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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KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART. NR. 3.211.39

250 EXC RACING

400 EXC RACING

450 SX, MXC, EXC RACING

525 SX, MXC, EXC RACING

BEDIENUNGSANLEITUNG2005

ENGLISH

1

IMPORTANT »

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

Frame number

Engine number

Key number

Stamp of dealer

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 manufactur-

ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil-

ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models

partly contain extra equipment, which is not applied to standard models.

© 2004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in

extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

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 CAN BE DANGEROUS TO LIFE AND LIMB!

– IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR-

CYCLE’S TRAFFIC SAFETY!

COMSUMER INFORMATION FOR AUSTRALIA ONLY

Tampering with noise control system prohibited

Owners are warned that the law may prohibit:

(a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or

replacement, of any device or element of design incorporated into any new vehicle for the purpose of

noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

(b) the use of the vehicle after such device or element of design has been removed or rendered inopera-

tive by any person.

ENGLISH

2

INTRODUCTION »

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

You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and

enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure

to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new

motorcycle and with its characteristics, even if this means that you will have to dedicate some of your

valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific

needs and how to protect yourself against injury. Besides, this manual contains important information on

motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of

this production series. It cannot be completely ruled out, however, that minor discrepancies may exist

resulting from further design upgrades of these motorcycles.This manual is an important part of your motor-

cycle and should be passed on to any subsequent owner in case you decide to sell it.

We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chas-

sis and engine" must be performed. If maintenance work should become necessary during a competition

it should be performed by a trained mechanic. KTM strongly recommends that all service work to your

KTM should be performed by a qualified KTM dealer.

For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that

arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding

these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM

is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM

serviced by a recognized and qualified KTM dealer.

Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full.

It may, however, involve potential 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

ENGLISH

3

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 interna-

tional motorcycle associations.

Observance of the service, maintenance and tuning instructions for the engine and chassis specified in

the Owner's Manual is a prerequisite for faultless operation and the avoidance of premature wear. An

improperly tuned chassis can lead to damage and breakage of the chassis components (see chapter on

checking the basic chassis setting).

The service work specified in the "Lubrication and Maintenance Schedule" must be performed and serv-

ice records must be kept for warranty documentation. Lack of proper service and maintenance records or

documentation could void warranty.

The fuels and lubricants specified in the Owner's Manual or fluids with equivalent specifications must

be used in accordance with the maintenance schedule.

No claims can be filed under the warranty for damage or consequential damage caused by manipulations

or conversions to the motorcycle.

The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead

to higher than average wear on components such as the drive train or the brakes. In this case it may

become necessary to service or replace wear parts before the service limit specified in the maintenance

schedule has been reached.

The SX/SXS, MXC and other “competition only“ labeled models are prohibited on public roads.

“On the road“ approved models are only allowed on public roads in the original homologated (throttled)

version. Without this performance restriction (i.e. de-throttled), these models are only allowed to be driven

off-road and not on public roads.

The EXC models are designed for off-road sports endurance competitions(enduro) and not suitable for

predominant motocross use.

Note: The above is a general statement. Specific limited warranty and limited guarantee information may

vary depending upon distribution. Please check with your local KTM dealer for limited warranty and lim-

ited guarantee information specific to your KTM model and region.

In accordance with the international quality management ISO 9001 standard, KTM uses

quality assurance processes that lead to the highest possible product quality.

ENGLISH

4

TABLE OF CONTENTS »

Page

IMPORTANT LIMITED WARRANTY AND LIMITED GUARAN-

TEE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine number, engine type . . . . . . . . . . . . . . . . . . . .5

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . . . .6

Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . .6

Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Starter button (EXC) . . . . . . . . . . . . . . . . . . . . . . . . .7

Emergency OFF switch (EXC Australia) . . . . . . . . . . . .7

Digital speedometer, indicator lamps . . . . . . . . . . . . . .7

Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .8

Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . .12

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Hot start device (450/525 SX) . . . . . . . . . . . . . . . . .13

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Compression damping of fork . . . . . . . . . . . . . . . . . .15

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .15

Damping action during compression of shock absorber (SX)

.15

Compression damping of shock absorber (MXC, EXC) .16

Rebound damping of shock absorber (SX, MXC, EXC) .16

GENERAL TIPS AND WARNINGS FOR STARTING THE

MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Instructions for initial operation . . . . . . . . . . . . . . . .17

Running in the Racing models . . . . . . . . . . . . . . . . .17

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .18

Check the following before each start . . . . . . . . . . . .18

Starting when the engine is cold . . . . . . . . . . . . . . . .19

Starting when the engine is warm . . . . . . . . . . . . . . .19

What to do when the engine is “flooded” . . . . . . . . . .19

Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .20

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .21

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .24

Changing the spring preloading of the shock absorber .25

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Basic suspension setup for the weight of the driver . . .26

Checking the shock absorber and spring . . . . . . . . . .26

Determining the static sag of the shock absorber . . . .26

Determining the riding sag of the shock absorber . . . .26

Checking the basic setup of the telescopic fork . . . . .27

Changing the spring preload on the telescopic fork

(SX models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Changing the spring preload on the telescopic fork

(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . . .27

Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .27

Page

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .28

Cleaning the dust sleeves of the telescopic fork . . . . .28

Checking and adjusting the steering head bearing . . .28

Changing the fork offset (caster) (SX) . . . . . . . . . . . .29

Checking and adjusting the steering head bearing . . .30

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .31

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .32

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

General information about KTM disc brakes . . . . . . . .33

Adjusting the free travel at the hand brake lever . . . . .34

Checking the brake fluid level - front brake . . . . . . . .34

Refilling the front brake fluid reservoir . . . . . . . . . . .34

Checking the front brake pads . . . . . . . . . . . . . . . . .34

Replacing the front brake pads . . . . . . . . . . . . . . . . .35

Changing the basic position of the foot brake pedal . .35

Checking the rear brake fluid level . . . . . . . . . . . . . .35

Refilling the rear brake fluid reservoir . . . . . . . . . . . .35

Checking the rear brake pads . . . . . . . . . . . . . . . . . .36

Replacing the rear brake pads . . . . . . . . . . . . . . . . .36

Dismounting and mounting the front wheel . . . . . . . .36

Dismounting and mounting the rear wheel . . . . . . . . .37

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .38

Check/set distance of the magnetic sensor . . . . . . . . .38

Replacing the battery of the digital speedometer . . . .38

Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . .39

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .39

Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Replacing headlight lamp/parking light lamp . . . . . . .40

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Checking the coolant level . . . . . . . . . . . . . . . . . . . .41

Bleeding the cooling system . . . . . . . . . . . . . . . . . . .41

Replacing the glassfiber yarn packing of the silencer .42

Cleaning the spark arrester (MXC/EXC USA) . . . . . . . .42

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .43

Checking the adjustment of the hand decompression

release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Adjusting the throttle cables . . . . . . . . . . . . . . . . . . .43

Changing the original position of the clutch lever . . . .44

Checking the oil level of the hydraulic clutch . . . . . .44

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .44

CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41)

.45

Adjusting the mixture control screw . . . . . . . . . . . . .45

Checking the float level (float height) . . . . . . . . . . . .45

Draining the float chamber of the carburetor . . . . . . .46

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Checking the engine oil level . . . . . . . . . . . . . . . . . .46

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Changing the engine oil . . . . . . . . . . . . . . . . . . . . . .47

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .49

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

CONSERVATION FOR WINTER OPERATION . . . . . . . . . .51

USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . .51

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .52

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

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

ENGLISH

5

SERIAL NUMBER LOCATIONS »

Chassis number

The chassis number is stamped on the right side of the steering head tube.

Enter this number in the field on page no 1.

Engine number, engine type

The engine number and the engine type are stamped into the left side of the

engine below the engine sprocket. Enter this number on page 1.

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6

OPERATION INSTRUMENTS »

Clutch lever

The clutch lever [1] is located on the left side of the handlebar. The adjust-

ing screw [A] is used to change the original position of the clutch lever (see

maintenance work on chassis and engine).

The clutch is hydraulically actuated and adjusts itself automatically.

Hand decompression lever

The hand decompression lever [2] is needed only if the carburetor overflows

after a fall. To "pump the engine free", pull the hand decompression lever

during the starting procedure.

The outer end of the lever must provide for a backlash of approx. 10mm (0.4

in) at all times. Only thereafter may it cause valve motion (to be

recognized by the stronger resistance which the hand decompression lever

encounters).

Hand brake lever

The hand brake lever [3] is mounted on the handlebars on the right and

actuates the front wheel brake. The adjusting screw [B] can be used to change

the basic position of the hand brake lever (see "Maintenance").

Short circuit button (SX/MXC)

The short circuit button [4] turns off the engine. When pressing this button,

the ignition circuit is short-circuited.

Combination switch (EXC)

The light switch has 2, respectively 3 switch positions.

[A] = Light off (this 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.

A

B

C

1A

2

3

B

4

56

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7

OPERATION INSTRUMENTS »

Headlamp switch (EXC USA)

In this model the headlamp is switched on with the pull switch [1].

Flasher switch

The flasher switch is a separate unit and is mounted on the left portion of the

handlebar.

The wire harness is designed in a way that whenever you want to use your

bike off-road, you can dismount the entire turn indicator system without

affecting the function of the remaining electrical system.

Flasher left

Flasher right

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.

2

3

4

5

6

Digital speedometer, indicator lamps

The green control lamp [5] flashes in the same rhythm as the flash-

ing indicator when the indicator is working.

The blue control lamp [6] lights up when the high beam is on.

1

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8

OPERATION INSTRUMENTS »

TEST

All of the display segments briefly light up for the display function test.

WS (wheel size)

The display changes and the circumference of the front wheel is briefly dis-

played in millimeters (2205 mm corresponds to a front wheel circumference

of 21" with production tires).

Afterwards the display will return to the previous display mode.

Electronic speedometer

The display in the electronic speedometer is activated as soon as you press

a button on the speedometer or an impulse is received from the wheel sen-

sor. The display lights up when the engine is running.

