clearance unloaded 380 mm 15 1 in Weight without fuel STANDARD ADJUSTMENT approx 106 kg 233 2 Ibs approx 113 kg 248 6 Ibs FORK 250 SX F 450 525 SX 250 400 450 525 XC EXC WP4860MA 14187 06 14187 29 450 525 XC USA 925 EXC SIXDAYS WP
90. n tensioner Check clearance of wheel bearings ENGINE CARBURETOR ADD ON PARTS BRAKES CHASSIS 250 400 450 525 5 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Treat electric contacts and switches with contact spray Treat battery connections with contact grease Change hydraulic clutch fluid Change hydraulic clutch fluid Clean Sparkarrestor XC EXC USA 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 250 400 450 525 SX XC EXC 2006 IMPORTANT CHECKS AND MAINTENANCE TO CARRIED OUT BY THE RIDER Before After For cross At least each every country once start cleaning use a year 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 6 Clean and lubricate chain check
91. ng loosen the five pinch bolts 3 and 5 of the top triple clamp and turn steering stem bolt clockwise 4 until there is no more play Don t tighten the steering stem bolt all the way other wise the bearings will be damaged With a plastic hammer lightly tap on the triple clamp to release tension Retighten the five pinch bolts to 20 Nm EXC and 17 Nm SX Si WARNING IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL A PLASTIC INSERT IN THE THREAD OF THE CLAMPING SCREW 5 MAKES IT SELF LOCKING THE CLAMPING SCREW MUST BE REPLACED IF IT CAN BE TURNED IN BY HAND CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI ODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED The steering head bearings should be regreased at least once a year e g Motorex Long Term 2000 AND ENGIN Changing the fork offset caster SX The fork offset A in the SX models center fork legs center steering head angle can be set to either 18 or 20 mm This allows you to optimize the han dling to match the race course Remove the blind screw 1 to see which offset is set If the mark B is in front the offset is 18 mm This setting will deliver more directional stability on fast race courses If the mark B is in the rear as illustrated the offset is 20 mm Th
92. nsion struts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubricants Grease and other lubricants cause the Teflon coat to dissolve whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing AND ENGIN Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork shock absorber swing arm and frame from being damaged the basic setup of the Suspension components must be suitable for your weight At delivery 5 offroad motorcycles are set to accommodate a driver weighing 70 80 kg wear ing full protective clothing If your weight exceeds or falls short of this range you will need to adjust the basic setup for the suspension components accord ingly Minor deviations in weight can be compensated by adjusting the spring preload Different springs must be installed for larger deviations XXXYY 100 007 100000000909 TOO DD ad d ZA v gt x CL er Gi D Q X Q le 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
93. nual 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 XC EXC models NOTE WP precisely adjusts the spring pressure by inserting pretension spacers Fluctuations in production are compensated with pretension spacers in vari ous heights This can cause the fork springs in the fork legs to have different degrees of pretension Fork springs and pretension spacers should always stay together Replacing fork springs If you weigh less than 70 kg or more than 80 kg you should install the respec tive fork springs The correct spring rate is shown in the illustrations The stan dard spring is shown in bold print The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork If you are uncertain which spring to use contact your KTM workshop According to our experience the damping rate of the compression stage can remain unchanged The damping rate of the rebound stage can be reduced by a few clicks for a softer spring or increased by a few clicks for a harder spring AND ENGIN Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs 1 a few turns order to relieve excess pressure from the inside of the fork To do this place the motorc
94. ompression damping of shock absorber XC 16 Checking the coolant evel sca usc es 43 Rebound damping of shock absorber SX XC EXC 16 Bleeding the cooling system 43 Replacing the glassfiber yarn packing of the silencer 44 GENERAL TIPS AND WARNINGS FOR STARTING Cleaning the spark arrester XC EXC USA 44 THE MOTORCYCLE 2222 17 Cleaning the air filter 45 Instructions for initial operation 17 Checking the adjustment of the hand decompression Running in the Racing models 17 release cable 45 Adjusting the throttle cables 45 DRIVING INSTRUCTIONS 22 18 Changing the original position of the clutch lever 46 Check the following before each start 18 Checking the oil level of the hydraulic clutch 46 Starting when the engine is cold 18 Bleeding of the hydraulic clutch 46 Starting when the engine is warm 19 Carburetor Adjust idling Keihin FCRMX 37 39 41 47 What to do when the engine is flooded 19 Adjusting the mixture control screw TIME 47 Starting 19 Checking the float level float height 47 Shifting Riding 19 Draining the float chamber of the carburetor 48 Braking OR RE 20 Oil circuit TEM DEE 48 Stopping and parking
