Ktm 400 Exc Racing Users Manual

MXC 2005,250,400exc,450,525sx,mxc,exc

EXC RACING to the manual 2147754a-a263-e364-093e-12522acad22f

2015-02-04

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BEDIENUNGSANLEITUNG2005
250 EXC RACING
400 EXC RACING
450 SX, MXC, EXC RACING
525 SX, MXC, EXC RACING
OWNER`S MANUAL
MANUALE D`USO
MANUEL D`UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.211.39

KTM Group Partner

KTM-Sportmotorcycle AG
A–5230 Mattighofen
www.ktm.at

IMPORTANT »
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:

– IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTORCYCLE’S TRAFFIC SAFETY!

Please insert the serial numbers of your motorcycle in the boxes below

ENGLISH

– IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB!

Frame number

1
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 inoperative by any person.
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right
to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work,
constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the
above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models
partly contain extra equipment, which is not applied to standard models.
© 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in
extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

INTRODUCTION »

We would like to congratulate you on your purchase of a KTM motorcycle.

ENGLISH
2

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and
enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure
to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new
motorcycle and with its characteristics, even if this means that you will have to dedicate some of your
valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific
needs and how to protect yourself against injury. Besides, this manual contains important information on
motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of
this production series. It cannot be completely ruled out, however, that minor discrepancies may exist
resulting from further design upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it.
We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed. If maintenance work should become necessary during a competition
it should be performed by a trained mechanic. KTM strongly recommends that all service work to your
KTM should be performed by a qualified KTM dealer.
For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that
arises in connection with the use of other products.
Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding
these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM
is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM
serviced by a recognized and qualified KTM dealer.
Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full.
It may, however, involve potential problems for the environment or lead to conflicts with others. These
problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of
motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are
environmentally conscious and respect the rights of others.
We wish you a lot of fun when driving !

KTM-SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA

Attachments: 1 spare parts manual chassis & engine

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION »

KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in
competitions.
The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.
Observance of the service, maintenance and tuning instructions for the engine and chassis specified in
the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An
improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on
checking the basic chassis setting).

The fuels and lubricants specified in the Owner's Manual or fluids with equivalent specifications must
be used in accordance with the maintenance schedule.

ENGLISH

The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or
documentation could void warranty.

No claims can be filed under the warranty for damage or consequential damage caused by manipulations
or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead
to higher than average wear on components such as the drive train or the brakes. In this case it may
become necessary to service or replace wear parts before the service limit specified in the maintenance
schedule has been reached.
The SX/SXS, MXC and other “competition only“ labeled models are prohibited on public roads.
“On the road“ approved models are only allowed on public roads in the original homologated (throttled)
version. Without this performance restriction (i.e. de-throttled), these models are only allowed to be driven
off-road and not on public roads.
The EXC models are designed for off-road sports endurance competitions(enduro) and not suitable for
predominant motocross use.
Note: The above is a general statement. Specific limited warranty and limited guarantee information may
vary depending upon distribution. Please check with your local KTM dealer for limited warranty and limited guarantee information specific to your KTM model and region.

In accordance with the international quality management ISO 9001 standard, KTM uses
quality assurance processes that lead to the highest possible product quality.

TABLE OF CONTENTS »
Page
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

ENGLISH
4

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . .
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hand decompression lever . . . . . . . . . . . . . . . . . . .
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . .
Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . .
Combination switch (EXC) . . . . . . . . . . . . . . . . . . .
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter button (EXC) . . . . . . . . . . . . . . . . . . . . . . .
Emergency OFF switch (EXC Australia) . . . . . . . . . .
Digital speedometer, indicator lamps . . . . . . . . . . . .
Electronic speedometer . . . . . . . . . . . . . . . . . . . . .
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . .
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot start device (450/525 SX) . . . . . . . . . . . . . . . .
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . .
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression damping of fork . . . . . . . . . . . . . . . . .
Rebound damping of fork . . . . . . . . . . . . . . . . . . . .
Damping action during compression of shock absorber (SX)
Compression damping of shock absorber (MXC, EXC)
Rebound damping of shock absorber (SX, MXC, EXC)

. .6
. .6
. .6
. .6
. .6
. .6
. .7
. .7
. .7
. .7
. .8
.12
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.13
.13
.13
.14
.14
.14
.14
.14
.15
.15
.15
.16
.16

GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Instructions for initial operation . . . . . . . . . . . . . . . .17
Running in the Racing models . . . . . . . . . . . . . . . . .17
DRIVING INSTRUCTIONS . . . . . . . . . . . .
Check the following before each start . .
Starting when the engine is cold . . . . . .
Starting when the engine is warm . . . . .
What to do when the engine is “flooded”
Starting off . . . . . . . . . . . . . . . . . . . . .
Shifting/Riding . . . . . . . . . . . . . . . . . .
Braking . . . . . . . . . . . . . . . . . . . . . . .
Stopping and parking . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .

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.
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.

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.19
.19
.19
.19
.19
.20
.20
.20

Breather plug front fork . . . . . . . . . . . . . . . . . . . . .
Cleaning the dust sleeves of the telescopic fork . . . .
Checking and adjusting the steering head bearing . .
Changing the fork offset (caster) (SX) . . . . . . . . . . .
Checking and adjusting the steering head bearing . .
Check chain tension . . . . . . . . . . . . . . . . . . . . . . .
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . .
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . .
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information about KTM disc brakes . . . . . . .
Adjusting the free travel at the hand brake lever . . . .
Checking the brake fluid level - front brake . . . . . . .
Refilling the front brake fluid reservoir . . . . . . . . . .
Checking the front brake pads . . . . . . . . . . . . . . . .
Replacing the front brake pads . . . . . . . . . . . . . . . .
Changing the basic position of the foot brake pedal .
Checking the rear brake fluid level . . . . . . . . . . . . .
Refilling the rear brake fluid reservoir . . . . . . . . . . .
Checking the rear brake pads . . . . . . . . . . . . . . . . .
Replacing the rear brake pads . . . . . . . . . . . . . . . .
Dismounting and mounting the front wheel . . . . . . .
Dismounting and mounting the rear wheel . . . . . . . .
Checking spoke tension . . . . . . . . . . . . . . . . . . . . .
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . .
Check/set distance of the magnetic sensor . . . . . . . .
Replacing the battery of the digital speedometer . . .
Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . .
Charging the battery . . . . . . . . . . . . . . . . . . . . . . .
Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing headlight lamp/parking light lamp . . . . . .
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the coolant level . . . . . . . . . . . . . . . . . . .
Bleeding the cooling system . . . . . . . . . . . . . . . . . .
Replacing the glassfiber yarn packing of the silencer
Cleaning the spark arrester (MXC/EXC USA) . . . . . . .
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . .
Checking the adjustment of the hand decompression
release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the throttle cables . . . . . . . . . . . . . . . . . .
Changing the original position of the clutch lever . . .
Checking the oil level of the hydraulic clutch . . . . .
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . .
CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41)
Adjusting the mixture control screw . . . . . . . . . . . .
Checking the float level (float height) . . . . . . . . . . .
Draining the float chamber of the carburetor . . . . . .
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the engine oil level . . . . . . . . . . . . . . . . .
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the engine oil . . . . . . . . . . . . . . . . . . . . .

Page
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.47

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .21
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .49
MAINTENANCE WORK ON CHASSIS AND ENGINE . . .
Changing the spring preloading of the shock absorber
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic suspension setup for the weight of the driver . .
Checking the shock absorber and spring . . . . . . . . .
Determining the static sag of the shock absorber . . .
Determining the riding sag of the shock absorber . . .
Checking the basic setup of the telescopic fork . . . .
Changing the spring preload on the telescopic fork
(SX models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the spring preload on the telescopic fork
(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . .
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . .

.24
.25
.25
.26
.26
.26
.26
.27

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .51
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . .51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .52

.27
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .55
.27
.27

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix

SERIAL NUMBER LOCATIONS »
Chassis number
The chassis number is stamped on the right side of the steering head tube.
Enter this number in the field on page no 1.

The engine number and the engine type are stamped into the left side of the
engine below the engine sprocket. Enter this number on page 1.

ENGLISH

Engine number, engine type

OPERATION INSTRUMENTS »
Clutch lever
The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see
maintenance work on chassis and engine).
The clutch is hydraulically actuated and adjusts itself automatically.

Hand decompression lever
2

ENGLISH

The hand decompression lever [2] is needed only if the carburetor overflows
after a fall. To "pump the engine free", pull the hand decompression lever
during the starting procedure.
The outer end of the lever must provide for a backlash of approx. 10mm (0.4
in) at all times. Only thereafter may it cause valve motion (to be
recognized by the stronger resistance which the hand decompression lever
encounters).

Hand brake lever
The hand brake lever [3] is mounted on the handlebars on the right and
actuates the front wheel brake. The adjusting screw [B] can be used to change
the basic position of the hand brake lever (see "Maintenance").

Short circuit button (SX/MXC)
The short circuit button [4] turns off the engine. When pressing this button,
the ignition circuit is short-circuited.

Combination switch (EXC)
6

A
B
C

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.

OPERATION INSTRUMENTS »
Headlamp switch (EXC USA)
In this model the headlamp is switched on with the pull switch [1].

The flasher switch is a separate unit and is mounted on the left portion of the
handlebar.
The wire harness is designed in a way that whenever you want to use your
bike off-road, you can dismount the entire turn indicator system without
affecting the function of the remaining electrical system.
Flasher left
Flasher right

ENGLISH

Flasher switch

Starter button (EXC)
Pushing the black starter button [2] will actuate the E-starter.

Emergency OFF switch (EXC Australia)
The red emergency-OFF switch [3] is arranged adjacent to the throttle grip.
In this position, the E-starter is operational and the engine can
be started.

In this position, the E-starter and ignition circuits are
interrupted.The E-starter cannot be actuated, and the engine will
not start, not even if you attempt to start it with the kickstarter.

Pushing the black starter button [4] will actuate the E-starter.

Digital speedometer, indicator lamps
6

The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working.
The blue control lamp [6] lights up when the high beam is on.

OPERATION INSTRUMENTS »
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 sensor. 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 | 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.

ENGLISH
8

WS (wheel size)
The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference
of 21" with production tires).
Afterwards the display will return to the previous display mode.

SPEED display mode / H (service hours)
Only the SPEED / H and SPEED / ODO display modes are activated in the
condition at delivery. SPEED/H is displayed whenever the display is activated
and the front wheel is not turning. It automatically changes to the SPEED/ODO
display mode as soon as the front wheel starts turning.
SPEED displays the speed.
H displays the engine's service hours. The service hour counter starts to count
as soon as you start the engine. The displayed figure cannot be changed.
Service intervals are indicated in service hours for some KTM offroad motorcycles, 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.
+ button
– button
briefly press | button
hold | button 3 secs.

no function
no function
changes to the next display mode
changes to the next display mode

The electronic speedometer has a number of display modes (functions) that
you can also activate (reveal) (see: Activating and deactivating display modes).

OPERATION INSTRUMENTS »
Activating and deactivating display modes
In the display mode SPEED/H, press and hold the | button for 3 seconds to
access the SETUP menu. The active functions will be displayed. The blinking 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 automatically and the display will return to the SPEED/H mode.

hold | 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:
TR1
tripmaster 1
TR2
tripmaster 2
A1
average speed 1
A2
average speed 2
S1
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 | button
hold | 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 | button
hold | button 3 secs.