The display is cleared if no button is pressed for 1 minute or no impulse is

received from the wheel sensor.

The |button is used to change between display modes.

The +and –buttons are used to control various functions.

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 motor-

cycles, making the service hour counter a very practical function.

SPEED / ODO display mode (odometer)

The SPEED/ODO mode displays the speed and the total distance traveled.

The display automatically changes to the SPEED/H display mode when the

front wheel stops turning.

+button no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. 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).

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9

OPERATION INSTRUMENTS »

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 Starts and stops the stop watch, lap time is not

reset to 0

–button 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 con-

tinues to run after you press the - button, all 10 mem-

ory locations are occupied.To clear all of the stored

lap times, hold the |button for 3 seconds in the

SPEED/LAP mode.Up to 10 lap times can be stored

in this way.

briefly press |button Changes to the next display mode.If no lap time is

stored or the motorcycle is driving, the LAP/LAP

mode will be skipped.

hold |button 3 secs. Clears all LAP figures

SPEED / CLK (time) display mode

CLK displays the time in hours, minutes and seconds.

+button no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. set the clock menu

To set the clock, see „Setting the clock“.

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 blink-

ing function can be activated by pressing the +button and deactivated by

pressing the –button.

Press and hold the |button 3 seconds to store the settings.

If no button is pressed for 20 seconds, the setting will be stored automati-

cally and the display will return to the SPEED/H mode.

+button activates the blinking display

–button deactivates the blinking display

briefly press |button changes to the next display without changing any

settings

hold |button 3 secs. 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

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10

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 changes to the next lap time

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. changes to the next display mode

SPEED / MAX display mode (maximum speed)

MAX displays the maximum speed traveled and is always active.

+button no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. clears the MAX figure

SPEED / TR1 display mode (tripmaster 1)

The TR1 tripmaster is always active and counts to 999.9. It is used to meas-

ure the length of a trip or the distance between 2 refueling stops.

TR1 is linked to A1 (average speed 1). The calculation of these figures is acti-

vated by the first impulse received from the wheel sensor (when the front wheel

starts to turn) and stops 3 seconds after the last impulse is received (when

the front wheel has stopped).

The TR1, A1 and S1 figures are automatically cleared after passing 999.9.

+button no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. 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 use-

ful function for trips taken according to a roadbook.

+button increases the TR2 figure

–button decreases the TR2 figure

briefly press |button changes to the next display mode

hold |button 3 secs. 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 no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. clears the TR1, S1, A1 figures

ENGLISH

11

OPERATION INSTRUMENTS »

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 sec-

onds 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 dis-

play returns to the SPEED/H mode.

If no button is pressed for 20 seconds, the setting will be stored automati-

cally and the display will return to the SPEED/H mode.

+button to access the menu

to activate the KMH display

–button to activate the MPH display

briefly press |button changes to the next mode

changes from the menu to the SETUP menu

hold |button 3 secs. stores and closes the SETUP menu

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 no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. changes to the next display mode

SPEED / S1 display mode (stop watch 1)

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 acti-

vated by the first impulse received from the wheel sensor and stops 3 sec-

onds after the last impulse is received.

+button no function

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. clears the TR1, S1, A1 figures

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 starts and stops the stop watch

–button no function

briefly press |button changes to the next display mode

hold |button 3 secs. clears the S2 figure

ENGLISH

12

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. 0-

12 will show the time in the 12-hour mode, 0-24 in the 24-hour mode.

Press and hold the |button for 3 seconds to store the settings.

If no button is pressed for 20 seconds, the settings will be stored automati-

cally and the display will return to the SPEED/CLK mode.

+button time +

–button time -

briefly press |button changes to the next digit

hold |button 3 secs. starts the SETUP menu

stores the time and changes to the SPEED/CLK dis-

play mode

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.

Motorcycle is standing

Motorcycle is driving

OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS

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

XSPEED / H no function no function next display mode

displays the SETUP menu

X X SPEED / CLK no function no function next display mode Setting the clock menu

X X 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

XLAP / LAP next figure no function next display mode next display mode

X X SPEED / MAX no function no function next display mode clears MAX

XSPEED / ODO no function no function next display mode next display mode

X X SPEED / TR1 no function no function next display mode clears TR1, S1, A1

X X SPEED / TR2 increases the TR2 figure reduces the TR2 figure next display mode clears TR2

X X SPEED / A1 no function no function next display mode clears TR1, S1, A1

X X SPEED / A2 no function no function next display mode next display mode

X X SPEED / S1 no function no function next display mode clears TR1, S1, A1

X X SPEED / S2 starts - stops S2 no function next display mode clears S2

ENGLISH

13

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.

Choke

If you pull the choke button [2] out as far as possible, a bore in the carbure-

tor will be opened through which the engine may take in additional fuel. The

result is a „fat“ fuel-air mixture of the type needed for cold starts.

To deactivate the choke, push the choke button back into its basic position.

Hot start device (450/525 SX)

If you pull the hot start device [3] out as far as possible, a bore in the carbu-

retor will be opened through which the engine may take in additional air. The

result is a „lean“ fuel-air mixture of the type needed for hot starts.

To deactivate the hot start device, push the hot start button back into its basic

position.

1

2

3

Fuel tap

OFF In this position the fuel tap is closed. No fuel can flow to the

carburetor.

ON During operation the twist grip must be turned to ON. This means that

the fuel can flow to the carburetor. With the twist grip in this position

the tank will be emptied until only the reserve is left.

RES The reserve tank cannot be tapped until the rotating handle is turned

to the RES position. Fill the tank as soon as possible and remember to

turn the rotating handle back to the ON position so that you will have

backup fuel next time, too.

Reserve MXC . . . . . .3.0 l (0,8 US gallons)

Reserve EXC . . . . . .1.0 l (0,3 US gallons)

ON RESOFF

SX

MXC

EXC

ENGLISH

14

OPERATION INSTRUMENTS »

Shift lever

The shift lever is mounted on the left side of the engine. The position of the

gears is shown in the illustration. Neutral, or the idle speed, is located

between first and second gear.

Kickstarter

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

be swivelled.

Foot brake pedal

The foot brake pedal is located in front of the right footrest. Its basic position

can be adjusted to your seat position (see maintenance work).

Side stand

Push the side stand to the ground with your foot and load it with the motor-

cycle. Make sure that you put your bike on solid ground and in a secure posi-

tion. For off-road riding, you can use the rubber band [1] to additionally secure

the center stand in its folded-up position

Steering lock

The handlebar can be locked by means of the lock located on the steering

head. To lock it, turn handlebar all the way to the right, insert key, turn it to

left, press it in, turn it to right, and remove it.

NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK. IF YOU TURN THE HAN-

DLEBAR TO THE LEFT THE KEY COULD GET DAMAGED.

2,3,4 (5,6)

1

N

1

ENGLISH

15

OPERATION INSTRUMENTS »

Compression damping of fork

Hydraulic compression damping determines the reaction when the fork is com-

pressed. The degree of compression can be adjusted with adjusting

screws at the bottom of the fork legs.Remove the protecting cap [1].

Turn the adjusting screws [2] clockwise to increase damping, turn it counter-

clockwise to reduce damping during compression.

STANDARD ADJUSTMENT

– turn adjusting screw clockwise as far as it will go

– turn it back by as many clicks as are specified for the relevant type of fork

Typ White Power 14187A05...............22 clicks (SX)

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

Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is

rebound. By turning the adjusting screw [3] (REB), the degree of damping of

the rebound can be adjusted. Turn the knob clockwise to increase damping,

turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT

– turn adjusting screw clockwise as far as it will go

– turn it back by as many clicks as are specified for the relevant type of fork

Typ White Power 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 com-

pression and not to the speed of the motorcycle.

The low and high-speed technology overlaps.

The low-speed setting is primarily for slow to normal shock absorber compres-

sion rates.

The high-speed setting is effective at fast compression rates.

Turning in a clockwise direction will increase the damping, turning

counterclockwise will decrease the damping.

STANDARD LOW-SPEED SETTING:

– turn the adjusting screw [4] to the limit in a clockwise direction using a

screwdriver .

– unscrew the respective number of clicks for the specific type of shock absor-

ber in a counterclockwise direction.

Typ White Power 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 absor-

ber in a counterclockwise direction.

Typ White Power 12187A05...............2 turns

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRES-

SION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO

ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW CONNECTION [6] (24MM).

1

2

2

3

3

5

6

4

ENGLISH

16

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, turn-

ing in a counterclockwise direction will decrease the damping.

STANDARD ADJUSTMENT:

– turn the adjusting screw clockwise to the stop.

– then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

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

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRES-

SION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO

ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW CONNECTION [2] (24MM).

Rebound damping of shock absorber (SX, MXC, EXC)

By using the adjusting screw [3], the degree of damping of the rebound can

be adjusted. Turn the knob clockwise to increase damping, turn it counter-

clockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT:

– turn the adjusting screw clockwise to the stop.

– then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

Type White Power 12187A05 ..............22 clicks

Type White Power 12187A06 ..............22 clicks

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRES-

SION NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO

ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW CONNECTION [4] (15MM).

2

1

4

3

ENGLISH

17

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »

– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE.

CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES

AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY

OR JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING

SHOULD BE BRIGHTLY COLORED SO THAT OTHER VEHICLES CAN

SEE YOU AS EARLY AS POSSIBLE.

– ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER

DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE.

– DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

– ONLY USE ACCESSORIES RECOMMENDED BY KTM. FOR EXAM-

PLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES

OF THE MOTORCYCLE. CASES, EXTRA TANKS, ETC. CAN ALTER

THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHI-

CLES DRIVING PROPERTIES.

– 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 CONDI-

TIONS AND YOUR DRIVING SKILLS.

– DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR

TRIALS.

– WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SEC-

OND MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN

HELP EACH OTHER SHOULD DIFFICULTIES ARISE.

– REPLACE THE HELMET VISOR OR GOGGLE LENS WHEN

SCRATCHED OR DAMAGED. IF BRIGHT LIGHT SHINES THROUGH

A SCRATCHED VISOR OR LENS, THE OPERATOR WILL BE BLINDED.

– NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF

THE ENGINE IS RUNNING.

– THE SX/SXS/MXC MODELS ARE NOT APPROVED FOR USE ON PUB-

LIC ROADS AND FREEWAYS.

– WHEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND

THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE

NOISE.

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Read these operating instructions carefully before your first

ride.

– Familiarize yourself with the operating elements.

– Set the clutch lever, the handbrake lever, 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 abi-

tily and experience.

– Hold the handlebars with both hands and leave your feet on

the foot rests while driving.

– Remove your foot from the foot brake lever when you are not

braking. 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 slid-

ing across one another for quite some time. Therefore, every engine

needs to be broken in.

For this reason, do not load the engine more than 50% of its

capacity during the first 3 operating hours. Besides, the engine

speed must not exceed 7000 rpm. Avoid going full-throttle!

In the following 12 operating hours, you may load the engine

up to 75% of its capacity. Use the motorcycle on various types

of terrain (road, easy off-road trails).

THE 250/400/450/525 SX/MXC/EXC RACING MODELS WERE UNCOM-

PROMISINGLY DESIGNED FOR OFF-ROAD COMPETITION PURPOSES

ONLY. “ON THE ROAD“ APPROVED MODELS ARE ONLY ALLOWED ON

PUBLIC ROADS IN THE ORIGINAL HOMOLOGATED (THROTTLED)

VERSION. AVOID EXTENDED ON-ROAD RIDES AT FULL THROTTLE.

ENGLISH

18

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:

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 com-

plete failure of the braking system can be avoided.

Also check the state of the brake hose and the thickness of the brake

linings.

Check free travel at the hand brake lever and foot brake lever.

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, indica-

tors, control lamps and horn while the engine is running.

9 LUGGAGE

If you are taking luggage with you, check that this is securely fastened.

A

B

ENGLISH

19

DRIVING INSTRUCTIONS »

Starting when the engine is cold

1 Open the fuel tap [1].

2 Swing up the side stand or center stand.

3 Put the gear in neutral.

4 Operate the choke [2].

5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actu-

ate the E-starter.

– 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 THROT-

TLE GRIP, THE KICK-BACK HAZARD WILL BE HIGHER.

– DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.

EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS-

NESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE

ENGINE IS RUNNING.

– ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE (NEUTRAL)

BEFORE ACTUATING THE STARTER BUTTON. IF YOU START THE MOTORCYCLE

WITH A GEAR ENGAGED, THE MOTORCYCLE WILL MOVE FORWARD.

– MAXIMAL PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST

5 SECONDS BEFORE TRYING AGAIN.

– DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV UP THE

ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN

THE WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE.

Starting when the engine is warm

1 Open the fuel tap [1].

2 Swing up the side stand.

3 Put the gear in neutral.

4 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or

actuate the E-starter.

What to do when the engine is “flooded”

In the event of a fall, more fuel than necessary may get into the engine. In

order to "pump the engine free", pull the hand decompression lever, fully rev

up the engine, actuate the kickstarter 5 to 10 times or 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 throt-

tle back to 3/4; the speed hardly decreases although the engine will use less

gas. Only give as much gas as the engine can handle. Through quick and high

revving of the throttle, the fuel usage increases.

By shifting down, use the brakes if necessary and close the throttle at the

same time. Pull the clutch lever and shift down to the next gear. Let clutch

lever go slowly and open the throttle or shift down again.

1

2

ENGLISH

20

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).

– 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 GIV-

ING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRE-

CAUTIONS IN THIS RESPECT NEED TO BE TAKEN. THE ENGINE HAS

REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADI-

ATORS BECOME WARM.

– NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN

TO A LOWER GEAR. THE ENGINE WILL OVER-REV, DAMAGING THE

VALVES. IN ADDITION, THE REAR WHEEL LOCKS SO THAT THE

MOTORCYCLE CAN EASILY GET OUT OF CONTROL.

– IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK

THAT THE ENGINE FASTENING BOLTS ARE TIGHT.

– IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMME-

DIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED

KTM DEALER.

Braking

Close throttle and apply the hand and foot brakes at the same time.

When driving on sandy, wet or slippery ground use mainly the rear

wheel brake. Always brake with feeling, blocking wheels can cause

you to skid or fall. Also change down to lower gears depending on

your speed.

When driving down hill, use the braking effect of the engine.

Change down one or two gears but do not overspeed the engine.

In this way, you will not need to brake so much and the brakes will

not overheat.

– IN CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER

RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF-ROAD

TRACKS, HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAK-

ING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY

OR CLEAN.

–

RIDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRAK-

ING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN.

– DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS.

– WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE

CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS

GET, THE WEAKER THE BREAKING EFFECT. IN EXTREME CASES,

THE ENTIRE BRAKING SYSTEM CAN FAIL.

– IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE

PEDAL FEELS “SPONGY” (TOO MUCH PLAY), THIS IS AN INDICA-

TION THAT SOMETHING IS WRONG 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.

MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN-

NING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND

SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE

PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK

IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED.

– NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE

ENGINE. USE THE SHORT-CIRCUIT BUTTON OR THE EMERGENCY-

OFF BUTTON INSTEAD.

– CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE

THE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE

ENGINE.

– NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE ARE

FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMA-

BLE MATERIALS.

NOTE REGARDING THE SIDE STAND:

Use your foot to kick side stand forward up to the stop and lean

the motorcycle sideways. Make sure that the ground is solid and

that your motorcycle is standing securely. Just 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 MOTOR-

CYCLE, THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND.

Fuel

The racing engine needs unleaded fuel with at least RON 95 (USA

= Premium RON 91).

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

ENGLISH

21

PERIODIC MAINTENANCE »

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

1. service after

3 hours

or

20 l fuel

after/every

15 hours

or

100 l fuel

ENGINE

Change engine oil, short and long oil filters z z

Clean oil screen and drain plug magnet z z

Check oil lines for damage or bends z z

Replace spark plug (after 30 hours)

Check and adjust valve clearance z z

Check engine mounting bolts for tightness z z

CARBURETOR

Check carburetor connection boot for cracks and leaks z

Check idle speed setting z z

Check vent hoses for damage or bends z z

ADD- ON PARTS

Check cooling system for leaks, check quantity of antifreeze z z

Check exhaust system for leaks and fitment z

Check cables for damage, smooth operation and bends adjust and lubricate z z

Check fluid level of the clutch master cylinder z z

Clean air filter and filter box z

Check electric wires for damage and bends z

Check headlamp setting z

Check function of electric systems (low high beam, brake light, indicator lamps,

speedometer illumination, horn, emergency OFF switch or button z z

BRAKES

Check brake fluid level, lining thickness, brake discs z z

Check brake lines for damage and leaks z z

Check/function smooth operation and adjust free travel of handbrake/foot brake lever z z

Check tightness of brake system screws z z

CHASSIS

Check shock absorber and fork for leaks and function z z

Clean fork dust bellows z

Bleed fork legs z

Check swing arm bearings z

Check/adjust steering head bearings z z

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

WHEELS

Check spoke tension and rim joint z z

Check tires and air pressure z z

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

Lubricate chain z z

Check clearance of wheel bearings z z

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

at least

once a year

Complete maintenance of fork z

Complete maintenance of shock absorber z

Clean and grease steering head bearings and gasket elements z

Clean and adjust carburetor z

Replace glass fibre yarn filling of the exhaust main silencer z

Treat electric contacts and switches with contact spray z

Treat battery connections with contact grease z

Change hydraulic clutch fluid z

Change brake fluid z

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

22

PERIODIC MAINTENANCE »

IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER

Before each

start

After every

cleaning

For cross-

country use

Check oil level z

Check brake fluid level z

Check brake pads for wear z

Check lights for function z

Check horn for function z

Lubricate and adjust cables and nipples z

Bleed fork legs regularly z

Remove and clean fork dust bellows regularly z

Clean and lubricate chain, check tension and adjust if necessary z z

Clean air filter and filter box z

Check tires for pressure and wear z

Check cooling fluid level z

Check fuel lines for leaks z

Drain and clean float chamber z

Check all control elements for smooth operation z

Check brake performance z z

Treat blank metal parts (with the exception of brake and exhaust system)

with wax-based anti corrosion agent z

Treat ignition and steering locks and light switches with contact spray z

Check tightness of screws, nuts and hose clamps regularly z

ENGLISH

23

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)

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

15

hours

100

liter

30

hours

200

liter

45

hours

300

liter

60

hours

400

liter

90

hours

600

liter

120

hours

800

liter

35

hours

900

liter

Check the clutch disks for wear z z z z z z z

Check the length of the clutch springs z z z z z z

Check the cylinder and piston for wear zzz

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

Check the camshaft for wear (visual check) zzz

Replace the camshaft bearings zzz

Check the length of the valve springs zzz

Check the spring cap for wear zzz

Check the eccentricity of the valve disk zzz

Check the valve guides for wear zzz

Check the radial clearance of the rocker arm rollers zzz

Check the elongation of the timing chain zzz

Check the chain tensioner tooting for damage (visual check) z z z z z z

Check the eccentricity of the crankshaft journal zzz

Replace the conrod bearings zzz

Check piston pin bearing zzz

Replace the balancer shaft bearings zzz

Replace the crankshaft main bearings zzz

Check the entire transmission including the roller and bearings for wear zzz

Check the length of the bypass valve spring zzz

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS

MUST BE REPLACED.