95. osition 32 Important limited warranty and limited guarantee information 3 55 EE 7 Instructions for initial operation 17 IC 21 11 EN E 14 Kilometers or miles 11 Maintenance work on chassis and engine 27 BOUR eet 20250 SXF amie ded 48 X6 EXO ad es e Dita 48 Operation instruments 5 Overview of the electronic speedometer functions 12 Periodic maintenance 21 PIVOU DEALING ctm 27 Rebound damping of fork 15 Rebound damping of shock absorber SX XC EXC 16 Refilling the front brake fluid reservoir 36 Refilling the rear brake fluid reservoir 37 Replacing fork Springs 29 Replacing headlight lamp parking light lamp 42 Replacing the battery of the digital speedometer 40 Replacing the front brake pads 37 Replacing the glassfiber yarn packing of the silencer 44 Replacing the rear brake pads 38 Running in the Racing models 17 Serial number locations 5 Setting the clock 12 in Lana 14 Shifting Riding 19 Shorn circuit DURON E WEE 6 SIGE siad NEEN 14 Sta
96. ove the screw 1 and swing the brake fluid container sideward Place a receptacle underneath the engine to collect the drained oil Remove the 4 screws 2 and dismount the two oil filter covers Using circlip pliers pull the oil filter inserts 3 out of the housing Clean the oil filter cover the sealing surfaces of the O rings and the engine casing Check the O rings of the oil filter covers for damage and if necessary replace them NOTE The 250 SX F engine only has one oil filter insert 3 Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil Fill oil filter with oil place the long oil filter in the front and the short filter in the back of the filter box Grease the O rings 4 of the oil filter covers and mount the covers Mount the screws and tighten them to 6 Nm Position the brake fluid container and tighten the screw to 8 Nm Return the motorcycle to an upright position Remove the oil dipstick 5 at the clutch cover and fill in 1 2 liters 250 SX F 1 1 liters of fully synthetic engine oil Motorex Power Synt 4T 10W 50 Start the engine and check all screwed connections and the oil filter cover for leaks Finally check the engine oil level and if necessary correct it TROUBLESHOOTING gt 4 7 0 If you had the specified maintenance work on your motorcycle carried out disturbances can hardly be expected Should an error occur nevertheless we advise
97. pressing this button the ignition circuit is short circuited Combination switch EXC The light switch has 2 respectively 3 switch positions A Light off this function is not available in all models B Low beam on C High beam on You may use button 5 to actuate the horn The red short circuit button 6 serves to switch off the engine Leave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch 1 Flasher switch The flasher switch is a Separate unit and is mounted on the left portion of the handlebar The wire harness is designed in a way that whenever you want to use your bike off road you can dismount the entire turn indicator system without affecting the function of the remaining electrical system a Flasher left gt Flasher right Starter button EXC 9 Pushing the black starter button 2 will actuate the E starter Emergency OFF switch EXC Australia The red emergency OFF switch 15 arranged adjacent to the throttle grip In this position the E starter is operational the engine be started 00 In this position the E starter ignition circuits are interrupted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter 9 Pushing the black starter button 4 will actuate the E starter Indicator lamps in
98. r operation 53 eet tu BEER 43 Correct chain 33 Damping action during compression of shock absorber OX AC SAN a ok Rl ta E ark ae ege 15 Determining the riding sag of the shock absorber 28 Determining the static sag of the shock absorber 28 Dismounting and mounting the front wheel 38 Dismounting and mounting the rear wheel 39 Draining the float chamber of the carburetor 48 Driving ANS LUC oris v 225 dc Ce e 18 Page Electronic speedometer 8 Emergency OFF switch EXC Australia 7 Engine number engine 5 ak ri RC ca secs Seg ha cas hc abn 49 Filler cap bayonet Cap 12 Filler cap Screw Cap 15 Flasher e ita ne 7 Foot brake pedal 14 acd Ae age ah i a A 20 EE Geet esis chan Ee Tk Ed KU 159 USA EXC ur pacco E eM 42 General information about KTM disc brakes 35 General tips and warnings for starting the motorcycle 17 Hand brake 6 Hand decompression lever 450 525 SX 6 Headlamp switch EXC USA 7 Hot start device 450 525 SX 13 Hot start lever 250 SX F 6 How to change the handlebar p
99. right to modify any equipment technical specifications prices colors shapes materials services service work constructions equipment and the like so as to adapt them to local conditions or to cancel any of the above items all without previous announcement and without giving reasons KTM stop manufactur ing certain models without previous notice KTM shall not be held liable for any deviations of availabil ity and or ability to deliver illustrations descriptions printing and or other errors The illustrated models partly contain extra equipment which is not applied to standard models 2005 by KTM SPORTMOTORCYCLE AG Mattighofen AUSTRIA All rights reserved Reprint also in extracts with written allowance of KTM SPORTMOTORCYCLE AG Mattighofen only We would like to congratulate you on your purchase of a 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 impor