Starts and stops the stop watch, lap time is not
reset to 0
Stops the stop watch, stores the lap time and restarts
the stop watch again. The time is reset to 0. A total
of 10 lap times can be stored. If the lap time continues to run after you press the - button, all 10 memory locations are occupied.To clear all of the stored
lap times, hold the | 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.If no lap time is
stored or the motorcycle is driving, the LAP/LAP
mode will be skipped.
Clears all LAP figures

ENGLISH

+ button
– button
briefly press | button

OPERATION INSTRUMENTS »
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 | button for 3 seconds in the
SPEED/LAP mode.
+ button
– button
briefly press | button
hold | button 3 secs.

changes to the next lap time
no function
changes to the next display mode
changes to the next display mode

SPEED / MAX display mode (maximum speed)
MAX displays the maximum speed traveled and is always active.

ENGLISH

+ button
– button
briefly press | button
hold | button 3 secs.

no function
no function
changes to the next display mode
clears the MAX figure

SPEED / TR1 display mode (tripmaster 1)
The TR1 tripmaster is always active and counts to 999.9. It is used to measure the length of a trip or the distance between 2 refueling stops.
TR1 is linked to A1 (average speed 1). The calculation of these figures is activated by the first impulse received from the wheel sensor (when the front wheel
starts to turn) and stops 3 seconds after the last impulse is received (when
the front wheel has stopped).
The TR1, A1 and S1 figures are automatically cleared after passing 999.9.
+ button
– button
briefly press | button
hold | button 3 secs.

no function
no function
changes to the next display mode
clears the TR1, S1, A1 figures

SPEED / TR2 display mode (tripmaster 2)
The tripmaster 2 is always active and counts to 999.9. Contrary to TR1, the
displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook.
+ button
– button
briefly press | button
hold | button 3 secs.

increases the TR2 figure
decreases the TR2 figure
changes to the next display mode
clears the TR2 figure

SPEED / A1 display mode (average speed 1)
A1 shows the average speed based on the TR1 (tripmaster 1) and S1 (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
– button
briefly press | button
hold | button 3 secs.

no function
no function
changes to the next display mode
clears the TR1, S1, A1 figures

OPERATION INSTRUMENTS »
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.
+ button
– button
briefly press | button
hold | button 3 secs.

no function
no function
changes to the next display mode
changes to the next display mode

S1 shows the traveling time based on TR1 and continues to run whenever it
receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.
+ button
– button
briefly press | button
hold | button 3 secs.

no function
no function
changes to the next display mode
clears the TR1, S1, A1 figures

ENGLISH

SPEED / S1 display mode (stop watch 1)

SPEED / S2 display mode (stop watch 2)
S2 is a manual stop watch. Start the stop watch by pressing the + button,
press again to hold. Press again to continue timing.
Press the | button to change to the next mode. The S2 display will blink in
the other modes if S2 continues to run in the background. To stop S2, return
to the SPEED/S2 mode and press the + button.
+ button
– button
briefly press | button
hold | button 3 secs.

starts and stops the stop watch
no function
changes to the next display mode
clears the S2 figure

Kilometers or miles
The unit (kilometers or miles) can also be changed. The ODO figure will be
retained and converted accordingly. The TR1, A1, S1, TR2 and A2 figures
will be cleared.
To select the unit, select the SPEED/H mode and hold the | button for 3 seconds to access the SETUP menu. Press the | 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 | button 1 x and hold for 3 seconds until the display returns to the SPEED/H mode.
If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode.
+ button
– button
briefly press | button
hold | button 3 secs.

to access the menu
to activate the KMH display
to activate the MPH display
changes to the next mode
changes from the menu to the SETUP menu
stores and closes the SETUP menu

OPERATION INSTRUMENTS »
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 can be changed
using the + and - buttons. Press the | button to move to the next digit. 012 will show the time in the 12-hour mode, 0-24 in the 24-hour mode.
Press and hold the | button for 3 seconds to store the settings.
If no button is pressed for 20 seconds, the settings will be stored automatically and the display will return to the SPEED/CLK mode.

Motorcycle is driving

ENGLISH
12

Motorcycle is standing

+ button
– button
briefly press | button
hold | button 3 secs.

time +
time changes to the next digit
starts the SETUP menu
stores the time and changes to the SPEED/CLK display mode

OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS

display

briefly press + button

briefly press – button

briefly press | button

hold | button 3 secs.

SPEED / H

no function

next display mode

displays the SETUP menu

SPEED / CLK

no function

next display mode

Setting the clock menu

SPEED / LAP

starts/stops LAP without
clearing LAP figure

stops LAP, stores LAP
figure, resets LAP to 0

next display mode

clears all LAP figures

LAP / LAP

next figure

no function

next display mode

SPEED / MAX

no function

next display mode

clears MAX

SPEED / ODO

no function

next display mode

SPEED / TR1

no function

next display mode

clears TR1, S1, A1

SPEED / TR2

increases the TR2 figure

reduces the TR2 figure

next display mode

clears TR2

SPEED / A1

no function

next display mode

clears TR1, S1, A1

SPEED / A2

no function

next display mode

SPEED / S1

no function

next display mode

clears TR1, S1, A1

SPEED / S2

starts - stops S2

no function

next display mode

clears S2

X
X

If the CLK, LAP, MAX, TR1, TR2 A1, A2, S1 and S2 figures are suddenly cleared, the battery in the electronic speedometer is empty
and must be replaced (see: Replacing the battery in the electronic speedometer).
A tripmaster switch is available as an accessory that lets you control the electronic speedometer functions from the handlebar.

OPERATION INSTRUMENTS »
Filler cap
To open the filler cap: Turn the filler cap counter-clockwise.
To close the filler cap: Put the filler cap on and tighten it by turning it
clockwise.

Install the tank breather hose [1] without kinks.

Fuel tap
In this position the fuel tap is closed. No fuel can flow to the
carburetor.
ON During operation the twist grip must be turned to ON. This means that
the fuel can flow to the carburetor. With the twist grip in this position
the tank will be emptied until only the reserve is left.
RES The reserve tank cannot be tapped until the rotating handle is turned
to the RES position. Fill the tank as soon as possible and remember to
turn the rotating handle back to the ON position so that you will have
backup fuel next time, too.
Reserve MXC . . . . . .3.0 l (0,8 US gallons)
Reserve EXC . . . . . .1.0 l (0,3 US gallons)

OFF

RES

MXC
EXC
Choke

If you pull the choke button [2] out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional fuel. The
result is 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 carburetor 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.

ENGLISH

OFF

OPERATION INSTRUMENTS »
Shift lever

2,3,4 (5,6)

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.

N
1
Kickstarter

ENGLISH

The kickstarter is mounted on the right side of the engine. Its upper part can
be swivelled.

Foot brake pedal
The foot brake pedal is located in front of the right footrest. Its basic position
can be adjusted to your seat position (see maintenance work).

Side stand
1

Push the side stand to the ground with your foot and load it with the motorcycle. Make sure that you put your bike on solid ground and in a secure position. For off-road riding, you can use the rubber band [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.
NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK. IF YOU TURN THE HANDLEBAR TO THE LEFT THE KEY COULD GET DAMAGED.

OPERATION INSTRUMENTS »
Compression damping of fork
Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting
screws at the bottom of the fork legs.Remove the protecting cap [1].
Turn the adjusting screws [2] clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

STANDARD ADJUSTMENT
– turn adjusting screw clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of fork
Typ White Power 14187A05...............22 clicks (SX)
Typ White Power 14187A06...............20 clicks (EXC/MXC)

Hydraulic rebound damping determines the reaction when the fork is
rebound. By turning the adjusting screw [3] (REB), the degree of damping of
the rebound can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT
– turn adjusting screw clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of fork

ENGLISH

Rebound damping of fork

Typ White Power 14187A05...............20 clicks (SX)
Typ White Power 14187A06...............20 clicks (EXC/MXC)

Damping action during compression of shock absorber (SX)
The shock absorber on the SX models can synchronize the compression
damping in the low and high-speed range separately (Dual Compression
Control).
Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle.
The low and high-speed technology overlaps.
The low-speed setting is primarily for slow to normal shock absorber compression rates.
The high-speed setting is effective at fast compression rates.
Turning in a clockwise direction will increase the damping, turning
counterclockwise will decrease the damping.

STANDARD LOW-SPEED SETTING:
– turn the adjusting screw [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.
Typ White Power 12187A05...............15 clicks

STANDARD HIGH-SPEED SETTING:
– turn the adjusting screw [5] to the limit in a clockwise direction using a
box wrench.
– unscrew the respective number of turns for the specific type of shock absorber in a counterclockwise direction.
Typ White Power 12187A05...............2 turns

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO
ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
NEVER UNSCREW THE BLACK SCREW CONNECTION [6] (24MM).

OPERATION INSTRUMENTS »
Compression damping of shock absorber (MXC, EXC)
The compression damping (during compression) can be adjusted for the MXC
and EXC shock absorbers (Mono Compression Control).
The degree of damping can be adjusted by turning adjusting screw [1] with
a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping.

Type White Power 12187A06 ..............15 clicks

ENGLISH

Rebound damping of shock absorber (SX, MXC, EXC)
By using the adjusting screw [3], the degree of damping of the rebound can
be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

3
4

STANDARD ADJUSTMENT:
– turn the adjusting screw clockwise to the stop.
– then turn the adjusting screw counterclockwise, counting the number of
clicks that corresponds to the respective type of shock absorber.
Type White Power 12187A05 ..............22 clicks
Type White Power 12187A06 ..............22 clicks
THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO
ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
NEVER UNSCREW THE BLACK SCREW CONNECTION [4] (15MM).

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »
– Verify that your KTM dealer performed the PREPARATION
OF VEHICLE jobs (see Customer Service Manual).
– Read these operating instructions carefully before your first
ride.
– Familiarize yourself with the operating elements.
– Set the clutch lever, the handbrake lever, and the footbrake
pedal to the positions that are most convenient for you.
– Get used to handling the motorcycle on an empty parking
lot or open space, before starting on a longer drive. Also try
to drive as slowly as possible and in a standing position, to
improve your feeling for the vehicle.
– Do not drive along off-road tracks which go beyond your abitily and experience.
– Hold the handlebars with both hands and leave your feet on
the foot rests while driving.
– Remove your foot from the foot brake lever when you are not
braking. If the foot brake lever is not released the brake
pads rub continuously and the braking system is
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 sliding across one another for quite some time. Therefore, every engine
needs to be broken in.
For this reason, do not load the engine more than 50% of its
capacity during the first 3 operating hours. Besides, the engine
speed must not exceed 7000 rpm. Avoid going full-throttle!
In the following 12 operating hours, you may load the engine
up to 75% of its capacity. Use the motorcycle on various types
of terrain (road, easy off-road trails).
THE 250/400/450/525 SX/MXC/EXC RACING MODELS WERE UNCOMPROMISINGLY 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.

– 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 EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES
OF THE MOTORCYCLE. CASES, EXTRA TANKS, ETC. CAN ALTER
THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES.
– THE FRONT AND REAR WHEEL MAY ONLY BE FITTED WITH TIRES
THAT HAVE THE SAME PROFILE TYPE.
– THE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR
1 PERSON ONLY. NEVER TAKE ANOTHER RIDER ALONG.
– OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY
AND TRY TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY
HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE.
– ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS.
– DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR
TRIALS.
– WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN
HELP EACH OTHER SHOULD DIFFICULTIES ARISE.
– REPLACE THE HELMET VISOR OR GOGGLE LENS WHEN
SCRATCHED OR DAMAGED. IF BRIGHT LIGHT SHINES THROUGH
A SCRATCHED VISOR OR LENS, THE OPERATOR WILL BE BLINDED.
– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF
THE ENGINE IS RUNNING.
– THE SX/SXS/MXC MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS AND FREEWAYS.
– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND
THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE
NOISE.