ENGLISH

24

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)

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

30

hours

200

liter

60

hours

400

liter

90

hours

600

liter

120

hours

800

liter

180

hours

1200

liter

240

hours

1600

liter

270

hours

1800

liter

Check the clutch disks for wear z z z z z z z

Check the length of the clutch springs z z z z z z

Check the cylinder and piston for wear zzz

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

Check the camshaft for wear (visual check) zzz

Replace the camshaft bearings zzz

Check the length of the valve springs zzz

Check the spring cap for wear zzz

Check the eccentricity of the valve disk zzz

Check the valve guides for wear zzz

Check the radial clearance of the rocker arm rollers zzz

Check the elongation of the timing chain zzz

Check the chain tensioner tooting for damage (visual check) z z z z z z

Check the eccentricity of the crankshaft journal zzz

Replace the conrod bearings zzz

Check piston pin bearing zzz

Replace the balancer shaft bearings zzz

Replace the crankshaft main bearings zzz

Check the entire transmission including the roller and bearings for wear zzz

Check the length of the bypass valve spring zzz

NOTE: IF THE INSPECTION ESTABLISHES THAT PERMISSIBLE TOLERANCES ARE EXCEEDED, THE RESPECTIVE COMPONENTS

MUST BE REPLACED.

ENGLISH

25

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Changing the spring preloading of the shock absorber

The spring preload can be changed by turning the adjusting ring [1]. For this

purpose, you should dismount the shock absorber and clean it thoroughly.

NOTE:

– Before changing the spring preload note down the basic setting, e.g. how

many threads are visible above the adjusting ring.

– One rotation of the adjusting ring [1] changes the spring pretension by

approximately 1.75 mm (0.07 in).

Loosen the clamping screw [2] and use the hook wrench contained in the

vehicle tool set to turn the adjusting ring as desired. Turning it counterclock-

wise will reduce the preload, turning it clockwise will increase the

preload.

After readjusting the clamping screw [2], tighten it to 8 Nm.

ADJUSTMENT VALUES - SPRING PRELOAD A

minimum preload..................... 4 mm (0,15 in)

STANDARD PRELOAD .............. 7 mm

maximum preload ....................10 mm (0,4 in)

Pivot bearing

The pivot bearing [3] for PDS suspension struts at the swinging fork is Teflon-

coated and must not be lubricated with either grease or other lubricants. Grease

and other lubricants cause the Teflon coat to dissolve, whereby the bearing’s

lifecycle will be reduced dramatically.

When cleaning your bike with a high-pressure cleaner, do not aim the high-

pressure spray directly at the pivot bearing.

A

3

1

2

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 SERV-

ICED BY APPROPRIATELY QUALIFIED,SKILLED STAFF.

– 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

26

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 (wear-

ing full protective clothing). If your weight exceeds or falls short of this range,

you will need to adjust the basic setup for the suspension components accord-

ingly. Minor deviations in weight can be compensated by adjusting the spring

preload. Different springs must be installed for larger deviations.

Checking the shock absorber and spring

You can establish whether or not the shock absorber spring is suitable for your

weight by checking the riding sag. The static slag must be correctly adjusted

before the riding sag can be determined.

Determining the static sag of the shock absorber

The static sag should be as close as possible to 35 mm. Deviations of more

than 2 mm can strongly influence the motorcycle's performance.

Procedure:

– Jack up the motorcycle until the rear wheel no longer touches the ground.

– Measure the vertical distance between the rear wheel axle and a fixed point

(e.g. a mark on the side cover) and write it down as dimension A.

– Place the motorcycle on the ground again.

– Ask a helper to hold the 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."

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

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).

A

B

B

C

A

B

C

60

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

80/250

84/250

76/250

PDS 12187A05 450/525 SX

ENGLISH

27

MAINTENANCE WORK ON CHASSIS AND ENGINE »

According to our experience, the damping rate of the compression stage can

remain unchanged. The damping rate of the rebound stage can be reduced

by a few clicks for a softer spring or increased by a few clicks for a harder

spring.

Checking the basic setup of the telescopic fork

The precise riding sag of the telescopic fork cannot be determined for

various reasons. Similar to the shock absorber, smaller deviations in your weight

can be compensated by adjusting the spring preload. However, if your

telescopic fork bumps frequently (hard end stop during compression), you should

install harder fork springs to avoid damaging the telescopic fork and frame.

Changing the spring preload on the telescopic fork (SX models)

The telescopic forks of the SX models come with a preload adjuster for easy

adjustment of the spring preload. You can adjust the spring preload ± 9 mm

by turning the adjusting screws (basic position = middle position).

NOTE:

Always turn the adjusting screws the same distance on both fork legs. Different

spring preloads on the fork legs will reduce the telescopic fork's response.

Changing the spring preload on the telescopic fork (MXC/EXC models)

The telescopic forks for these models must be partly disassembled to adjust

the spring preload (see WP manual). Pretension spacers are available in

heights of 1.5, 2.5 and 5 mm (see spare parts catalog). The fork springs may

not be pretensioned by more than 20 mm.

The preload adjuster used in the SX models can easily be retrofitted for the

telescopic forks of the MXC/EXC models.

NOTE:

WP precisely adjusts the spring pressure by inserting pretension spacers.

Fluctuations in production are compensated with pretension spacers in vari-

ous heights. This can cause the fork springs in the fork legs to have different

degrees of pretension. Fork springs and pretension spacers should always stay

together.

Replacing fork springs

If you weigh less than 70 kg or more than 80 kg, you should install the respec-

tive fork springs. The correct spring rate is shown in the illustrations. The stan-

dard spring is shown in bold print. The type number of the telescopic fork is

embossed on the caps on the top of the telescopic fork.

If you are uncertain which spring to use, contact your KTM workshop.

According to our experience, the damping rate of the compression stage can

remain unchanged. The damping rate of the rebound stage can be reduced

by a few clicks for a softer spring or increased by a few clicks for a harder

spring.

60

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

80/250

84/250

76/250

PDS 12187A06 250/400/450/525

MXC/MXC-Desert/EXC/EXC-G

60

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

4,6 N/mm

4,8 N/mm

4,2 N/mm

14187A05 450/525 SX

60

SPRING RATE

65 70 75 80 85 90

RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM

4,2 N/mm

4,4 N/mm

4,0 N/mm

14187A06 250/400/450/525

MXC/MXC-Desert/EXC/EXC-G

ENGLISH

28

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 serv-

ice.

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.

Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and

oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine

oil. Then, push the dust-protection bellows into the outer tubes by hand.

NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD

CONSIDERABLY REDUCE THE TIRE'S ROAD GRIP AND THE BRAKING EFFECT OF

THE FRONT BRAKE.

Checking and adjusting the steering head bearing *

Check steering head bearing for play periodically. To check, put the motorcy-

cle on a stand so that the front wheel is off the ground. Now try to move the

fork forward and backward. For readjusting, loosen the five pinch bolts [3] of

the top triple clamp and turn steering stem bolt clockwise [4] until there is

no more play. Don’t tighten the steering stem bolt all the way, otherwise the

bearings will be damaged. With a plastic hammer, lightly tap on the triple

clamp to release tension. Retighten the five pinch bolts to 20 Nm(EXC) and

15 Nm (SX).

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 PERI-

ODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME

WILL BE DESTROYED.

The steering head bearings should be regreased at least once a year

(e.g. Motorex Long Therm 2000).

1

2

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows [2] are to remove dust and coarse dirt particles

from the fork tube. However, after some time, dirt may also get in behind the

dust-protection bellows. If this dirt is not removed, the oil sealing rings located

behind it may start to leak.

Use a screwdriver to lift the dust-protection bellows out of the outer tubes

and slide them downward.

3

4

3

3

ENGLISH

29

MAINTENANCE WORK ON CHASSIS AND ENGINE »

B

A

2

1

3

2

5

4

3

4

5

2

Changing the fork offset (caster) (SX) *

The fork offset [A] in the SX models (center fork legs - center steering head

angle) can be set to either 18 or 20 mm. This allows you to optimize the han-

dling to match the race course.

Remove the blind screw [1] to see which offset is set. If the mark [B] is in

front, the offset is 18 mm. This setting will deliver more directional stability

on fast race courses.

If the mark [B] is in the rear as illustrated, the offset is 20 mm. This setting

will deliver better handling in curves.

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

To adjust the offset, dismount the front wheel and remove the front wheel

fender.

Remove the screw on the starting number plate. Remove the clamp screws

on the hand brake cylinder and fasten the hand brake cylinder to the left fork

leg with a cable tie to keep the brake line from kinking (see illustration).

Loosen the clamp screws and take the fork legs out of the triple clamps.

Loosen the collar screw [2] on the lower triple clamp 2 turns.

Remove the blind screw [1] from the upper triple clamp, loosen the clamp

screw and upper triple clamp on the seat. Remove the O-ring [3] and the pro-

tection ring [4].

Tap gently on the lower triple clamp with a rubber hammer to loosen the steer-

ing stem [5] out of the bearing seat. Take the lower triple clamp with the steer-

ing stem out of the steering head.

Remove the collar screw from the lower triple clamp and pull out the steer-

ing stem. Thoroughly clean all parts. Turn the steering stem 180° and insert

it in the triple clamp, tighten the collar screw all the way to the stop.

– 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 COL-

LAR SCREW IS SELF-LOCKING.

Grease the steering head bearing and sealing elements.

ENGLISH

30

MAINTENANCE WORK ON CHASSIS AND ENGINE »

15 mm

3,5 mm

1

2

3

4

Mount the lower triple clamp, upper steering head bearing, protection ring,

O-ring, upper triple clamp and the blind screw.

Tighten the collar screw on the lower triple clamp to 80 Nm.

Mount the fork legs and tighten the clamp screws on the lower triple clamp

to 10 Nm in 3 stages.

Adjust the steering head bearing without clearance (see: Checking and adjust-

ing the steering head support) and tighten the clamp screws on the upper

triple clamp to 15 Nm in 3 stages.

Mount the front wheel fender and tighten the screws to 10 Nm.

Mount the hand brake cylinder and tighten the screws to 10 Nm.

Mount the staring number plate.

Mount the front wheel (see: Dismounting and mounting the front wheel).

Checking and adjusting the steering head bearing *

Check steering head bearing for play periodically. To check, put the motorcy-

cle on a stand so that the front wheel is off the ground. Now try to move the

fork forward and backward. For readjusting, loosen the five pinch bolts [1] of

the top triple clamp and turn steering stem bolt [2] clockwise until there is

no more play. Don’t tighten the steering stem bolt all the way, otherwise the

bearings will be damaged. With a plastic hammer, lightly tap on the triple

clamp to release tension. Retighten the five pinch bolts to 15 Nm (SX) / 20

Nm (EXC, MXC).