100. rt drive until the engine has reached the working temperature and also use the brakes By warm ing 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 In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean the motorcycle thoroughly and let it dry after each ride treat the engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corro sion agent A KEEP THE ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER CAUTION AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL STORAGE gt gt Should you wish to make a pause over a longer space of time please observe the following instructions
101. rter Dutton EXC aesan wu ccn e Cal e I A eh 7 SLAIN SOM SET SR Oe Go Siw DG 19 Starting when the engine is cold 18 Starting when the engine is warm 19 Steering lock an i ie 14 stopping and 20 shat wee ble 53 Tabl COIT Ss Do AUS As a SECO aom E 4 Technical Data Chassis 59 Technical Data 54 Tires DIesSUEG 3x 33 oem X De 40 Troubleshooting eae La hide bee ee s 51 Use after a period of storage 53 What to do when the engine is flooded 19 Wiring appendix ENGLISH JIIONJdY LU ET Tl ERE E Pe Pe CU black ellow black green 2 5 5 2 58 5 brown blue white Do E Loea H pick up ignition coil 250 SX F 2005 06 CDI harness 594 39 032 000 20 02 2005 ANHANG APPENDICE APPENDIX APENDICE N black stop button generator ellow black gl 5 c 58 brown blue white green OO ignition coil SX 450 525 2005 06 CDI harness 594 39 032 000 pick up 20 02 2005 JIIONJdY XIGN4iddV 1910N dd high low beam switch horn switc
102. shock absorber 27 Chassis number 5 Check chain tension 33 Check the following before each start 18 Check set distance of the magnetic sensor 40 Checking and adjusting the steering head bearing 30 Checking spoke tension 39 Checking the adjustment of the hand decompression release cable 45 Checking the basic setup of the telescopic fork 29 Checking the brake fluid level front brake 36 Checking the coolant level 43 Checking the engine oil level 48 Checking the float level float height 47 Checking the front brake pads 36 Checking the oil level of the hydraulic clutch 46 Checking the rear brake fluid level 37 Checking the rear brake pads 38 Checking the shock absorber and spring 28 dee a FF ee ic eo AE 13 SE Un cu ROC 53 Cleaning the air filter 45 Cleaning the dust sleeves of the telescopic fork 30 Cleaning the spark arrester XC EXC USA 44 Clutch euer Sur dva Sages ds Mae a Mae e 5 Combination Switch EXC 6 Compression damping of fork 15 Compression damping of shock absorber XC EXC 16 Conservation for winte
103. spark plug connector and check for a tight fit Check the screws on the kick starter and shift lever for a tight fit Vergasermanschetten auf Risse und Dichtheit pr fen Check idle speed setting Entl ftungsschl uche auf Besch digung und knickfreie Verlegung pr fen Check cooling system for leaks check quantity of antifreeze Check exhaust system for leaks and fitment Check cables for damage smooth operation and bends 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 Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks Check function smooth operation and adjust free travel of handbrake foot brake lever Check the screws and guide bolts on the brake system for a tight fit 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 triple clamps fork leg axle passage swingarm shock aborber Check spoke tension and rim joint Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wear fit and tension Lubricate chain clean and grease the adjusting screws on the chai
104. st be replaced by new ones Glass fiber yarn packings are available from your licensed KTM mechanic Make sure the caps are screwed on tightly Mount the muffler stress free before tightening the fixing screws AN WARNING eee THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN NING TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN Cleaning the spark arrester XC EXC USA The spark arrester should be cleaned every time the glassfiber yarn filling is changed or at least once annually For this purpose dismount the silencer cap and remove any deposits that might exist in region B Renew the O ring and mount the silencer cap AND ENGIN Cleaning the air filter The air filter must be cleaned prior to each race or whenever dust has accu mulated To clean lift the filter box cover 1 see illustration and pull off towards the front Detach the bottom of the filter retaining bracket 2 tilt aside and remove the throttle cap 3 and the air filter 4 and filter support 5 from the filter box The SX models do not have a throttle cap CAUTION DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM AGE THE FOAM KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE BIO DIRT REMOVER AND LIQUID BIO POWER NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS OTHERWISE DUST AND DIRT MAY PENETRATE AND CAUSE