ENGLISH

Instructions for initial operation

DRIVING INSTRUCTIONS »
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:

B
A

ENGLISH
18

1 CHECK THE OIL LEVEL
Insufficient oil results in premature wear and consequently to engine
damage.
2 FUEL
Check that there is sufficient fuel in the tank; when closing the filler cap,
check that the tank venting hose is free of kinks.
3 CHAIN
A loose chain can fall from the chain wheels; an extremely worn chain can
tear, and insufficient lubrication can result in unnecessary wear to the chain
and chain wheels. Excessive tensioning of the chain will put additional
load on the components of the secondary drivetrain (chain, bearings of
transmission and rear wheel). Aside from resulting in premature wear, if
worst comes to worst the chain may rupture or the countershaft of the
transmission may break.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must be replaced.
The tread depth must comply with the legal regulations. Also check the
air pressure. Insufficient tread and incorrect air pressure deteriorate the
driving performance.
5 BRAKES
Check correct functioning of the braking system. Check for sufficient
brake fluid in the reservoir. The reservoirs have been designed in such a
way that brake fluid does not need to be refilled even when the brake pads
are worn. If the level of brake fluid falls below the minimum value, this
indicates a leak in the braking system or completely worn out brake pads.
Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided.
Also check the state of the brake hose and the thickness of the brake
linings.
Check free travel at the hand brake lever and foot brake lever.
6 CABLES
Check correct setting and easy running of all control cables.
7 COOLING FLUID
Check the level of the cooling fluid when the engine is cold.
8 ELECTRICAL SYSTEM
Check correct functioning of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running.
9 LUGGAGE
If you are taking luggage with you, check that this is securely fastened.

DRIVING INSTRUCTIONS »
Starting when the engine is cold

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 actuate the E-starter.

– 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.
– ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING
THE THROTTLE. IF YOU DO NOT KICK HARD ENOUGHT, WITH AN OPEN THROTTLE GRIP, THE KICK-BACK HAZARD WILL BE HIGHER.
– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.
EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE
ENGINE IS RUNNING.
– ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE (NEUTRAL)
BEFORE ACTUATING THE STARTER BUTTON. IF YOU START THE MOTORCYCLE
WITH A GEAR ENGAGED, THE MOTORCYCLE WILL MOVE FORWARD.
– MAXIMAL PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST
5 SECONDS BEFORE TRYING AGAIN.
– DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV UP THE
ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN
THE WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE.

Starting when the engine is warm
1
2
3
4

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.

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.
BEFORE YOU START OFF, CHECK THAT THE SIDE STAND HAS BEEN SWUNG UP
FULLY. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT
OF CONTROL.

Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear. Depending on
the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close
throttle, at the same time pull clutch lever in and shift to the next higher gear.
Let clutch lever go again and accelerate. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through opening the throttle all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less
gas. Only give as much gas as the engine can handle. Through quick and high
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.

ENGLISH

1
2
3
4
5

DRIVING INSTRUCTIONS »
NOTE:
Dedicated to nothing but offroad racing, 250/400/450/525
SX/MXC/EXC Racing models make no compromises in their design.
As such, they do not include any radiator fan, and the size of the
radiator is dimensioned for optimum ergonomics.
In normal racing, the cooling system is sufficient.
If you use your motorbike in other conditions, please note that:
the E-starter allows you to start MXC/EXC Racing models again at
any time. Therefore, turn off the engine if you intend to run your
motorcycle in idle or at a standstill for longer periods of time (more
than 2 minutes).
Avoid letting the clutch slip frequently and for extended periods.
This would cause the engine oil to heat up, thereby heating up the
cooling system. You should drive at low speeds (4-stroke style letting the engine pull you) and not at high speeds not by letting
the clutch slip (2-stroke style).

ENGLISH
20

MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND
SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE
PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK
IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED.
– NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE
ENGINE. USE THE SHORT-CIRCUIT BUTTON OR THE EMERGENCYOFF BUTTON INSTEAD.
– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE
THE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE
ENGINE.
– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE ARE
FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.

– 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.
– HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE
EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN
THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED TO BE TAKEN. THE ENGINE HAS
REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM.
– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN
TO A LOWER GEAR. THE ENGINE WILL OVER-REV, DAMAGING THE
VALVES. IN ADDITION, THE REAR WHEEL LOCKS SO THAT THE
MOTORCYCLE CAN EASILY GET OUT OF CONTROL.
– IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK
THAT THE ENGINE FASTENING BOLTS ARE TIGHT.
– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU
NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED
KTM DEALER.

Braking
Close throttle and apply the hand and foot brakes at the same time.
When driving on sandy, wet or slippery ground use mainly the rear
wheel brake. Always brake with feeling, blocking wheels can cause
you to skid or fall. Also change down to lower gears depending on
your speed.
When driving down hill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the engine.
In this way, you will not need to brake so much and the brakes will
not overheat.
– IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER
RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD
TRACKS, HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY
OR CLEAN.
– RIDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN.
– DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND
BRAKE DISCS.
– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE
CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS
GET, THE 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 INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T
RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE
BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

Stopping and parking
Apply the brakes fully and put the engine into neutral. To turn off
the engine, push the short-circuit button or the emergency-OFF
button with the engine at idling speed until the engine stops. Turn
the fuel tap to the OFF position, park on an area where the ground
is firm, and lock the motorcycle.

NOTE REGARDING THE SIDE STAND:
Use your foot to kick side stand forward up to the stop and lean
the motorcycle sideways. Make sure that the ground is solid and
that your motorcycle is standing securely. Just in case, you can
shift into first gear.
THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE
MOTORCYCLE. THE SIDE STAND AND/OR THE FRAME CAN BE DAMAGED
AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTORCYCLE, 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).
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.).

35 mm

PERIODIC MAINTENANCE »
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!

after/every
15 hours
or
100 l fuel
z

Clean oil screen and drain plug magnet

Check oil lines for damage or bends

Check and adjust valve clearance

Check engine mounting bolts for tightness

Replace spark plug (after 30 hours)

Check carburetor connection boot for cracks and leaks
Check idle speed setting

Check vent hoses for damage or bends

Check cooling system for leaks, check quantity of antifreeze

z
z

WHEELS

CHASSIS

BRAKES

ADD- ON PARTS

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 tightness of brake system screws

Check shock absorber and fork for leaks and function

Clean fork dust bellows

Bleed fork legs

Check swing arm bearings

Check/adjust steering head bearings

Check tightness of chassis screws (triple clamps, fork leg axle passage)

Check spoke tension and rim joint

Check tires and air pressure

Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension

Lubricate chain

Check clearance of wheel bearings

IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OUT BY EXTRA ORDER

Complete maintenance of fork

at least
once a year
z

Complete maintenance of shock absorber

Clean and grease steering head bearings and gasket elements

Clean and adjust carburetor

Replace glass fibre yarn filling of the exhaust main silencer

Treat electric contacts and switches with contact spray

Treat battery connections with contact grease

Change hydraulic clutch fluid

Change brake fluid

IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE.
Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel.
Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider.

ENGLISH

CARBURETOR

ENGINE

Change engine oil, short and long oil filters

1. service after
3 hours
or
20 l fuel
z

PERIODIC MAINTENANCE »
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Before each
start
Check oil level

Check brake fluid level

Check brake pads for wear

Check lights for function

Check horn for function

After every
cleaning

Lubricate and adjust cables and nipples

Bleed fork legs regularly

Remove and clean fork dust bellows regularly
z

Clean and lubricate chain, check tension and adjust if necessary

ENGLISH
22

z
z

Clean air filter and filter box
Check tires for pressure and wear

Check cooling fluid level

Check fuel lines for leaks

z
z

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

For crosscountry use

PERIODIC MAINTENANCE »
RECOMMENDED INSPECTION OF THE 250/400/450/525 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)

Check the clutch disks for wear
Check the length of the clutch springs

15
hours
100
liter
z

30
hours
200
liter
z
z

45
hours
300
liter
z
z

60
hours
400
liter
z
z

90
hours
600
liter
z
z

120
hours
800
liter
z
z

35
hours
900
liter
z
z

Check the cylinder and piston for wear

Check the groove on the piston pin retainer for wear (visual check)

Check the camshaft for wear (visual check)

Replace the camshaft bearings

Check the length of the valve springs

Check the spring cap for wear

Check the eccentricity of the valve disk

Check the valve guides for wear

Check the radial clearance of the rocker arm rollers

Check the elongation of the timing chain

Check the chain tensioner tooting for damage (visual check)

ENGLISH

a 100 liter fuel consumption is equivalent to approx. 15 operating hours

Check the eccentricity of the crankshaft journal

Replace the conrod bearings

Check piston pin bearing

Replace the balancer shaft bearings

Replace the crankshaft main bearings

Check the entire transmission including the roller and bearings for wear

Check the length of the bypass valve spring

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS
MUST BE REPLACED.

PERIODIC MAINTENANCE »
RECOMMENDED INSPECTION OF THE 250/400/450/525 EXC ENGINE USED FOR HOBBY - ENDURO COMPETITIONS BY YOUR KTM WORKSHOP
(ADDITIONAL ORDER FOR THE KTM WORKSHOP)
30
60
90
120
180
240
270
hours
hours
hours
hours
hours
hours
hours
a 100 liter fuel consumption is equivalent to approx. 15 operating hours 200
400
600
800
1200
1600
1800
liter
liter
liter
liter
liter
liter
liter
Check the clutch disks for wear
Check the length of the clutch springs

ENGLISH

Check the cylinder and piston for wear

Check the groove on the piston pin retainer for wear (visual check)

Check the camshaft for wear (visual check)

Replace the camshaft bearings

Check the length of the valve springs

Check the spring cap for wear

Check the eccentricity of the valve disk

Check the valve guides for wear

Check the radial clearance of the rocker arm rollers

Check the elongation of the timing chain

Check the chain tensioner tooting for damage (visual check)

Check the eccentricity of the crankshaft journal

Replace the conrod bearings

Check piston pin bearing

Replace the balancer shaft bearings

Replace the crankshaft main bearings

Check the entire transmission including the roller and bearings for wear

Check the length of the bypass valve spring

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS
MUST BE REPLACED.

MAINTENANCE WORK ON CHASSIS AND ENGINE »

– WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE
THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS, ETC.
– WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING
DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE
CARBURETOR OR FUEL TANK
– ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING
OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.
– DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS
AND KEEP WORKING LOOSE. INSTEAD, USE SELF-LOCKING NUTS.
– LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
– DISPOSE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. PROPERLY.
– UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. 1 LITER OF USED
OIL CONTAMINATES 1,000,000 LITERS OF WATER.

ENGLISH

MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR
OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED,SKILLED STAFF.

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 counterclockwise will reduce the preload, turning it clockwise will increase the
preload.
After readjusting the clamping screw [2], tighten it to 8 Nm.

ADJUSTMENT VALUES - SPRING PRELOAD A
minimum preload..................... 4 mm (0,15 in)
STANDARD PRELOAD .............. 7 mm
maximum preload ....................10 mm (0,4 in)

Pivot bearing
The pivot bearing [3] for PDS suspension struts at the swinging fork is Tefloncoated 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 highpressure spray directly at the pivot bearing.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Basic suspension setup for the weight of the driver

To achieve maximum handling performance and to prevent the fork, shock
absorber, swing arm and frame from being damaged, the basic setup of the
suspension components must be suitable for your weight. At delivery, KTM's
offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing). If your weight exceeds or falls short of this range,
you will need to adjust the basic setup for the suspension components accordingly. Minor deviations in weight can be compensated by adjusting the spring
preload. Different springs must be installed for larger deviations.