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 PERI-

ODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME

WILL BE DESTROYED.

The steering head bearings should be regreased at least once a year

(e.g. Motorex Long Therm 2000).

ENGLISH

31

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.

– EXCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE

COMPONENTS OF THE SECONDARY DRIVETRAIN (CHAIN, BEARINGS OF TRANS-

MISSION AND REAR WHEEL). ASIDE FROM RESULTING PREMATURE WEAR, IF

WORST COMES TO WORST THE CHAIN MAY RUPTURE OR THE COUNTERSHAFT

OF THE TRANSMISSION MAY BREAK.

– TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE

CHAIN JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD

ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE.

– IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE

MOTORCYCLE.

Correct chain tension

Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting

screws [3] equally far. Tighten lock nuts.

To ensure the correct alignment of the rear wheel, the marks at the left and

right chain adjusters must be positioned identically in relation to the

reference marks [B]. Tighten the counter nut of the 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 BEHAV-

IOR OF YOUR MOTORCYCLE.

– TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL

SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

NOTE:

The large adjusting range of the chain adjusters (32mm) allows you to use

different secondary ratios in combination with the same chain length. The

chain adjusters [4] can be rotated by 180°.

8-10 mm / 0,3-04in

A

2

2

3

1

4

B

B

3

4

ENGLISH

32

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.

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.

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.

15 KG

33 lbs

max. 272 mm

1 2 3

16 17 18

ENGLISH

33

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.

BRAKE PADS:

The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front

and TOSHIBA H 38 sintered lining at the back. These linings provide an opti-

mal combination of dosing, brake performance and life cycle. The lining type

is stated on the back of the brake pad and also recorded in the homologation

papers.

Other brake pads are available for competition sports.

FRONT: TOSHIBA H 38 (SINTERED) – harder to dose, good brake per-

formance, long life, for wet slippery terrain.

FERODO ID 450 (ORGANIC) – easy to dose, good brake per-

formance, short life, for dry terrain, low price

REAR: FERODO 4424 (organic) – better 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 IMMEDI-

ATELY AS SOON AS THEY REACH THE WEAR LIMIT.

– HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER

BRAKE FLUID RESERVOIRS:

The brake fluid reservoirs on the front and rear wheel brakes have been

designed in such a way that even if the brake pads are worn it is not neces-

sary to top up the brake fluid. If the brake fluid level drops below the mini-

mum level either the brake system has a leak or the brake pads are completely

worn.In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID:

KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid,

one of the best brake currently available. We recommend that you continue

to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid.

However, you should replace it as soon as possible with DOT 5.1.

Never 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 FRE-

QUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCK-

ETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING

THE BRAKE SYSTEM TO FAIL.

1

A

ENGLISH

34

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.

AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN).

ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE

RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF THIS

FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAKING

SYSTEM, AND THE FRONT-WHEEL BRAKE MAY FAIL DUE TO OVERHEATING.

Checking the brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the handle-

bar and the reservoir is provided with an inspection glass. With the reservoir

in a horizontal position, the brake fluid level should not drop below the

middle of the glass.

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE

SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE,

CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws [2] and remove lid [3] and membrane [4].

Place hand brake cylinder in a horizontal position and fill the brake fluid reser-

voir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (e.g. Motorex

Brake Fluid DOT 5.1). Replace membrane and lid, tighten screws. Rinse off

spilled or overflowing brake fluid with water.

– 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.

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.

min.

1 mm

5 mm

min. 3 mm

1

3

2

4

ENGLISH

35

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Replacing the front brake pads *

Press the brake caliper toward the brake disk, to put the brake piston in its

basic position. Remove clips [1] and pull out bolt [2]. Remove brake pads

from the brake caliper. Clean the brake caliper and the brake caliper support

with compressed air. Check the sleeves of the guide bolts for damage, and

grease guide bolts if necessary.

Mount the right brake pad and fix it with the bolt. Mount the left brake pad

and insert the bolt until it stops. Mount the clips.

When mounting the brake pads, be sure to check for correct fit of the

sliding metal-sheet [3] in the caliper support and of the leaf spring [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.

Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop

screw [5]. The free play at the foot brake pedal must then be adjusted by

means of the piston rod [6].

Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20

in) of free play before the piston rod can move the piston in the brake cylin-

der (to be recognised from the resistance on the foot brake pedal).

IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE

BRAKE SYSTEM WHEN DRIVING, CAUSING THE REAR WHEEL TO BRAKE.THE

BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME

CASES.

Checking the rear brake fluid level

The reservoir for the rear brake disk is located on the right side of the motor-

cycle on the rear brake cylinder.

No air bubble should be visible in inspection glass [A] when the vehicle is

parked in a vertical position.

IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE

SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE,

CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

Add brake fluid as soon as a bubble is visible in inspection glass [A].

To top up, remove screw [7]. Fill DOT5.1 brake fluid (e.g. Motorex Brake Fluid

DOT 5.1) up to the mark [B] on the inside of the reservoir and remount the

screw. Spilled brake fluid must be rinsed off with water.

– 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.

3-5mm

1

1

2

21

2

4

3

6

5

A

B

7

ENGLISH

36

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings

may not be less than 1 mm (0.04 in).

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.

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

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).

min.

1 mm

1

2

3

4

5

6

ENGLISH

37

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 BEHAV-

IOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE

UNTIL THE PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY

MATTERS, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

Dismounting and mounting the rear wheel

Jack the motorcycle up on its frame so that the rear wheel no longer

touches the ground.

Loosen the collar nut [1], remove chain tensioner [2], hold the rear wheel and

pull out the wheel spindle [3] until the rear wheel is free but the brake caliper

support is still held.

Push the rear wheel as far forward as possible, take the chain from the chain

wheel and carefully take the rear wheel out of the swingarm.

– DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN

DISMOUNTED.

– MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE

WHEEL, OTHERWISE THE BRAKE DISC CAN BE DAMAGED.

– IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE

AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PRE-

VENT THE THREAD FROM JAMMING.

The rear wheel is remounted in the reverse order. Before tightening the col-

lar nut to 80 Nm, push the rear wheel forwards so that the chain tensioners

lie on the tension screws.

– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE

YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON

AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV-

IOR OF YOUR MOTORCYCLE.

– AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL

THE PRESSURE POINT RETURNS.

– IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY

MATTERS, EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

– TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL

SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE.

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels and

thus for riding safety. A loose spoke causes the wheel to become unbalanced

and before long other spokes will have come loose. Check spoke tension, espe-

cially on a new motorcycle, at regular intervals. For checking, tap on each

spoke 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 OVERLOAD-

ING.THE SPOKES MUST BE TENSIONED TO 5 NM.

7

1

2

3

ENGLISH

38

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 homolo-

gation certificate

– Tire condition has to be checked every time you want to ride your motor-

cycle. Before leaving, check tires for punctures and nails or other sharp

objects that might have become embedded in them.

Refer to the specific regulations in your country for minimum tire tread

requirements. We recommend you replace the tires at the latest when the

tread is down to 2 mm (0.08 in).

– Tire pressure should be checked regularly on a “cold” tire. Proper pres-

sure ensures optimum driving comfort and extends the life of your tires.

– DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER

TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE

BEHAVES.

– FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE

SAME TREAD LAYOUT. USE HOMOLOGATED TIRES.

– FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.

– WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE

PERFORMS, ESPECIALLY ON WET SURFACES.

– IF AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE

TIRE CAN RESULT.

Check/set distance of the magnetic sensor

The distance between magnet [2] and sensor [1] must be 2-4 mm

(0,08-0,16 in), otherwise malfunctions on the speedometer might occur.

This distance can be corrected by screwing in or off the sensor [1].

Replacing the battery of the digital speedometer

Remove the headlight mask and disassemble the electronic speedometer.

Remove the screw connection [3], insert the battery (type CR 2430) with the

writing facing up and reinstall the screw connection.

1

1

2

TIRES-AIR PRESSURE

front rear

Off road 1,0 bar 1,0 bar

Road driver only 1,5 bar 2,0 bar

3

ENGLISH

39

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.

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 illus-

tration), connecting the negative terminal post to the battery last.

– IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH

GREAT CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS.

– IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER.

– IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH

WATER FOR AT LEAST 15 MINUTES. IMMEDIATELY CONSULT A DOCTOR.

– THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLO-

SIVE GASES. AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY.

– DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN.

ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES.

– 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.

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.

VOLT

1

2

off load voltage

Volt

charging level

%

charging time

0,4 A

charging voltage

>12,7

~12,5

~12,2

~12,0

~11,8

100

75

50

25

0

––

4 h

7 h

11 h

14 h

Max.

14,4 V

ENGLISH

40

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Fuse (MXC/EXC)

The fuse [1] is located in the starter relay of the E-starter [2] underneath the

left side paneling.

Having removed the left side paneling, the air box cover and the protection

cover [A], you will be able to see the fuse.

The following loads are connected to it:

– E-starter system

– horn

– flasher lights

– electronic speedometer

The starter relay also contains a (10 amp) spare fuse [3].

Replace a blown fuse only with an equivalent one. If a new fuse that has just

been installed gets blown again, you are strongly advised to have it

inspected by a KTM dealer.

The fuse capacity is 10 Ampere.

UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED

OR A FUSE ALLOWED TO BE “REPAIRED”. AN IMPROPER TREATMENT COULD DAM-

AGE THE WHOLE ELECTRICAL INSTALLATION.

Replacing headlight lamp/parking light lamp

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

ing light lamp with holder [4] carefully out of the reflector. Pull connector [5]

off the headlamp and remove rubber cap [6]. Disengage retaining clip and

take bulb out of reflector. When changing the parking-light lamp, simply pull

it out of the holder.

Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out

of the socket.

To mount the lamp reverse the worksteps indicated above.