105. t 10 60 Engine brace 33 Nm Spoke nipple 4 5 M5 5 Nm Screw adjusting ring spring preload shock abs Other screws on chassis M6 8 10 Other collar nuts on chassis 6 8 Page Activating and deactivating display modes 9 Adjusting the free travel at the hand brake lever 36 Adjusting the mixture control screw 47 Adjusting the throttle cables 45 Basic information on carburetor wear 47 Basic suspension setup for the weight of the driver 28 Battery XO EXC Staa uem ac s dae e 5 41 Bleeding of the hydraulic clutch 46 Bleeding the cooling system 250 SX F 44 Bleeding the cooling system SX XC EXC 43 BUE Lean hes eae EE 20 Breather plug front fork 30 Carburetor Adjust idling Keihin FCRMX 37 39 41 47 Chain maintenance 34 CHAN WES 34 Changing the basic position of the foot brake pedal 37 Changing the engine oil 49 Changing the fork offset caster SX 31 Changing the oil 5 50 Changing the original position of the clutch lever 46 Changing the spring preload on the telescopic fork SX e heo 29 Changing the spring preload on the telescopic fork XCIEXC MOdEIS DEER 29 Changing the spring preloading of the
106. t lever for a tight fit Check carburetor connection boot for cracks and leaks Check idle speed setting CARBURETOR 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 adjust and lubricate Check fluid level of the clutch master cylinder ADD ON PARTS Clean air filter and filter box Check electric wires for damage and bends Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks BRAKES Check function smooth operation and adjust free travel of handbrake foot brake lever Check the screws and guide bolts on the brake system for a tight fit Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs Check swing arm bearings CHASSIS Check adjust steering head bearings Check tightness of chassis screws triple clamps fork leg axle passage swingarm shock aborber Check adjust steering head bearings Check tires and air pressure Check chain chain joint rear sprockets and chain guides for wear fit and tension WHEELS Lubricate chain clean and grease the adjusting screws on the chain tensioner Check clearance of wheel bearings 250 SX F 2006 IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER at least once a
107. t wheel no longer touches the ground Loosen the 2 clamping screws 4 on the left side of the fork fists Loosen and remove the collar nut 5 loosen the clamping screews 6 on the right side of the fork fist Hold the front wheel pull out the wheel spindle 7 NOTE The wheel spindle can be easily removed if you slightly revolve it with a ring spanner SW 27 mm Carefully remove the front wheel from the fork CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED To install the front wheel lift it into the fork position and mount the axle shaft Mount the collar nut 5 tighten the clamping screws 6 on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm 30ft Ib Loosen the clamp screws on the right fork leg Take the motorcycle down from 115 stand Press the front wheel brakes and push down on the fork a few times vigorously so that the fork legs come into alignment Only after this has been accomplished tighten the clamp screws on both fork legs with 15 Nm IF YOU DON T HAPPEN TO HAVE TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEE
108. tal standing master cylinder should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Motorex Kupplungs Fluid 75 Biodegradable hydraulic oil is available from your KTM dealer bOml CAUTION KTM USES BIODEGRADABLE HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL ALWAYS USE ORIGINAL KTM HYDRAULIC OIL AVAILABLE FROM YOUR AUTHORIZED KTM WORK SHOP TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY NEVER REFILL WITH BRAKE FLUID Bleeding of the hydraulic clutch If the clutch lever starts to feel unresponsive the clutch control system needs to be bled You will need a bleeder syringe special tool and biodegradable hydraulic oil Both are available from your KTM dealer Turn the handlebar until the master cylinder is in a horizontal position remove the screws 2 the cover 3 and the rubber boot 4 Fill the bleeder syringe 6 with biodegradable hydraulic oil Motorex Kupplungs fluid 75 Remove the bleeder screw 5 from the slave cylinder and mount the bleeder syringe Press oil into the system until the oil runs out of the hole 7 in the master cylinder without bubbles Occasionally extract the oil from the master cylinder reservoir to keep it from overflowing After you finish bleeding remove the bleeder syringe mount the bleeder screw correct the oil level in the reservoir and mount the cover see above CAUTION KTM U
109. tant information on motorcycle maintenance At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out however that minor discrepancies may exist resulting from further design upgrades of these motorcycles This manual is an important part of your motor cycle and should be passed on to any subsequent owner case you decide to sell 11 We expressly point out that work marked with an asterisk in the chapter Maintenance work on the chas sis and engine must be performed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer For your own safety use KTM approved parts and accessories only KTM 15 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