Checking the shock absorber and spring
You can establish whether or not the shock absorber spring is suitable for your
weight by checking the riding sag. The static slag must be correctly adjusted
before the riding sag can be determined.

ENGLISH

Determining the static sag of the shock absorber

The static sag should be as close as possible to 35 mm. Deviations of more
than 2 mm can strongly influence the motorcycle's performance.
Procedure:
– Jack up the motorcycle until the rear wheel no longer touches the ground.
– Measure the vertical distance between the rear wheel axle and a fixed point
(e.g. a mark on the side cover) and write it down as dimension A.
– Place the motorcycle on the ground again.
– Ask a helper to hold the 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
Static sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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."

C
C

Determining the riding sag of the shock absorber
– Have a helper hold the motorcycle while you sit on the bike in a normal
seating position (feet on the footrests) wearing full protective clothing and
bounce up and down a few times to allow the rear wheel suspension to
become level.
– Stay on the bike and have another person measure the distance between
the same two points and write it down as dimension C.
– The riding sag is the difference between dimensions A and C.
EXAMPLE:
Motorcycle jacked up (dimension A) . . . . . . . . . . . . . . . . . . . . .600 mm
Motorcycle on ground, loaded (dimension C) . . . . . . . . . . . . . .– 510 mm
Riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 mm

SPRING RATE

PDS 12187A05

450/525 SX

84/250
80/250
76/250

60
65
70
75
80
85
90
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

The riding sag should lie between 90 and 105 mm.
If the riding sag is less than 90 mm, the spring is too hard (the spring rate is
too high). If the riding sag is more than 105 mm, the spring is too soft (the
spring rate is too low).
The spring rate is written on the outside of the spring (e.g. 88/250). The type
number of the shock absorber is embossed on the bottom of the tank.
The illustrations show which spring should be installed. The standard spring
is shown in bold print.
After installing a different spring, readjust the static sag to 35 mm (± 2 mm).

MAINTENANCE WORK ON CHASSIS AND ENGINE »

SPRING RATE

PDS 12187A06
250/400/450/525
MXC/MXC-Desert/EXC/EXC-G

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.

84/250
80/250
76/250

60
65
70
75
80
85
90
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

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.

SPRING RATE

14187A05

450/525 SX

4,8 N/mm
4,6 N/mm
4,2 N/mm

60
65
70
75
80
85
90
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

SPRING RATE

14187A06

250/400/450/525
MXC/MXC-Desert/EXC/EXC-G
4,4 N/mm
4,2 N/mm

4,0 N/mm

60
65
70
75
80
85
90
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

Changing the spring preload on the telescopic fork (MXC/EXC models)
The telescopic forks for these models must be partly disassembled to adjust
the spring preload (see WP manual). Pretension spacers are available in
heights of 1.5, 2.5 and 5 mm (see spare parts catalog). The fork springs may
not be pretensioned by more than 20 mm.
The preload adjuster used in the SX models can easily be retrofitted for the
telescopic forks of the MXC/EXC models.
NOTE:
WP precisely adjusts the spring pressure by inserting pretension spacers.
Fluctuations in production are compensated with pretension spacers in various heights. This can cause the fork springs in the fork legs to have different
degrees of pretension. Fork springs and pretension spacers should always stay
together.

Replacing fork springs
If you weigh less than 70 kg or more than 80 kg, you should install the respective fork springs. The correct spring rate is shown in the illustrations. The standard 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.

ENGLISH

Checking the basic setup of the telescopic fork

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather
plugs [1] a few turns in order to relieve excess pressure from the inside of the
fork. To do this, place the motorcycle on a stand with the front wheel lifted
off the ground. When riding the motorcycle mainly on the road, it will suffice
to have this job performed in the course of the periodical maintenance service.

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

ENGLISH

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.

28
Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and
oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine
oil. Then, push the dust-protection bellows into the outer tubes by hand.
NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD
CONSIDERABLY REDUCE THE TIRE'S ROAD GRIP AND THE BRAKING EFFECT OF
THE FRONT BRAKE.

Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. To check, put the motorcycle on a stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. For readjusting, loosen the five pinch bolts [3] of
the top triple clamp and turn steering stem bolt clockwise [4] until there is
no more play. Don’t tighten the steering stem bolt all the way, otherwise the
bearings will be damaged. With a plastic hammer, lightly tap on the triple
clamp to release tension. Retighten the five pinch bolts to 20 Nm(EXC) and
15 Nm (SX).

3
3

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.
IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME
WILL BE DESTROYED.

The steering head bearings should be regreased at least once a year
(e.g. Motorex Long Therm 2000).

MAINTENANCE WORK ON CHASSIS AND ENGINE »
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 handling to match the race course.

If the mark [B] is in the rear as illustrated, the offset is 20 mm. This setting
will deliver better handling in curves.

The offset is set to 20 mm in the condition at delivery.

ENGLISH

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.

29
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 protection ring [4].
Tap gently on the lower triple clamp with a rubber hammer to loosen the steering stem [5] out of the bearing seat. Take the lower triple clamp with the steering stem out of the steering head.

4
2
Remove the collar screw from the lower triple clamp and pull out the steering 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.

– A 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 COLLAR SCREW IS SELF-LOCKING.

Grease the steering head bearing and sealing elements.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Mount the lower triple clamp, upper steering head bearing, protection ring,
O-ring, upper triple clamp and the blind screw.
Tighten the collar screw on the lower triple clamp to 80 Nm.
Mount the fork legs and tighten the clamp screws on the lower triple clamp
to 10 Nm in 3 stages.
Adjust the steering head bearing without clearance (see: Checking and adjusting the steering head support) and tighten the clamp screws on the upper
triple clamp to 15 Nm in 3 stages.

ENGLISH

Mount
Mount
Mount
Mount

the
the
the
the

front wheel fender and tighten the screws to 10 Nm.
hand brake cylinder and tighten the screws to 10 Nm.
staring number plate.
front wheel (see: Dismounting and mounting the front wheel).

Checking and adjusting the steering head bearing *
Check steering head bearing for play periodically. To check, put the motorcycle on a stand so that the front wheel is off the ground. Now try to move the
fork forward and backward. For readjusting, loosen the five pinch bolts [1] of
the top triple clamp and turn steering stem bolt [2] clockwise until there is
no more play. Don’t tighten the steering stem bolt all the way, otherwise the
bearings will be damaged. With a plastic hammer, lightly tap on the triple
clamp to release tension. Retighten the five pinch bolts to 15 Nm (SX) / 20
Nm (EXC, MXC).
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.

3
4

IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME
WILL BE DESTROYED.

The steering head bearings should be regreased at least once a year
(e.g. Motorex Long Therm 2000).
mm
15

3,5 mm

MAINTENANCE WORK ON CHASSIS AND ENGINE »
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.

8-1
0m
m/

ENGLISH

– EXCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE
COMPONENTS OF THE SECONDARY DRIVETRAIN (CHAIN, BEARINGS OF TRANSMISSION AND REAR WHEEL). ASIDE FROM RESULTING 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.

0,304in

Correct chain tension
B

Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting
screws [3] equally far. Tighten lock nuts.
To ensure the correct alignment of the rear wheel, the marks at the left and
right chain adjusters must be positioned identically in relation to the
reference marks [B]. Tighten the counter nut of the adjusting screws.
Before tightening thr collar nut, verify that the chain adjusters [4] are sitting
close to the adjusting screws and that the rear wheel has been aligned with
the front wheel.
Tighten collar nut [1] to 80 Nm.

– 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 BEHAVIOR 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 in combination with the same chain length. The
chain adjusters [4] can be rotated by 180°.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
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).
NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE 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.
WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE
MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION.

ENGLISH

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 lb) 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.

15 KG
33 lbs

NOTE:
If you mount a new chain, the sprockets should also be replaced. New chains
wear faster if used on old used sprockets.
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.

max. 272 mm
1 2 3

16 17 18

MAINTENANCE WORK ON CHASSIS AND ENGINE »
General information about KTM disc brakes
BRAKE CALIPERS:
The brake calipers of this series use a “floating” mount. This means that the
brake calipers are not solidly attached to the caliper support, which enables
them to “float” for maximum braking contact. Secure the screws of the caliper
support with Loctite 243 and tighten to 25 Nm.

FRONT: TOSHIBA H 38 (SINTERED) – harder to dose, good brake performance, long life, for wet slippery terrain.
FERODO ID 450 (ORGANIC) – easy to dose, good brake performance, 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.

– BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,4 MM (0,016 IN)
CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS THEY REACH THE WEAR LIMIT.
– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER

BRAKE FLUID RESERVOIRS:
The brake fluid reservoirs on the front and rear wheel brakes have been
designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid. If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely
worn.In this case, consult an authorized KTM dealer immediately.
BRAKE FLUID:
KTM fills the brake systems with 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.
HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR
MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCKETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING
THE BRAKE SYSTEM TO FAIL.

ENGLISH

BRAKE PADS:
The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front
and TOSHIBA H 38 sintered lining at the back. These linings provide an optimal combination of dosing, brake performance and life cycle. The lining type
is stated on the back of the brake pad and also recorded in the homologation
papers.
Other brake pads are available for competition sports.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Adjusting the free travel at the hand brake lever

Free travel at the hand brake lever may be readjusted by using adjustment
screw [1]. In this way, the position of the point of pressure (i.e. the resis-tance
you feel on the hand brake lever when the brake pads are pressed against the
brake disc) can be adjusted for any hand size.
When you press the hand brake lever forwards, you should have at least
3 mm free travel. Turn the adjusting screw [1] if necessary.

min. 3 mm

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

ENGLISH

The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. With the reservoir
in a horizontal position, the brake fluid level should not drop below the
middle of the glass.
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 *

3
2

5 mm

min.
1 mm

Loosen screws [2] and remove lid [3] and membrane [4].
Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (e.g. Motorex
Brake Fluid DOT 5.1). Replace membrane and lid, tighten screws. Rinse off
spilled or overflowing brake fluid with water.

– 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.
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.
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.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Replacing the front brake pads *
1

Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips [1] and pull out bolt [2]. Remove brake pads
from the brake caliper. Clean the brake caliper and the brake caliper support
with compressed air. Check the sleeves of the guide bolts for damage, and
grease guide bolts if necessary.
Mount the right brake pad and fix it with the bolt. Mount the left brake pad
and insert the bolt until it stops. Mount the clips.
When mounting the brake pads, be sure to check for correct fit of the
sliding metal-sheet [3] in the caliper support and of the leaf spring [4].

– 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.

2
2

Changing the basic position of the foot brake pedal *
The basic position of the foot brake pedal can be altered by turning the stop
screw [5]. The free play at the foot brake pedal must then be adjusted by
means of the piston rod [6].
Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20
in) of free play before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal).

3-5mm

IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE
BRAKE SYSTEM WHEN DRIVING, CAUSING THE REAR WHEEL TO BRAKE.THE
BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME
CASES.

Checking the rear brake fluid level
The reservoir for the rear brake disk is located on the right side of the motorcycle on the rear brake cylinder.
No air bubble should be visible in inspection glass [A] when the vehicle is
parked in a vertical position.