2A

1

3

4

6

5

5

ENGLISH

41

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Cooling system

Coolant is circulated by a water pump [1] located in the engine. When the

engine is cold the coolant only circulates through the cylinder and the cylin-

der head. After the engine has reached its operating temperature (about 70°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.

– IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN THE ENGINE

IS COLD. IF YOU HAVE TO OPEN THE RADIATOR CAP [3] WHEN THE ENGINE

IS HOT, USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRES-

SURE. CAUTION - SCALDING HAZARD.

– DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE

ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS.

– IN CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER

RUNNING COLD WATER RIGHT AWAY.

– COOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN.

– IN CASE COOLANT IS INGESTED, CONSULT A DOCTOR IMMEDIATELY.

– IF COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDI-

ATELY AND CONSULT DOCTOR.

A mixture of 50% antifreeze liquid and 50% water is used as coolant. However,

the antifreeze protection must be at least -25° C (-13° F). This mixture offers

antifreeze protection but also good corrosion protection and should therefore

not be replaced by pure water.

– THE COOLING SYSTEM MUST BE BLED AFTER DRAINING THE COOLING LIQ-

UID OR AFTER ADDING MORE THAN 0.25 L (0.06 US GALLONS) COOLING

LIQUID.(SEE BELOW).

– FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZE (E.G.

MOTOREX ANTI FREEZE). USING LOWER-GRADE ANTIFREEZE AGENTS CAN

CAUSE CORROSION AND COOLANT FOAMING.

– EXTREME CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVER-

HEATING PROBLEMS. TO AVOID THIS, AN ELECTRIC BLOWER [4] IS OFFERED

FOR MODELS WITH ELECTRIC STARTERS (ASK YOUR KTM DEALER)

Checking the coolant level

The coolant should be 10 mm (0.4 in) above the radiator fins when the engine

is cold (see diagram). In the event of the coolant being drained, always fill

and bleed the system.

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.

1

2

3

4

56

when engine is cold

10 mm

ENGLISH

42

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Replacing the glassfiber yarn packing of the silencer *

Aluminum silencers are filled with glassfiber yarn to muffle noise. The effect

of heat causes the glassfiber yarn to become loose. This may lead to a loss of

performance and reduce the silencer's muffling power. By experience, the front

glassfiber yarn packing [1] needs to be replaced more often than the rear silenc-

ing mat [2].

For this purpose, remove the silencer from the vehicle and dismount the front

cap [3]. Pull the front glassfiber yarn packing together with the inner exhaust

pipe [4] out of the silencer. Clean the front inner exhaust pipe.

To facilitate the mounting procedure, you can make a mounting tool [5] out

of wood, plastic, or metal. Insert the mounting tool into the inner pipe and

mount the glassfiber packing. Push the inner pipe containing the packing into

the silencer such that the slot engages the web [A]. Use a blunt ended object

to stuff the glassfiber yarn packing all the way into the silencer, and mount

the front cap [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.

THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN-

NING. TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL

IT HAS PROPERLY COOLED DOWN.

Cleaning the spark arrester (MXC/EXC USA) *

The spark arrester should be cleaned every time the glassfiber yarn filling is

changed or at least once annually.

For this purpose, dismount the silencer cap and remove any deposits that might

exist in region [B]. Renew the O-ring and mount the silencer cap.

SX

EXC

C

4

31

5

15

3

C

24

A

B

ENGLISH

43

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Cleaning the air filter *

The air filter must be cleaned prior to each race or whenever dust has accu-

mulated. To clean, lift the filter box cover [1]

(see illustration) and pull off towards the front.

Detach the bottom of the filter retaining bracket [2], tilt aside and remove

the throttle cap [3] and the air filter [4] and filter support [5] from the filter

box. The SX models do not have a throttle cap.

– DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM-

AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY

MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID

BIO POWER).

– NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. OTHERWISE,

DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR.

– DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL-

TER IS NOT MOUNTED CORRECTLY.

Thoroughly wash the air filter in special cleaning fluid and allow it to dry well.

Only press out the filter, do not wring it out under any circumstances. Oil the

dry air filter with a high-grade filter oil. Also clean the air filter box. Check

the carburetor collar for damage and that it is filled correctly.

Mount the air filter on the filter support. Insert the air filter and filter support

in the throttle cap and mount them in the filter box, aligning in a central posi-

tion, and fix with the filter retaining bracket.

10 mm

6

8

7

10

11

1

2

3

2

3

4

5

Checking the adjustment of the hand decompression release cable *

Start the engine and, at idling speed, slowly pull the hand decompression

lever until you can feel the thumping of the rocker arm on the lever. The back-

lash until said thumping should be approx. 10mm, measured at the lever's

outer end. If necessary, correct this backlash.

To adjust, move back the protective cover [6], loosen the counter nut [7] and

correct the adjustment screw [8] accordingly. Tighten counter nut and push

back protective cover.

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 clock-

wise will increase the backlash.

Tighten the counternut and check whether the throttle grip can be

actuated smoothly. Mount tank and seat.

9

ENGLISH

44

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 CER-

TAIN LIMITS. ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY

EXCESSIVE FORCE.

Checking the oil level of the hydraulic clutch

To check the oil level in the master cylinder of the clutch remove the cover.

For this purpose, remove screws [2] and cover [3] together with the rubber

boot [4]. The oil level in the horizontal-standing master cylinder should be 4

mm below the upper edge.

If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Motorex

Kupplungs-Fluid 75).Biodegradable hydraulic oil is available from your KTM

dealer (50ml).

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON-

TROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER

REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

Bleeding of the hydraulic clutch

If the clutch lever starts to feel unresponsive, the clutch control system needs

to be bled. You will need a bleeder syringe (special tool) and biodegradable

hydraulic oil. Both are available from your KTM dealer.

Turn the handlebar until the master cylinder is in a horizontal position, remove

the screws [2], the cover [3] and the rubber boot [4].

Fill the bleeder syringe [6] with biodegradable hydraulic oil (Motorex Kupplungs-

fluid 75). Remove the bleeder screw [5] from the slave cylinder and mount

the bleeder syringe. Press oil into the system until the oil runs out of the hole

[7] in the master cylinder without bubbles. Occasionally extract the oil from

the master cylinder reservoir to keep it from overflowing.

After you finish bleeding, remove the bleeder syringe, mount the bleeder screw,

correct the oil level in the reservoir and mount the cover (see above).

KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON-

TROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER

REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.

1

2

4

3

6

5

7

ENGLISH

45

MAINTENANCE WORK ON CHASSIS AND ENGINE »

CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) *

Idling adjustment of the carburetor strongly affects the engine’s starting

behavior. That is, an engine whose idling speed is adjusted correctly will be

easier to start than one whose idling speed has not been adjusted correctly.

The idle speed is controlled by means of the adjusting wheel [1] and the

mixture control screw [2]. The adjusting wheel is used to adjust the basic set-

ting of the slide. The mixture control screw is used to control the idle mixture

which arrives at the engine by way of the idle system. Clockwise turning reduces

the fuel quantity (lean mixture), counterclockwise turning increases the fuel

quantity (rich mixture).

TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:

1 Turn in mixture control screw [2] up to the stop, and turn it back out to

the basic position (see technical date-engine)

2 Warm up the engine

3

Use the adjusting wheel [1] to set the normal idle speed (1400 - 1500 rpm).

4 Turn mixture control screw [2] slowly clockwise until idling speed starts

to decrease. Memorize this position, and turn mixture control screw slowly

counterclockwise until the idling speed decreases again. Adjust the point

of the highest idling speed between these two positions. If, in the course

of this procedure, the speed undergoes a relatively high increase, reduce

the idle speed to a normal level and repeat the procedure specified in 4.

Serious competitive racers will choose a setting approx. 1/4 turn (clock-

wise) leaner than this ideal value because their engine will heat up more

when used in competitions.

NOTE: If you fail to obtain a satisfying result by following the procedure

described above, an incorrectly dimensioned idling nozzle may be the cause.

If:

a) the mixture control screw has been screwed in up to the stop without

causing any change in rotational speed, a smaller idling jet has to be

installed;

b) the engine dies when the mixture control screw is still open by

2 turns, a larger idling jet needs to be selected.

Naturally, in cases of jet changes, you have to start your adjusting work

from the beginning.

5 Then, use the adjusting wheel to set the desired idle speed.

6 In cases of greater changes in the outside temperature and extremely

different altitudes, the idling speed should be readjusted.

Basic information on carburetor wear

As a result of engine vibrations, the throttle valve, jet needle, and needle jet

are subjected to increased wear. This wear may cause the carburetor to mal-

function (e.g., overly rich mixture). Therefore, these parts should be replaced

after 200 hours.

Adjusting the mixture control screw *

Especially on the EXC models, accessing the mixture control screw is diffi-

cult. For this reasons, we have created an appropriate special tool.

Introduce the special tool on the mixture control screw [2] at the carburetor

bottom. Press the tool slightly upward and turn the adjusting wheel [3] until

the tool engages the slot of the mixture control screw.

Now, you can go about adjusting the screw. Marks were provided on the

adjusting wheel, making it easier to keep track of the turns.

Checking the float level (float height) *

For this purpose, dismount the carburetor and remove the float chamber. Hold

the carburetor in a slanted position such that the float will abut the float nee-

dle valve but not compress it.

In this position, the edge of the float should be parallel with the float cham-

ber sealing surface (see 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.

1

2

3

4

ENGLISH

46

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.

– FUEL IS EASILY FLAMMABLE AND TOXIC. WHEN HANDLING FUEL, BE SURE

TO EXERCISE THE UTMOST CAUTION. NEVER PERFORM ANY WORK ON THE

FUEL SYSTEM NEAR OPEN FLAMES OR BURNING CIGARETTES.

– ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST. IMMEDIATELY CLEAN UP

ANY FUEL WHICH MAY HAVE BEEN SPILLED. MATERIALS SATURATED WITH

FUEL ARE ALSO EASILY FLAMMABLE. IN CASE YOU INGESTED FUEL OR FUEL

SPLASHED INTO YOUR EYES, CONSULT A DOCTOR IMMEDIATELY.