110. the glass fiber yarn filling in the silencer SX Replace the glass fiber yarn filling in the silencer Enduro Replace the sealing cup for the foot brake cylinder SX Replace the sealing cup for the foot brake cylinder Enduro Replace the throttle slide jet needle and main jet holder every 210 hours NOTE If the inspection establishes that permissible tolerances are exceeded the respective components must be replaced 250 400 450 525 SX XC EXC 2006 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED WORKSHOP FOR HOBBY USE ADDITIONAL ORDER FOR THE KTM WORKSHOP 100 liter fuel consumption is equivalent to approx 15 operating hours Check the clutch disks for wear See E A 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 SSES Replace the camshaft bearings ied bet oe eg 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 111111 Check the chain tensioner toting for damage visual check ss Check the eccentricity of the crankshaft journal Check piston pin bearing See E E Replace the crankshaft main bearings Replace the crankshaft main bearings Check the entire transmission including the roller and bearings for wear ied te ls Replace the
111. ver M5 Loctite 222 6 Nm Hexagon collar screw cylinder cylinder head 6 10 Cylinder head screw 10 Oil 40 50 Nm Hexagon collar screw exhaust flange 6 Loctite 243 10 Nm 6 Valve cover screws 10 Nm Camshaft screw 12 1 Loctite 243 80 Nm Collar screw nut camshaft bearing support M7 Oil 18 Nm Hexagon nut primary gear M18x1 5 left Loctite 243 150 Nm Nut for inner clutch hub M18x1 5 Loctite 243 120 Nm Hexagon collar screw clutch spring 6 10 Allan head screw shift roller locking piece 6 Loctite 243 10 Nm M5 Hexagon collar screw locking lever Loctite 243 6 Nm M6 Loctite 243 6 Nm Locking screw for shift roller bearing Locking screw for main shaft bearing 6 Loctite 243 6 Nm HH collar screw clip tensioning rail M6 Loctite 243 10 Nm Plug for chain tensioner M24x1 5 25 Nm Loctite 243 6 Nm Loctite 243 6 Nm Hexagon collar screw stator SX Hexagon collar screw pulser coil Hexagon collar nut flywheel 60 Nm Hexagon collar screw bump part kickstarter 6 Loctite 243 10 Nm Cable retaining bracket ignition M6 Loctite 243 6 Nm Allan head screw kickstarter M8 Loctite 243 25 Nm 6 Hexagon collar screw shift lever Loctite 243 10 Nm Hexagon screw engine sprocket 10 Loctite 243 60 Nm Spark plug 10 10 12 BASIC CARBURATOR SETTING 250 SX F Type Keihin FCR MX 3925 Main jet 168 Jet needle OBETP
112. ycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on the road it will suffice to have this job performed in the course of the periodical maintenance 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 2 are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them downward Clean the dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with Universal oil spray Motorex Joker 440 or engine oil Then push the dust protection bellows into the outer tubes by hand WARNING NO OIL MAY REACH THE FRONT THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE Checking and adjusting the steering head bearing Check steering head bearing for play periodically To check put the motorcy cle on stand so that the front wheel 15 off the ground Now try to move the fork forward and backward For readjusti
113. year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Treat electric contacts and switches with contact spray Change hydraulic clutch fluid Change brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 10 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 250 5 2006 IMPORTANT CHECKS AND MAINTENANCE TO CARRIED OUT BY THE RIDER After For cross at least every country once cleaning Check oil level Check brake fluid level Check brake pads for wear 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 system with wax based anti corrosion agent Check tightness of screws nuts and hose clamps regularly 250 SX F 2006 RECOMMENDED INSPECTIONS OR MAINTENANC
114. you to use the troubleshooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by yourself In case of uncertainty please contact a KTM dealer TROUBLE CAUSE REMEDY Engine doesn t crank E starter Operating errror Blown fuse Discharged battery Low outside temperature Turn on the emergency OFF switch Australia only Dismount the left paneling and the filter box cover and replace the fuse in the starter relay Recharge the battery and investigate the causes for discharging contact a KTM dealer Start the engine with the kickstarter Engine cranks but doesn t start E Starter Engine will not start Kickstarter Operating error The motorcycle has been out of opera tion for a longer period of time Therefore old fuel has accumulated the float chamber Fuel supply interrupted Flooded engine Sooty or wet spark plug Electrode gap too large Spark plug connector or spark plug faulty Short circuit cable scored wiring har ness emergency OFF switch or short cir cuit button faulty The plug connection of the CDl unit the pulse generator or the ignition coil has oxydized Water in carburetor or jets blocked Open fuel tap tank fuel actuate choke Pay attention to Starting information see driving instructions The easily inflammable components of the new fuels evap orate during longer periods of standing st

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