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE
SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE,
CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *
Add brake fluid as soon as a bubble is visible in inspection glass [A].
To top up, remove screw [7]. Fill DOT5.1 brake fluid (e.g. Motorex Brake Fluid
DOT 5.1) up to the mark [B] on the inside of the reservoir and remount the
screw. Spilled brake fluid must be rinsed off with water.

B
7

ENGLISH

– 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.
– 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.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Checking the rear brake pads

min.
1 mm

The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).
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.
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.

ENGLISH
36

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].

– 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
4
5

To remove the front wheel, jack the motorcycle up on its frame so that the
front wheel no longer touches the ground.
Loosen the 2 clamping screws [4] on the left side of the fork fists.
Loosen and remove the collar nut [5]., loosen the clamping screews [6] on
the right side of the fork fist.
Hold the front wheel, pull out the wheel spindle [7].
NOTE: The wheel spindle can be easily removed if you slightly revolve it with
a ring spanner (SW 27 mm).
Carefully remove the front wheel from the fork.
– 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.lb).
Loosen the clamp screws on the right fork leg. Take the motorcycle down from
its stand. Press the front wheel brakes and push down on the fork a few times
vigorously so that the fork legs come into alignment.
Only after this has been accomplished, tighten the clamp screws on both fork
legs with 10 Nm(7 ft. lbs).

MAINTENANCE WORK ON CHASSIS AND ENGINE »
– 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 BEHAVIOR OF YOUR MOTORCYCLE.
– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE
UNTIL THE PRESSURE POINT RETURNS.
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY
MATTERS, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

Jack the motorcycle up on its frame so that the rear wheel no longer
touches the ground.
Loosen the collar nut [1], remove chain tensioner [2], hold the rear wheel and
pull out the wheel spindle [3] until the rear wheel is free but the brake caliper
support is still held.
Push the rear wheel as far forward as possible, take the chain from the chain
wheel and carefully take the rear wheel out of the swingarm.

– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN
DISMOUNTED.
– MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE
WHEEL, OTHERWISE THE BRAKE DISC CAN BE DAMAGED.
– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE
AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM JAMMING.

The rear wheel is remounted in the reverse order. Before tightening the collar nut to 80 Nm, push the rear wheel forwards so that the chain tensioners
lie on the tension screws.

– 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 BEHAVIOR OF YOUR MOTORCYCLE.
– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL
THE PRESSURE POINT RETURNS.
– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY
MATTERS, EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.
– TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL
SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

Checking spoke tension
The correct spoke tension is very important for the stability of the wheels and
thus for riding safety. A loose spoke causes the wheel to become unbalanced
and before long other spokes will have come loose. Check spoke tension, especially 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.
– SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY
LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE.
– EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOADING.THE SPOKES MUST BE TENSIONED TO 5 NM.

ENGLISH

Dismounting and mounting the rear wheel

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Tires, air pressure
Tire type, tire condition, and air pressure level affect the way your motor-cycle
rides and must therefore be checked whenever you are getting ready to go
anywhere on your motorcycle.
– Tire size can be found in the technical specifications and in the homologation certificate
– Tire condition has to be checked every time you want to ride your motorcycle. Before leaving, check tires for punctures and nails or other sharp
objects that might have become embedded in them.
Refer to the specific regulations in your country for minimum tire tread
requirements. We recommend you replace the tires at the latest when the
tread is down to 2 mm (0.08 in).
– Tire pressure should be checked regularly on a “cold” tire. Proper pressure ensures optimum driving comfort and extends the life of your tires.
TIRES-AIR PRESSURE

ENGLISH

front

rear

1,0 bar

Road driver only 1,5 bar

2,0 bar

Off road

– DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER
TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE
BEHAVES.
– FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE
SAME TREAD LAYOUT. USE HOMOLOGATED TIRES.
– FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.
– WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE
PERFORMS, ESPECIALLY ON WET SURFACES.
– IF AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE
TIRE CAN RESULT.

Check/set distance of the magnetic sensor
The distance between magnet [2] and sensor [1] must be 2-4 mm
(0,08-0,16 in), otherwise malfunctions on the speedometer might occur.
This distance can be corrected by screwing in or off the sensor [1].

Replacing the battery of the digital speedometer
3

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.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Battery (MXC/EXC)
The battery is located under the seat and is maintenance-free.
It is not necessary to check the electrolyte level or to refill water. Simply keep
the battery poles clean and slightly grease them with an acid-free grease if
necessary.

– IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH
GREAT CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS.
– IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER.
– IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH
WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY CONSULT A DOCTOR.
– THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES. AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY.
– DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN.
ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES.
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR [2] !
– NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS
WILL DESTROY THE RECTIFIER-REGULATOR.
– THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT
(AS SHOWN IN THE ILLUSTRATION), OTHERWISE ELECTROLYTE CAN ESCAPE.

BATTERY STORAGE:
When preparing the motorcycle for a longer period of standstill, remove the
battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not
expose to direct sunlight.

Charging the battery
Remove the battery and check the charging level. Use a voltmeter to
measure the voltage between the battery poles (off-load voltage).
Accurate results can only be obtained if the battery has neither been charged
nor discharged during a period of 30 minutes preceding the measuring.

VOLT

off load voltage
Volt

charging level
%

charging time
0,4 A

>12,7
~12,5
~12,2
~12,0
~11,8

100
75
50
25
0

––
4h
7h
11 h
14 h

charging voltage

Max.
14,4 V

If the battery is empty, it can be recharged for a maximum period of
10 hours at 0.4 A and a maximum of 14.4 V.
– TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.
– ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING
THE CHARGING UNIT ON.
– WHEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT
VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY
CHARGING PROCESS.
– CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED
VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY
VALVES.
– AVOID QUICK CHARGING IF POSSIBLE.

ENGLISH

Removing the battery:
First disconnect the negative and then the positive pole of the battery.
Remove the filter box cover and unhitch both rubber bands [1].
Remove battery.Install the battery with the terminals facing the front (see illustration), connecting the negative terminal post to the battery last.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Fuse (MXC/EXC)
A

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.

ENGLISH

UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED
OR A FUSE ALLOWED TO BE “REPAIRED”. AN IMPROPER TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION.

Replacing headlight lamp/parking light lamp

5
6

Loosen both rubber bands and tilt headlight mask to the front. Pull the parking 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.

5
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.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Cooling system

2
1

– IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN THE ENGINE
IS COLD. IF YOU HAVE TO OPEN THE RADIATOR CAP [3] WHEN THE ENGINE
IS HOT, USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE. CAUTION - SCALDING HAZARD.
– DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE
ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS.
– IN CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER
RUNNING COLD WATER RIGHT AWAY.
– COOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN.
– IN CASE COOLANT IS INGESTED, CONSULT A DOCTOR IMMEDIATELY.
– IF COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDIATELY AND CONSULT DOCTOR.

A mixture of 50% antifreeze liquid and 50% water is used as coolant. However,
the antifreeze protection must be at least -25° C (-13° F). This mixture offers
antifreeze protection but also good corrosion protection and should therefore
not be replaced by pure water.
– THE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQUID 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 OVERHEATING 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 radiator fins when the engine
is cold (see diagram). In the event of the coolant being drained, always fill
and bleed the system.

10 mm
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 [3] WHEN THE ENGINE IS
HOT, USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE.

Bleeding the cooling system
By removing the screw [5] at the front end of the cylinder you can drain the
coolant.
To bleed the cooling system, fill in approx. 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 10mm above the
radiator fins.
After a short ride, check the coolant level once more.

ENGLISH

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 cylinder head. After the engine has reached its operating temperature (about 70°C,
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.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Replacing the glassfiber yarn packing of the silencer *

SX
1

3
C

5
4

EXC

ENGLISH

C
2

Aluminum silencers are filled with glassfiber yarn to muffle noise. The effect
of heat causes the glassfiber yarn to become loose. This may lead to a loss of
performance and reduce the silencer's muffling power. By experience, the front
glassfiber yarn packing [1] needs to be replaced more often than the rear silencing mat [2].
For this purpose, remove the silencer from the vehicle and dismount the front
cap [3]. Pull the front glassfiber yarn packing together with the inner exhaust
pipe [4] out of the silencer. Clean the front inner exhaust pipe.
To facilitate the mounting procedure, you can make a mounting tool [5] out
of wood, plastic, or metal. Insert the mounting tool into the inner pipe and
mount the glassfiber packing. Push the inner pipe containing the packing into
the silencer such that the slot engages the web [A]. Use a blunt ended object
to stuff the glassfiber yarn packing all the way into the silencer, and mount
the front cap [C].
To change the rear silencing mat, start by removing the front packing and the
inner exhaust pipe. Then, drill open the rivets and remove the end cap.
NOTE!
In every exhaust repair procedure, the O-rings must be replaced by new ones.
Glass fiber yarn packings are available from your licensed KTM
mechanic.

4
THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING. TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL
IT HAS PROPERLY COOLED DOWN.

A
Cleaning the spark arrester (MXC/EXC USA) *
The spark arrester should be cleaned every time the glassfiber yarn filling is
changed or at least once annually.
For this purpose, dismount the silencer cap and remove any deposits that might
exist in region [B]. Renew the O-ring and mount the silencer cap.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Cleaning the air filter *
The air filter must be cleaned prior to each race or whenever dust has accumulated. 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.

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 position, and fix with the filter retaining bracket.

ENGLISH

– DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAMAGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY
MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID
BIO POWER).
– NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. OTHERWISE,
DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR.
– DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FILTER IS NOT MOUNTED CORRECTLY.

5
4

3
2

Checking the adjustment of the hand decompression release cable *
6

8
7

10 mm

Start the engine and, at idling speed, slowly pull the hand decompression
lever until you can feel the thumping of the rocker arm on the lever. The backlash until said thumping should be approx. 10mm, measured at the lever's
outer end. If necessary, correct this backlash.
To adjust, move back the protective cover [6], loosen the counter nut [7] and
correct the adjustment screw [8] accordingly. Tighten counter nut and push
back protective cover.
THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE CHECKED REGULARY.
IF THERE IS NO PLAY IN THE DEKO-LEVER, THIS CAN RESULT IN ENGINE
DAMAGE.

note:
No adjustment need be made to the automatic decompressor.

Adjusting the throttle cables *

The throttle grip should always provide for a backlash of 3-5mm. Besides,
with the engine running, the idling speed must not change if you turn the
handlebar all the way to the left or right.
To adjust the throttle cables, dismount the seat and the tank together with
spoilers. Slide back the protection cover [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 clockwise will increase the backlash.
Tighten the counternut and check whether the throttle grip can be
actuated smoothly. Mount tank and seat.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
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 clockwise reduces the distance between the
clutch lever and the handlebar. Turning the adjusting screw counterclockwise
increases the distance between the clutch lever and the handlebar.

ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS. ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY
EXCESSIVE FORCE.

Checking the oil level of the hydraulic clutch

ENGLISH

2
3

To check the oil level in the master cylinder of the clutch remove the cover.
For this purpose, remove screws [2] and cover [3] together with the rubber
boot [4]. The oil level in the horizontal-standing master cylinder should be 4
mm below the upper edge.
If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Motorex
Kupplungs-Fluid 75).Biodegradable hydraulic oil is available from your KTM
dealer (50ml).
KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER
REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

Bleeding of the hydraulic clutch
If the clutch lever starts to feel unresponsive, the clutch control system needs
to be bled. You will need a bleeder syringe (special tool) and biodegradable
hydraulic oil. Both 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 Kupplungsfluid 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).