– DISPOSE OF THE FUEL PROPERLY.

Oil circuit

Via the long oil screen [4], the oil pump [3] draws engine oil from the oil sump

of the transmission. This engine oil flows through an oil line [5] into the cylin-

der head for camshaft lubrication [6]; the oil quantity is controlled by the jet

screw [7]. An oil duct branches off to the long oil filter [8] where the coarser

particles contained in the engine oil are filtered away. Then, the engine oil

arrives at the short oil filter [9] which also filters the fine particles. Now, the

purified engine oil is pumped past the bypass valve [10] to the conrod bear-

ing [11] and sprayed from below onto the piston through a nozzle [12].

The second oil pump [13] draws the engine oil via the short oil screen [14]

out of the crankcase, thereby lubricating the transmission gears [15].

Checking the engine oil level

The engine oil level can be checked with the engine either warm or cold. Place

the motorcycle in an upright position and on a horizontal surface (not on the

side stand).

If the engine is cold, the engine oil must be visible at the lower edge of the

inspection glass [A].

If the engine is warm, the engine oil must be visible up to the upper edge of

the inspection glass [B].

Replenish the engine oil, if necessary.

INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMATURE

WEAR IN THE ENGINE.

2

1

B

A

3

4

56

7

8

9

10

11

12

13

15 14

ENGLISH

47

MAINTENANCE WORK ON CHASSIS AND ENGINE »

Engine oil

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 inter-

vals, 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 require-

ments (see information on the can).

KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem-

peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

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

ENGINE.

Changing the engine oil *

Note: When changing the engine oil, it is necessary to clean the short and

long oil screens and to replace both oil filters.

Engine oil has be changed with the engine at an operating temperature.

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 com-

ponents thoroughly and blow compressed air through them. Check the O-rings

for damage and, if necessary, replace them.

To mount the long oil screen [5], place it on an approx. 300 mm (12 in) long

pin-type key or a similar tool. Insert the pin-type key through the opening into

the bore of the opposite engine casing wall. Then, push the oil screen into

the engine casing as far as possible. Remove the pin-type key, mount the plug

and tighten it to 15 Nm.

THE OIL SCREEN IS MOUNTED SLIGHTLY DOWNWARDS, INCORRECTLY FITTED,

THE SCREEN LOOSES ITS FUNCTION AND THIS CAN CAUSE INCREASED ENGINE

WEAR.

1

2

3

4

5

0°C

32°F

10W/50

5W/40

JASO T903 MA

TEMPERATUR

ENGLISH

48

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.

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.

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.

2

2

2

1

3

3

4

5

ENGLISH

49

TROUBLESHOOTING »

TROUBLE CAUSE REMEDY

Engine doesn’t crank (E-starter). Operating errror

Blown fuse

Discharged battery.

Low outside temperature

Turn on the emergency-OFF switch (Australia only)

Dismount the left paneling and the filter box cover and

replace the fuse in the starter relay.

Recharge the battery and investigate the causes for

discharging; contact a KTM dealer.

Start the engine with the kickstarter

Engine cranks but doesn’t start (E-

starter).

Engine will not start (Kickstarter).

Operating error

The motorcycle has been out of opera-

tion for a longer period of time. Therefore

old fuel has accumulated in the float

chamber

Fuel supply interrupted

Flooded engine

Sooty or wet spark plug

Electrode gap too large

Spark plug connector or spark plug

faulty

Short circuit cable scored in wiring har-

ness, emergency OFF switch or short cir-

cuit button faulty

The plug connection of the CDI-unit, the

pulse generator or the ignition coil has

oxydized

Water in carburetor or jets blocked

Open fuel tap, tank fuel, actuate choke. Pay attention to

starting information (see driving instructions).

The easily inflammable components of the new fuels evap-

orate during longer periods of standing still.

When the motorcycle has been out of operation for more

than a week, it is therefore recommended to drain the old

fuel from the float chamber. The engine will immediately

start when the float chamber is filled with new fuel.

Close fuel tap, loosen fuel hose at carburetor, lead into a

basin and open fuel tap

– if fuel leaks out, the carburetor may need cleaning

– if no fuel leaks out, check tank ventilation, i.e. clean

fuel tap

In order to "pump the engine free", pull the hand decompres-

sion lever, fully rev up the engine, actuate the kickstarter 5

to 10 times or actuate the E-starter 2 times for 5 seconds

each. Then, start the engine as described above.

If the engine fails to start, unscrew the spark plug and dry it.

Clean and dry the spark plug or exchange it, respectively

Adjust spark plug electrode gap to 0.6 mm

Dismount spark plug, connect ignition cable, hold to

ground (blank place on engine) and actuate starter, a

strong spark must be produced at the spark plug

– If no spark is created replace the spark plug.

– 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

Dismount the fuel tank, disconnect the black/yellow cable

from the cable of the emergency-OFF switch and the short-

circuit button, respectively, and check the ignition spark.

If a spark is generated, look for the problem in the short-

circuit circuit.

Remove the seat and the fuel tank. Clean the plug con-

nection and treat it with contact spray

Dismount and clean the carburetor

Engine fails to idle Glogged idling jet

Incorrect adjustment of adjusting

screws on carburetor

Defective spark plug

Defective ignition system

Disassemble the carburetor and clean the jets

Have the carburetor adjusted

Replace the spark plug

Have the ignition system checked

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.

ENGLISH

50

TROUBLESHOOTING »

TROUBLE CAUSE REMEDY

Engine does not rev high Carburetor fuel level too high because float

needle valve is dirty or worn out

Loose carburetor jets

Electronic ignition timing faulty

Dismount carburetor and check if worn out

Tighten jets

Have ignition system checked

Engine will not reach full power Fuel supply partially interrupted or carbu-

retor dirty

Float leaks

Air filter very dirty

Exhaust system is not tight, deformed, or

the silencer does not contain enough glass-

fiber yarn

Valve gap too small

Loss of compression because hand decom-

pressor has no play

Electronic ignition timing faulty

Clean and check fuel system as well as carburetor

Replace the float

Clean or replace air filter

Check if exhaust is damaged, replace glasfiber yarn in

exhaust silencer

Adjust valve gap

Check setting of the hand decompression cable

Have ignition system checked

Engine stops or splutters in

carburetor

Insuffient fuel

Engine takes air out of control

Clean and check fuel system and carburettor

Check rubber sleeve and carburetor for tight fit

Engine gets too hot Insufficient cooling liquid

Not enough air stream

Cooling system has not been bled

Radiators very dirty

Foam formation in cooling system

Bent cooling hose

Thermostat defective

Refill cooling liquid (see maintenace work), check cooling

system for leaks

Drive on briskly (electric fan can be retrofitted)

Bleed cooling system

Clean radiators with water jet

Replace cooling liquid, use antifreeze liquid with brand name

Shorten or replace cooling hose

Dismount and check thermostat (opening temperature

70°C, (158°F) or replace it

High oil consumption Hose of engine ventilation is bent

Engine oil level too high

Motor oil too thin (viscosity)

Dislocate i.e. replace non-buckling vetilation hose

Check engine oil level and, if necessary, correct it

Use thicker engine oil; see chapter “Engine oil“

All switched on lamps blown

out

Capacitor or voltage regulator faulty Dismount seat and fuel tank and check connections, have

capacitor and voltage regulator checked

Horn, flasher lights and

E-starter do not work

Blown fuse in the starter relay Dismount left side paneling and filter box cover, replace

fuse

The battery is discharged The battery isn’t charged by the generator

because

Remove seat and fuel tank and check voltage regulator con-

nections; voltage regulator and generator should be checked

by a KTM dealer.

ENGLISH

51

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.

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE

RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR, ETC. AND CAUSE DISTURBANCES

OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS.

– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should also be cleaned with the help

of a paint brush.

– Before cleaning with water, plug the exhaust pipe to prevent water ingress

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber

of the carburetor. Then take a short drive until the engine has reached the working temperature and also use the brakes. By war-

ming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of

the motorcycle is allowed to evaporate.

– Once the motorcycle has cooled down, oil or grease all sliding and bearing points. Treat the chain with a chain spray. Also oil the

fuel tap.

– To avoid any failures in of the electric system, you should treat the emergency-OFF switch, short-circuit button, light switch and

socket connectors with a contact spray.

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre-

cautions against the aggressive road salt.

– clean the motorcycle thoroughly and let it dry after each ride

– treat the engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corro-

sion agent.

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.

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.

CONSERVATION FOR WINTER OPERATION »

STORAGE »

ENGLISH

52

TECHNICAL DATA - ENGINE »

TYPE 250 EXC 400 EXC 450 SX 450 MXC 450 EXC 525 SX 525 MXC-G 525 EXC

525 MXC DESERT

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

Displacement 250 cm3398 cm3449 cm3448 cm3510 cm3

Bore/Stroke

75 / 56,5 mm

89 / 64 mm

95 / 63,4 mm

89 / 72 mm 95 / 72 mm

Ratio 12 : 1 11 : 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 55/21 590/5521

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 forged cast forged

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 6-speed 6-speed 4-speed 6-speed 6-speed 4-speed 6-speed 6-speed

Gear ratio 1st

Gear 14:38 14:34 16:32 16:32 14:34 16:32 16:32 14:34

2nd Gear 16:36 17:31 18:30 18:30 17:31 18:30 18:30 17:31

3rd Gear 19:34 19:28 20:28 20:28 19:28 20:28 20:28 19:28

4th Gear 21:32 22:26 22:26 22:26 22:26 22:26 22:26 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 -12V 150W -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 kickstarter kick - electric starter kickstarter kick - electric starter

ENGLISH

53

TECHNICAL DATA - ENGINE »