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER
REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) *

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 setting of the slide. The mixture control screw is used to control the idle mixture
which arrives at the engine by way of the idle system. Clockwise turning reduces
the fuel quantity (lean mixture), counterclockwise turning increases the fuel
quantity (rich mixture).
TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:
1 Turn in mixture control screw [2] up to the stop, and turn it back out to
the basic position (see technical date-engine)
2 Warm up the engine
3 Use the adjusting wheel [1] to set the normal idle speed (1400 - 1500 rpm).
4 Turn mixture control screw [2] slowly clockwise until idling speed starts
to decrease. Memorize this position, and turn mixture control screw slowly
counterclockwise until the idling speed decreases again. Adjust the point
of the highest idling speed between these two positions. If, in the course
of this procedure, the speed undergoes a relatively high increase, reduce
the idle speed to a normal level and repeat the procedure specified in 4.
Serious competitive racers will choose a setting approx. 1/4 turn (clockwise) 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 malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced
after 200 hours.

Adjusting the mixture control screw *
Especially on the EXC models, accessing the mixture control screw is difficult. 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 needle valve but not compress it.
In this position, the edge of the float should be parallel with the float chamber sealing surface (see illustration).
If the float height does not correspond to the desired value, check the float
needle valve and, if necessary, replace it.
If the float needle valve is o.k., you can adjust the float height by bending the
float lever [4].
Mount the float chamber, install the carburetor, and adjust the idle speed.

ENGLISH

Idling adjustment of the carburetor strongly affects the engine’s starting
behavior. That is, an engine whose idling speed is adjusted correctly will be
easier to start than one whose idling speed has not been adjusted correctly.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Draining the float chamber of the carburetor
Following every wet cleaning procedure, the float chamber of the carburetor
should be drained in order to remove any water that may have penetrated into
it. Water in the float chamber causes malfunctioning. Perform this task on a
cold engine.
Close the fuel tap and put one end of the hose [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.

ENGLISH

– 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
5
9

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 cylinder 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 bearing [11] and sprayed from below onto the piston through a nozzle [12].
The second oil pump [13] draws the engine oil via the short oil screen [14]
out of the crankcase, thereby lubricating the transmission gears [15].

13
12

3
15

Checking the engine oil level
The engine oil level can be checked with the engine either warm or cold. Place
the motorcycle in an upright position and on a horizontal surface (not on the
side stand).

B
A

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.
INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMATURE
WEAR IN THE ENGINE.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Engine oil

JASO T903 MA
TEMPERATUR
0°C
32°F

5W/40

10W/50

Automobile engine oil used to be used for four-stroke motorcycles before there
were separate motorcycle specifications. Different technical developments made
it necessary to have a separate specification for four-stroke motorcycles - the
JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines require a higher power output at higher speeds. Most
motorcycle engines also use the same oil to lubricate the transmission and
the clutch. The JASO MA standard responds to these special requirements.
Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

Changing the engine oil *
1

Note: When changing the engine oil, it is necessary to clean the short and
long oil screens and to replace both oil filters.
Engine oil has be changed with the engine at an operating temperature.
AN ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE
VERY HOT - DO NOT BURN OR SCALD YOURSELF.

Place the motorcycle on a horizontal surface, remove the plug [1] and allow
the oil to drain into a receptacle.
Clean plug (with magnet) thoroughly.
Once the entire oil has been drained, clean the sealing surface, mount the
plug together with the sealing ring and tighten it to 20 Nm.

CLEANING THE SHORT OIL SCREEN
The short oil screen [2] is accommodated in the hex-socket 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 components thoroughly and blow compressed air through them. Check the O-rings
for damage and, if necessary, replace them.

To mount the long oil screen [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.

5
THE OIL SCREEN IS MOUNTED SLIGHTLY DOWNWARDS, INCORRECTLY FITTED,
THE SCREEN LOOSES ITS FUNCTION AND THIS CAN CAUSE INCREASED ENGINE
WEAR.

ENGLISH

INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE
ENGINE.

MAINTENANCE WORK ON CHASSIS AND ENGINE »
Changing the oil filters
Remove the screw [1] and swing the brake fluid container sideward. Place a
receptacle underneath the engine to collect the drained oil. Remove the 4
screws [2] and dismount the two oil filter covers.

1
2

ENGLISH

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.

3
48
Put the motorcycle on its side and fill the oil filter housings about halfway
with engine oil. Fill oil filter with oil, place the long oil filter in the front and
the short filter in the back of the filter box.
Grease the O-rings [4] of the oil filter covers and mount the covers. Mount
the screws and tighten them to 6 Nm.
Position the brake fluid container and tighten the screw to 8 Nm.

Return the motorcycle to an upright position.
Remove the oil dipstick [5] at the clutch cover and fill in 1.2 liters of fully
synthetic engine oil (Motorex Power Synt 4T 10W/50).

Start the engine and check all screwed connections and the oil filter cover
for leaks.
Finally, check the engine oil level and, if necessary, correct it.

TROUBLESHOOTING »

TROUBLE
Engine doesn’t crank (E-starter).

CAUSE
Operating errror

REMEDY
Turn on the emergency-OFF switch (Australia only)

Blown fuse

Dismount the left paneling and the filter box cover and
replace the fuse in the starter relay.

Discharged battery.

Recharge the battery and investigate the causes for
discharging; contact a KTM dealer.

Low outside temperature

Start the engine with the kickstarter

Engine cranks but doesn’t start (E- Operating error
starter).

Open fuel tap, tank fuel, actuate choke. Pay attention to
starting information (see driving instructions).

Engine will not start (Kickstarter). The motorcycle has been out of operation for a longer period of time. Therefore
old fuel has accumulated in the float
chamber

The easily inflammable components of the new fuels evaporate during longer periods of standing still.
When the motorcycle has been out of operation for more
than a week, it is therefore recommended to drain the old
fuel from the float chamber. The engine will immediately
start when the float chamber is filled with new fuel.

Fuel supply interrupted

Close fuel tap, loosen fuel hose at carburetor, lead into a
basin and open fuel tap
– if fuel leaks out, the carburetor may need cleaning
– if no fuel leaks out, check tank ventilation, i.e. clean
fuel tap

Flooded engine

In order to "pump the engine free", pull the hand 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.

Sooty or wet spark plug

Clean and dry the spark plug or exchange it, respectively

Electrode gap too large

Adjust spark plug electrode gap to 0.6 mm

Spark plug connector or spark plug Dismount spark plug, connect ignition cable, hold to
faulty
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.
– If the 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.
– If a spark now occurs, replace spark plug cap
– If no spark is produced, control ignition system
Short circuit cable scored in wiring har- Dismount the fuel tank, disconnect the black/yellow cable
ness, emergency OFF switch or short cir- from the cable of the emergency-OFF switch and the shortcircuit button, respectively, and check the ignition spark.
cuit button faulty
If a spark is generated, look for the problem in the shortcircuit circuit.
The plug connection of the CDI-unit, the Remove the seat and the fuel tank. Clean the plug conpulse generator or the ignition coil has nection and treat it with contact spray
oxydized

Engine fails to idle

Water in carburetor or jets blocked

Dismount and clean the carburetor

Glogged idling jet

Disassemble the carburetor and clean the jets

Incorrect adjustment of adjusting Have the carburetor adjusted
screws on carburetor
Defective spark plug

Replace the spark plug

Defective ignition system

Have the ignition system checked

ENGLISH

If you had the specified maintenance work on your motorcycle carried out, disturbances can hardly be expected. Should an error occur
nevertheless, we advise you to use the troubleshooting chart in order to find the cause of error.
We would like to point out that many operations cannot be performed by yourself. In case of uncertainty, please contact a KTM-dealer.

TROUBLESHOOTING »
TROUBLE
Engine does not rev high

CAUSE
REMEDY
Carburetor fuel level too high because float Dismount carburetor and check if worn out
needle valve is dirty or worn out
Loose carburetor jets

Tighten jets

Electronic ignition timing faulty

Have ignition system checked

Engine will not reach full power Fuel supply partially interrupted or carbu- Clean and check fuel system as well as carburetor
retor dirty
Replace the float

Air filter very dirty

Clean or replace air filter

Exhaust system is not tight, deformed, or Check if exhaust is damaged, replace glasfiber yarn in
the silencer does not contain enough glass- exhaust silencer
fiber yarn

ENGLISH
50

Float leaks

Valve gap too small

Adjust valve gap

Loss of compression because hand decom- Check setting of the hand decompression cable
pressor has no play
Electronic ignition timing faulty

Have ignition system checked

Engine stops or splutters in Insuffient fuel
carburetor
Engine takes air out of control

Clean and check fuel system and carburettor

Engine gets too hot

Insufficient cooling liquid

Refill cooling liquid (see maintenace work), check cooling
system for leaks

Not enough air stream

Drive on briskly (electric fan can be retrofitted)

Cooling system has not been bled

Bleed cooling system

Radiators very dirty

Clean radiators with water jet

Foam formation in cooling system

Replace cooling liquid, use antifreeze liquid with brand name

Bent cooling hose

Shorten or replace cooling hose

Thermostat defective

Dismount and check thermostat (opening temperature
70°C, (158°F) or replace it

Hose of engine ventilation is bent

Dislocate i.e. replace non-buckling vetilation hose

Engine oil level too high

Check engine oil level and, if necessary, correct it

Motor oil too thin (viscosity)

Use thicker engine oil; see chapter “Engine oil“

High oil consumption

Check rubber sleeve and carburetor for tight fit

All switched on lamps blown Capacitor or voltage regulator faulty
out

Dismount seat and fuel tank and check connections, have
capacitor and voltage regulator checked

Horn, flasher lights and Blown fuse in the starter relay
E-starter do not work

Dismount left side paneling and filter box cover, replace
fuse

The battery is discharged

The battery isn’t charged by the generator Remove seat and fuel tank and check voltage regulator conbecause
nections; voltage regulator and generator should be checked
by a KTM dealer.

CLEANING »
Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.
The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.
The hard dirt can be removed before washing with the help of a soft water jet.

– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should also be cleaned with the help
of a paint brush.
– Before cleaning with water, plug the exhaust pipe to prevent water ingress
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber
of the carburetor. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.
– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of
the motorcycle is allowed to evaporate.
– Once the motorcycle has cooled down, oil or grease all sliding and bearing points. Treat the chain with a chain spray. Also oil the
fuel tap.
– To avoid any failures in of the electric system, you should treat the emergency-OFF switch, short-circuit button, light switch and
socket connectors with a contact spray.

CONSERVATION FOR WINTER OPERATION »
In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions 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-corrosion agent.
KEEP THE ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, OTHERWISE THIS WILL SIGNIFICANTLY REDUCE
THE BRAKING POWER.

AFTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL.

STORAGE »
Should you wish to make a pause over a longer space of time, please observe the following instructions:
– Clean motorcycle thoroughly (see chapter: CLEANING)
– Change engine oil, short and long oil filters (old engine oil contains aggressive contaminants).
– Check antifreeze and amount of cooling liquid.
– Warm up the engine once again, close the fuel cock and wait until the engine dies. Then open the drain plug of the float chamber
to remove the remaining fuel.
– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in
order to distribute the oil onto the cylinder walls and mount the spark plug.
– Set piston to compression so that the valves will be closed (slowly operate the kickstarter until you can hear the automatic
decompressor click (release))
– Let fuel flow out of tank into an appropriate container.
– Correct tire pressure.
– Lubricate pivot points of the control levers, foot rests, etc. as well as the chain.
– Service the shock absorber linkage
– Disassemble and charge battery (see chapter: BATTERY).
– The storage place should be dry and not subjected to excessive temperature fluctuations.
– Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use airtight materials as a possible humidity might not be
able to escape and could cause corrosion.
IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED
UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST
TO RUST.

USE AFTER A PERIOD OF STORAGE
–
–
–
–

Mount the charged battery (regard polarity).
Fill up tank with fresh fuel.
Check motorcycle as before each start (see driving instructions).
Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any service
jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics’ shops).
This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.

ENGLISH

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE
RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR, ETC. AND CAUSE DISTURBANCES
OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS.

TECHNICAL DATA - ENGINE »

ENGLISH
52

TYPE

250 EXC

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft

Displacement

250 cm3

Bore/Stroke

75 / 56,5 mm 89 / 64 mm 95 / 63,4 mm 89 / 72 mm

Ratio

12 : 1

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

Valve diameter Intake

28 mm

35 mm

35 mm (Titan) 35 mm

Valve diameter Exhaust

24 mm

30 mm

30 mm (Titan) 30 mm

Valve clearence cold Intake

0.12 mm (0.0047 in)

Valve clearence cold Exhaust

0.12 mm (0.0047 in)

Crank shaft bearing

2 cylinder roller bearing

Connecting rod bearing

needle bearing

Top end bearing

bronze bushing

Piston alluminium alloy -

cast

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
Gear ratio
Gear

1st

400 EXC

398 cm3

450 SX

449 cm3

450 MXC

450 EXC

448 cm3

525 SX

525 MXC-G 525 EXC
525 MXC DESERT

510 cm3
95 / 72 mm

11 : 1

forged

55/21

cast

590/5521

forged

6-speed

4-speed

6-speed

4-speed

6-speed

14:38

14:34

16:32

14:34

16:32

14:34

2nd Gear

16:36

17:31

18:30

17:31

18:30

17:31

3rd Gear

19:34

19:28

20:28

19:28

20:28

19:28

4th Gear

21:32

22:26

5th Gear

23:30

24:23

24:24

24:23

24:24

24:23

6th Gear

22:25

26:21

21:18

26:21

21:18

26:21

Ignition system

contactless DC-CDI ignition with digital advanced system by KOKUSAN

Generator

12V 150W

Spark plug

NGK DCPR 8 E

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, 40% antifreeze, 60% water, at least -25° (-13° F)

Starting equipment

kick - electric starter

12V 150W

kickstarter kick - electric starter

12V 150W

kickstarter kick - electric starter

TECHNICAL DATA - ENGINE »
BASIC CARBURATOR SETTING
400 EXC RACING
EU / AUS
12 kW

400 EXC-G RACING USA 450 EXC RACING
EU / AUS
12 kW

Type

Keihin FCR-MX 3700A Keihin FCR-MX 3900C Keihin FCR-MX 3900C Keihin FCR-MX 3900A

Main jet

160

178

Jet needle

OBEKT

OBDVR

Idling jet

Main air jet

200

Idling air jet

100

Needle position

3rd from top

1st from top

3rd from top

Starting jet

Mixture control screw open

0,75

1,25

Slide

Performance restrictor

Slide stop

–

Slide stop

Stop pump membrane

858 / 2,15 mm

Hot start device

–

450 EXC-G / MXC-G
RACING USA

450 EXC RACING
SIXDAYS

450 SX RACING

525 EXC / MXC
RACING / DESERT RACING
EU / AUS 12 kW

ENGLISH

250 EXC RACING
EU / AUS
11 kW

BASIC CARBURATOR SETTING

Type

Keihin FCR-MX 3900A Keihin FCR-MX 3900A Keihin FCR-MX 4122A Keihin FCR-MX 3900B

Main jet

178

185

178

Jet needle

OBDVR

OBDTR

OBDTP

OBDVT

Idling jet

Main air jet

200

Idling air jet

100

Needle position

3 from top

4 from top

3rd from top

Starting jet

Mixture control screw open

1,25

2,0

1,0

1,25

Slide

Performance restrictor

–

Slide stop

Stop pump membrane

858 / 2,15 mm

Hot start device

–

2,2 mm

–

525 MXC-G / EXC-G
RACING USA

525 EXC RACING
SIXDAYS

525 SX RACING

BASIC CARBURATOR SETTING

Type

Keihin FCR-MX 3900B Keihin FCR-MX 3900B Keihin FCR-MX 4125A

Main jet

178

185

Jet needle

OBDVT

OBDTR

OBDTP

Idling jet

Main air jet

200

Idling air jet

100

Needle position

3rd from top

5th from top

4th from top

Starting jet

Mixture control screw open

1,25

2,0

1,5

Slide

Performance restrictor

–

Stop pump membrane

858 / 2,15 mm

Hot start device

–

2,5 mm

TECHNICAL DATA - ENGINE »
TIGHTENING TORQUES

ENGLISH
54

Hexagon collar screw, engine case, clutch cover, ignition cover

10 Nm

Oil drain plug

M12x1,5

20 Nm

Allan head plug oil, screen short

M16x1,5

10 Nm

Hexagon plug, oil screen long

M20x1,5

15 Nm

Collar screw for oil filter cover

6 Nm

Plug pressure valve

M12x1,5

20 Nm

Jet screw and hollow screw, oil line

10 Nm

Screws, oil pump cover

Loctite 222 + 6 Nm

Hexagon collar screw, cylinder head top section

10 Nm

Hex.collar screw, cylinder head top section, water pump cover

8 Nm

Hexagon collar screw, exhaust flange

Loctite 243 + 8 Nm

Cylinder head screw

M10

40/50 Nm

Allan head screw, camshaft gear

Loctite 243 + 28 Nm

Stop screw, autodecompression

Loctite 222 + 8 Nm

Allan head screw, cap rocker arm

5 Nm

Counter nuts, valve adjustment screw

M6x0,75

11 Nm

Allan head screw, primary gear, free wheel

Loctite 648 + 16 Nm

Hexagon nut, primary gear

M20x1,5

Loctite 243 + 150 Nm

Allan head screw, balancer shaft gear

Loctite 243 + 8 Nm

Nut for inner clutch hub

M18x1,5

Loctite 243 + 150 Nm

Hexagon collar screw, clutch spring

8 Nm

Allan head screw, shift roller locking piece

Loctite 243 + 10 Nm

Hexagon collar screw, locking lever

Loctite 243 + 6 Nm

Hexagon collar screw, shift roller

Loctite 243 + 6 Nm

Hexagon collar screw securing guide, chain guide, chain tensioner

Loctite 243 + 8 Nm

Hexagon collar screw, clip

Loctite 243 + 6 Nm

Hexagon collar screw, chain adjuster

8 Nm

Hexagon collar screw, stator MXC/EXC

Loctite 243 + 8 Nm

Hexagon collar screw, stator SX

Loctite 243 + 6 Nm

Hexagon collar screw, pulser coil

Loctite 243 + 6 Nm

Hexagon collar nut, flywheel

M12x1

60 Nm

Hexagon collar screw, bump part kickstarter

Loctite 243 + 8 Nm

Hexagon collar screw, spring hanger kickstarter

Loctite 243 + 10 Nm

Hexagon collar screw, cover E-starter, only SX

Loctite 243 + 8 Nm

Hexagon collar screw, hanger vent hose

Loctite 243 + 8 Nm

Allan head screw, kickstarter

Loctite 243 + 25 Nm

Hexagon collar screw, shift lever

Loctite 243 + 10 Nm

Hexagon screw, engine sprocket

M10

Loctite 243 + 60 Nm

Spark plug

M10

10-12 Nm

Spark plug

M12x1,25

20 Nm

Engine oil

JASO T903 MA
TEMPERATUR
0°C
32°F

5W/40

Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE-WEAR.

10W/50

TECHNICAL DATA - CHASSIS »
CHASSIS

450/525 SX

Frame

Central tube chrome-moly-steel frame

250/400/450/525 EXC/MXC DESERT

450/525 MXC-G, EXC-G USA

Fork

4860 PA/MA

Wheel travel front/rear

300/335 mm

Rear suspension

WP Progressive Damping System shock absorber, aluminium swing arm

Front brake

Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated

Rear brake

Disk brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated

Brake disc

Wear limit max. 2,5 mm front and 3,5 mm rear

Front tires
80/100 - 21“
Air pressure offroad
1.0 bar (14 psi)
Air pressure road driver only –

90/90 - 21“
1.0 bar (14 psi)
1,5 bar

80/100 - 21“
1.0 bar (14 psi)
1.5 bar (21 psi)

Rear tires
110/90 - 19“
Air pressure offroad
1.0 bar (14 psi)
Air pressure road driver only –

140/80 - 18“
1.0 bar (14 psi)
2.0 bar (28 psi)

110/100 - 18“
1.0 bar (14 psi)
2.0 bar (28 psi)

Fuel tank capacity

7 liters (2 US gallons)

EXC 8,5 liters (2.1 US gallons) MXC 13 Liter (3.5 gallons)

Final drive ratio

450-14:52Z / 525-14:48Z

250-15:45Z / 450-15:45Z / 525-15:45Z

Chain

X-Ring 5/8 x 1/4 "

450-14:50Z / 525-14:48Z

Available final sprockets 38Z, 40Z, 42Z, 45Z, 48Z, 50Z, 52Z
Bulbs
headlight
12V 35/35W (Sockel BA20D)
parking light
12V 5W (Sockel W2, 1x9,5d)
brake - rear light
12V 21/5W (Sockel BaY15d)
flasher light
12V 10W (Sockel Ba15s)
license plate illmination
12V 1,2W (Sockel 1x4,6d)
Battery
maintenance-free battery 12V 8Ah
Steering head angle

63,5°

Wheel base

1481 ± 10 mm (58.3 ± 0.4 in)

Seat height, unloaded

925 mm (36.5 in)

Ground clearance, unloaded 380 mm (15.1 in)

STANDARD ADJUSTMENT - FORK
SX

MXC, MXC
Desert, EXC,
EXC-G

WP4860PA/MA WP4860MA
14187A05
14187A06
Compression adjuster

Rebound adjuster

Spring

4,6 N/mm

4,2 N/mm

Spring preload

5 mm

Air chamber length

100 mm

110 mm

Fork oil

SAE 5

ENGLISH

WP Up Side Down 4860 MA

STANADARD ADJUSTMENT-SHOCK ABSORBER
SX
MXC, MXC
Desert, EXC,
EXC-G
WP 5018 PDS WP 5018 PDS
DCC
MCC
12187A05
12187A06
Compression adjuster

15 LS (low speed)
15
2 HS (high speed)

Rebound adjuster

Spring

80/250

Spring preload

7 mm

TECHNICAL DATA - CHASSIS »
TIGHTENING TORQUES - CHASSIS

ENGLISH
56

Collar screw, front wheel spindle

M24x1,5

40 Nm

Brake caliper, front

Loctite 243 + 25 Nm

Brake caliper, FTE radial front

M10x1,25

Loctite 243 + 40 Nm

Brake disk

Loctite 243 + 10 Nm

Clamping screws, upper fork bridge EXC

20 Nm

Clamping screws, lower fork bridge EXC

15 Nm

Clamping screws, upper fork bridge SX

15 Nm

Clamping screws, lower fork bridge SX

10 Nm

Clamping screws, fork stubs

10 Nm

Hexagon nut, swing arm bolt

M16x1,5

100 Nm

Hexagon collar screw, handlebar clamp

20 Nm

Allan head srew, handlebar support

M10

Loctite 243 + 40 Nm

Shock absorber, top

M12

80 Nm

Shock absorber, bottom

M12

80 Nm

Collar nut, swing arm bolt

M20x1,5

80 Nm

Sprocket Screws

Loctite 243 + 35 Nm

Ball joint for push rod

Loctite 243 + 10 Nm

Engine mounting bolt

M10

60 Nm

Engine brace

33 Nm

Spoke nipple

M4,5 / M5

5 Nm

Screw adjusting ring spring preload shock abs.
Other screws on chassis

M6
M6
M8
M10
M6
M8
M10

8Nm
10 Nm
25 Nm
45 Nm
15 Nm
30 Nm
50 Nm

Other collar nuts on chassis

Activating and deactivating display modes . . . . . . .
Adjusting the free travel at the hand brake lever . . . .
Adjusting the mixture control screw . . . . . . . . . . . .
Adjusting the throttle cables . . . . . . . . . . . . . . . . . .
Basic suspension setup for the weight of the driver . .
Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . .
Bleeding the cooling system . . . . . . . . . . . . . . . . . .
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breather plug front fork . . . . . . . . . . . . . . . . . . . . .
Carburetor – Adjust idling (Keihin-FCRMX 37/39/41) . . .
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . .
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the basic position of the foot brake pedal .
Changing the engine oil . . . . . . . . . . . . . . . . . . . . .
Changing the fork offset (caster) (SX) . . . . . . . . . . .
Changing the original position of the clutch lever . . .
Changing the spring preload on the telescopic fork
(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . .
Changing the spring preload on the telescopic fork
(SX models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the spring preloading of the shock absorber
Charging the battery . . . . . . . . . . . . . . . . . . . . . . .
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . .
Check chain tension . . . . . . . . . . . . . . . . . . . . . . .
Check the following before each start . . . . . . . . . . .
Check/set distance of the magnetic sensor . . . . . . . .
Checking and adjusting the steering head bearing . .
Checking and adjusting the steering head bearing . .
Checking spoke tension . . . . . . . . . . . . . . . . . . . . .
Checking the adjustment of the hand decompression
release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the basic setup of the telescopic fork . . . .
Checking the brake fluid level - front brake . . . . . . .
Checking the coolant level . . . . . . . . . . . . . . . . . . .
Checking the engine oil level . . . . . . . . . . . . . . . . .
Checking the float level (float height) . . . . . . . . . . .
Checking the front brake pads . . . . . . . . . . . . . . . .
Checking the oil level of the hydraulic clutch . . . . .
Checking the rear brake fluid level . . . . . . . . . . . . .
Checking the rear brake pads . . . . . . . . . . . . . . . . .
Checking the shock absorber and spring . . . . . . . . .
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the dust sleeves of the telescopic fork . . . .
Cleaning the spark arrester (MXC/EXC USA) . . . . . . .
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination switch (EXC) . . . . . . . . . . . . . . . . . . .
Compression damping of fork . . . . . . . . . . . . . . . . .
Compression damping of shock absorber (MXC, EXC)
Conservation for winter operation . . . . . . . . . . . . . .
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . .
Damping action during compression of shock absorber (SX)
Determining the riding sag of the shock absorber . . .
Determining the static sag of the shock absorber . . .
Digital speedometer, indicator lamps . . . . . . . . . . . .
Dismounting and mounting the front wheel . . . . . . .
Dismounting and mounting the rear wheel . . . . . . . .

. .9
.34
.45
.43
.26
.39
.44
.41
.20
.28
.45
.32
.32
.35
.47
.29
.44
.27
.27
.25
.39
. .5
.31
.18
.38
.30
.28
.37
.43
.27
.34
.41
.46
.45
.34
.44
.35
.36
.26
.13
.51
.43
.28
.42
. .6
. .6
.15
.16
.51
.41
.31
.15
.26
.26
. .7
.36
.37

Draining the float chamber of the carburetor . . . . . . .46
Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . .18
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .8
Emergency OFF switch (EXC Australia) . . . . . . . . . . . .7
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . .40
General information about KTM disc brakes . . . . . . . .33
General tips and warnings for starting the motorcycle .17
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6
Head Word Index . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Hot start device (450/525 SX) . . . . . . . . . . . . . . . . .13
Instructions for initial operation . . . . . . . . . . . . . . . .17
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . .11
Maintence work on chassis and engine . . . . . . . . . . .25
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Operation instruments . . . . . . . . . . . . . . . . . . . . . . . .6
Overview of the electronic speedometer functions . . .12
Periodic maintance . . . . . . . . . . . . . . . . . . . . . . . . .21
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .15
Rebound damping of shock absorber (SX, MXC, EXC) .16
Refilling the front brake fluid reservoir . . . . . . . . . . .34
Refilling the rear brake fluid reservoir . . . . . . . . . . . .35
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .27
Replacing headlight lamp/parking light lamp . . . . . . .40
Replacing the battery of the digital speedometer . . . .38
Replacing the front brake pads . . . . . . . . . . . . . . . . .35
Replacing the glassfiber yarn packing of the silencer .42
Replacing the rear brake pads . . . . . . . . . . . . . . . . .36
Running in the Racing models . . . . . . . . . . . . . . . . .17
Serial number locations . . . . . . . . . . . . . . . . . . . . . . .5
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . . . .6
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Starter button (EXC) . . . . . . . . . . . . . . . . . . . . . . . . .7
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Starting when the engine is cold . . . . . . . . . . . . . . . .19
Starting when the engine is warm . . . . . . . . . . . . . . .19
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .20
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Technical Data - Chassis . . . . . . . . . . . . . . . . . . . . .55
Technical Data - Engine . . . . . . . . . . . . . . . . . . . . . .52
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Use after a period of storage . . . . . . . . . . . . . . . . . . .51
What to do when the engine is “flooded” . . . . . . . . . .19
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . .Appendix

ENGLISH

HEAD WORD INDEX »

ENGLISH

ANHANG – APPENDICE
APPENDIX – APÉNDICE

SCHALTPLAN » WIRING DIAGRAMM

SCHALTPLAN » WIRING DIAGRAMM
ANHANG – APPENDICE
APPENDIX – APÉNDICE

ANHANG – APPENDICE
APPENDIX – APÉNDICE

SCHALTPLAN » WIRING DIAGRAMM

SCHALTPLAN » WIRING DIAGRAMM
ANHANG – APPENDICE
APPENDIX – APÉNDICE
4

ENGLISH
Battery
Cooling fan
Driving light lamp
Flasher control lamp
Flasher relay
Front brake switch
Generator

DEUTSCH
Batterie
Lüftermotor
Fernlichtkontrolle
Blinkerkontrolle
Blinkerrelais
vorderer Bremslichtschalter
Generator
Handle bar switch for multi-func.-digital-speedometer Lenkerschalter für Kombiinstrument
Headlight
Scheinwerfer
High / low beam switch
Auf-Abblendschalter
Horn
Hupe
Ignition coil
Zündspule
Ignition switch
Zündschloss
Left front flasher
linker vorderer Blinker
Left rear flasher
linker hinterer Blinker
Multi-func.-digital-speedometer
Multifunktionsdigitaltacho
Pick up
Impulsgeber
Position light
Standlicht
Rear brake switch
hinterer Bremslichtschalter
Rear light / brakelight
hinteres Begrenzungslicht / Bremslicht
Regulator-rectifier
Regelgleichrichter
Right front flasher
rechter vorderer Blinker
Right rear flasher
Rechter hinterer Blinker
Speed sensor
Geschwindigkeitssensor
Start button
Starttaster
Start relay
Startrelais
Starter motor
Startermotor
Stop button
Not-Aus-Schalter
Throttle position sensor (TPS)
Vergaserpotentiometer

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 velocità
Pulsante d´avviamento
Relè d‘avviamento
Motorino d‘avviamento
Interrutore di aresto dèmergenza
Potenziometro carburatore (sensore 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

CAVO COLORATO
bl: nero
ye: giallo
bu: blu
gn: verde
re: rosso
wh: bianco
br: marrone
or: arancione
pi: rosa
gr: grigio
pu: violetto

KABELFARBEN
bl: blau
ye: gelb
bu: blau
gn: grün
re: rot
wh: weiß
br: braun
or: orange
pi: rosa
gr: grau
pu: violett

ITALIANO
Batteria
Motorino ventola
spia abbagliante
spia lampeggiatori
Relè indicatori
Interruttore luce ant. di stop
Generatore
Interruttore sul manubrio per tachimetro multifunzione

ENGLISH
Battery
Cooling fan
Driving light lamp
Flasher relay
Flasher control lamp
Front brake switch
Generator

FRANCAIS
Batterie
Ventilateur
temoin feu route
Relais de clignotants
temoin de clignoteur
Contacteur de frein avant
Alternateur
Handle bar switch for multi-func.-digital-speedometer Contacteur au guidon pour ordinateur de bord
Headlight
Phare
High / low beam switch
Contacteur code/phare
Horn
Avertisseur sonore
Ignition coil
Bobine d’allumage
Ignition switch
Contacteur d’allumage
Left front flasher
Clignotant avant gauche
Left rear flasher
Clignotant arrière gauche
Multi-func.-digital-speedometer
Ordinateur de bord
Pick up
Capteur d’allumage
Position light
feu de position
Rear brake switch
Contacteur de frein arrière
Rear light / brakelight
Feu rouge/stop
Regulator-rectifier
Régulateur/redresseur
Right front flasher
Clignotant avant droit
Right rear flasher
Clignotant arrière droit
Speed sensor
Capteur de vitesse
Start button
bouton de démarrage
Start relay
Relais de démarreur
Starter motor
Démarreur
Stop button
bouton d´arrêt d`urgence
Throttle position sensor (TPS)
Capteur d’ouverture de carburateur

Faro
Interruptor de encender/apagar la luz larga
Cláxon
Bobina de encendido
Cerradura de encendido
Luz intermitente izquierda delantera
Luz intermitente izquierda trasera
Velocímetro digital multifuncional
Generador de impulsos
luz de posicion
Interruptor de luz del freno trasero
Luces de parqueo traseras /luces de freno
Regulador rectificador
Luz intermitente derecha delantera
Luz intermitente derecha trasera
Sensor de velocidad
botón de arranque
Relé del arranque
Motor de arranque eléctrico
interruptor de parada de emergencia
Potenciómetro del carburador

CABLE COLOURS
bl: black
ye: yellow
bu: blue
gn : green
re: red
wh: white
br: brown
or: orange
pi: pink
gr: grey
pu: purple

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

COULEUR DE CABLE
bl: noir
ye: jaune
bu: bleu
gn: vert
re: rouge
wh: blanc
br: brun
or: orange
pi: rose
gr: gris
pu: violet

ESPANIOL
Batería
Motor del ventilador
lampara aviso luces largas
Relé de la luz intermitente
lampara aviso intermitentes
Interruptor de luz del freno delantero
Generador
Interruptor de manillar para instrumento combinado

ANHANG – APPENDICE
APPENDIX – APÉNDICE

SCHALTPLAN » WIRING DIAGRAMM

ANHANG – APPENDICE
APPENDIX – APÉNDICE

BEDIENUNGSANLEITUNG2005
250 EXC RACING
400 EXC RACING
450 SX, MXC, EXC RACING
525 SX, MXC, EXC RACING
OWNER`S MANUAL
MANUALE D`USO
MANUEL D`UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.211.39

KTM Group Partner

KTM-Sportmotorcycle AG
A–5230 Mattighofen
www.ktm.at

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Ktm 400 Exc Racing Users Manual

MXC 2005,250,400exc,450,525sx,mxc,exc

EXC RACING to the manual 2147754a-a263-e364-093e-12522acad22f

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