BASIC CARBURATOR SETTING

250 EXC RACING

EU / AUS

11 kW

400 EXC RACING

EU / AUS

12 kW

400 EXC-G RACING USA 450 EXC RACING

EU / AUS

12 kW

Type

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

Main jet 160 178 178 178

Jet needle OBEKT OBDVR OBDVR OBDVR

Idling jet 42 42 42 42

Main air jet 200 200 200 200

Idling air jet 100 100 100 100

Needle position 3rd from top 1st from top 1st from top 3rd from top

Starting jet 85 85 85 85

Mixture control screw open 0,75 1,25 1,25 1,25

Slide 15 15 15 15

Performance restrictor Slide stop Slide stop –Slide stop

Stop pump membrane 858 / 2,15 mm 858 / 2,15 mm 858 / 2,15 mm 858 / 2,15 mm

Hot start device ––––

BASIC CARBURATOR SETTING

450 EXC-G / MXC-G

RACING USA

450 EXC RACING

SIXDAYS

450 SX RACING 525 EXC / MXC

RACING / DESERT RACING

EU / AUS 12 kW

Type

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

Main jet 178 178 185 178

Jet needle OBDVR OBDTR OBDTP OBDVT

Idling jet 42 42 40 42

Main air jet 200 200 200 200

Idling air jet 100 100 100 100

Needle position 3rd from top 4th from top 4th from top 3rd from top

Starting jet 85 85 85 85

Mixture control screw open 1,25 2,0 1,0 1,25

Slide 15 15 15 15

Performance restrictor –––Slide stop

Stop pump membrane 858 / 2,15 mm 858 / 2,15 mm 858 / 2,15 mm 858 / 2,15 mm

Hot start device ––2,2 mm –

BASIC CARBURATOR SETTING

525 MXC-G / EXC-G

RACING USA

525 EXC RACING

SIXDAYS

525 SX RACING

Type

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

Main jet 178 178 185

Jet needle OBDVT OBDTR OBDTP

Idling jet 42 42 42

Main air jet 200 200 200

Idling air jet 100 100 100

Needle position 3rd from top 5th from top 4th from top

Starting jet 85 85 85

Mixture control screw open 1,25 2,0 1,5

Slide 15 15 15

Performance restrictor –––

Stop pump membrane 858 / 2,15 mm 858 / 2,15 mm 858 / 2,15 mm

Hot start device ––2,5 mm

ENGLISH

54

TECHNICAL DATA - ENGINE »

Engine oil

Only use fully synthetic engine oils that meet the JASO MA quality require-

ments (see information on the can).

KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem-

peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

POOR OIL QUALITY OR MINOR QUANTITY CAUSE EARLY ENGINE-WEAR.

TIGHTENING TORQUES

Hexagon collar screw, engine case, clutch cover, ignition cover M6 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 M5 6 Nm

Plug pressure valve M12x1,5 20 Nm

Jet screw and hollow screw, oil line M8 10 Nm

Screws, oil pump cover M5 Loctite 222 + 6 Nm

Hexagon collar screw, cylinder head top section M6 10 Nm

Hex.collar screw, cylinder head top section, water pump cover M6 8 Nm

Hexagon collar screw, exhaust flange M6 Loctite 243 + 8 Nm

Cylinder head screw M10 40/50 Nm

Allan head screw, camshaft gear M8 Loctite 243 + 28 Nm

Stop screw, autodecompression M5 Loctite 222 + 8 Nm

Allan head screw, cap rocker arm M5 5 Nm

Counter nuts, valve adjustment screw M6x0,75 11 Nm

Allan head screw, primary gear, free wheel M6 Loctite 648 + 16 Nm

Hexagon nut, primary gear M20x1,5 Loctite 243 + 150 Nm

Allan head screw, balancer shaft gear M6 Loctite 243 + 8 Nm

Nut for inner clutch hub M18x1,5 Loctite 243 + 150 Nm

Hexagon collar screw, clutch spring M6 8 Nm

Allan head screw, shift roller locking piece M6 Loctite 243 + 10 Nm

Hexagon collar screw, locking lever M5 Loctite 243 + 6 Nm

Hexagon collar screw, shift roller M5 Loctite 243 + 6 Nm

Hexagon collar screw securing guide, chain guide, chain tensioner M6 Loctite 243 + 8 Nm

Hexagon collar screw, clip M5 Loctite 243 + 6 Nm

Hexagon collar screw, chain adjuster M6 8 Nm

Hexagon collar screw, stator MXC/EXC M6 Loctite 243 + 8 Nm

Hexagon collar screw, stator SX M5 Loctite 243 + 6 Nm

Hexagon collar screw, pulser coil M5 Loctite 243 + 6 Nm

Hexagon collar nut, flywheel M12x1 60 Nm

Hexagon collar screw, bump part kickstarter M6 Loctite 243 + 8 Nm

Hexagon collar screw, spring hanger kickstarter M6 Loctite 243 + 10 Nm

Hexagon collar screw, cover E-starter, only SX M6 Loctite 243 + 8 Nm

Hexagon collar screw, hanger vent hose M6 Loctite 243 + 8 Nm

Allan head screw, kickstarter M8 Loctite 243 + 25 Nm

Hexagon collar screw, shift lever M6 Loctite 243 + 10 Nm

Hexagon screw, engine sprocket M10 Loctite 243 + 60 Nm

Spark plug M10 10-12 Nm

Spark plug M12x1,25 20 Nm

0°C

32°F

10W/50

5W/40

JASO T903 MA

TEMPERATUR

ENGLISH

55

TECHNICAL DATA - CHASSIS »

CHASSIS 450/525 SX 250/400/450/525 EXC/MXC DESERT 450/525 MXC-G, EXC-G USA

Frame Central tube chrome-moly-steel frame

Fork 4860 PA/MA WP Up Side Down 4860 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

Air pressure offroad

Air pressure road driver only

80/100 - 21“

1.0 bar (14 psi)

–

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

Air pressure offroad

Air pressure road driver only

110/90 - 19“

1.0 bar (14 psi)

–

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

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

Chain X-Ring 5/8 x 1/4 "

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

14187A05

WP4860MA

14187A06

Compression adjuster 22 20

Rebound adjuster 20 20

Spring 4,6 N/mm 4,2 N/mm

Spring preload 5 mm 5 mm

Air chamber length 100 mm 110 mm

Fork oil SAE 5 SAE 5

STANADARD ADJUSTMENT-SHOCK ABSORBER

SX MXC, MXC

Desert, EXC,

EXC-G

WP 5018 PDS

DCC

12187A05

WP 5018 PDS

MCC

12187A06

Compression adjuster

15 LS (low speed)

2 HS (high speed)

15

Rebound adjuster 22 22

Spring 80/250 80/250

Spring preload 7 mm 7 mm

ENGLISH

56

TECHNICAL DATA - CHASSIS »

TIGHTENING TORQUES - CHASSIS

Collar screw, front wheel spindle M24x1,5 40 Nm

Brake caliper, front M8 Loctite 243 + 25 Nm

Brake caliper, FTE radial front M10x1,25 Loctite 243 + 40 Nm

Brake disk M6 Loctite 243 + 10 Nm

Clamping screws, upper fork bridge EXC M8 20 Nm

Clamping screws, lower fork bridge EXC M8 15 Nm

Clamping screws, upper fork bridge SX M8 15 Nm

Clamping screws, lower fork bridge SX M8 10 Nm

Clamping screws, fork stubs M8 10 Nm

Hexagon nut, swing arm bolt M16x1,5 100 Nm

Hexagon collar screw, handlebar clamp M8 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 M8 Loctite 243 + 35 Nm

Ball joint for push rod M6 Loctite 243 + 10 Nm

Engine mounting bolt M10 60 Nm

Engine brace M8 33 Nm

Spoke nipple M4,5 / M5 5 Nm

Screw adjusting ring spring preload shock abs. M6 8Nm

Other screws on chassis M6

M8

M10

10 Nm

25 Nm

45 Nm

Other collar nuts on chassis M6

M8

M10

15 Nm

30 Nm

50 Nm

ENGLISH

57

HEAD WORD INDEX »

Activating and deactivating display modes . . . . . . . . .9

Adjusting the free travel at the hand brake lever . . . . .34

Adjusting the mixture control screw . . . . . . . . . . . . .45

Adjusting the throttle cables . . . . . . . . . . . . . . . . . . .43

Basic suspension setup for the weight of the driver . . .26

Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . .39

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .44

Bleeding the cooling system . . . . . . . . . . . . . . . . . . .41

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .28

Carburetor – Adjust idling (Keihin-FCRMX 37/39/41)

. . . .45

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .32

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Changing the basic position of the foot brake pedal . .35

Changing the engine oil . . . . . . . . . . . . . . . . . . . . . .47

Changing the fork offset (caster) (SX) . . . . . . . . . . . .29

Changing the original position of the clutch lever . . . .44

Changing the spring preload on the telescopic fork

(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . . .27

Changing the spring preload on the telescopic fork

(SX models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Changing the spring preloading of the shock absorber .25

Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .39

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .31

Check the following before each start . . . . . . . . . . . .18

Check/set distance of the magnetic sensor . . . . . . . . .38

Checking and adjusting the steering head bearing . . .30

Checking and adjusting the steering head bearing . . .28

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37

Checking the adjustment of the hand decompression

release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Checking the basic setup of the telescopic fork . . . . .27

Checking the brake fluid level - front brake . . . . . . . .34

Checking the coolant level . . . . . . . . . . . . . . . . . . . .41

Checking the engine oil level . . . . . . . . . . . . . . . . . .46

Checking the float level (float height) . . . . . . . . . . . .45

Checking the front brake pads . . . . . . . . . . . . . . . . .34

Checking the oil level of the hydraulic clutch . . . . . .44

Checking the rear brake fluid level . . . . . . . . . . . . . .35

Checking the rear brake pads . . . . . . . . . . . . . . . . . .36

Checking the shock absorber and spring . . . . . . . . . .26

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .43

Cleaning the dust sleeves of the telescopic fork . . . . .28

Cleaning the spark arrester (MXC/EXC USA) . . . . . . . .42

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . .6

Compression damping of fork . . . . . . . . . . . . . . . . . .15

Compression damping of shock absorber (MXC, EXC) .16

Conservation for winter operation . . . . . . . . . . . . . . .51

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31

Damping action during compression of shock absorber (SX)

.15

Determining the riding sag of the shock absorber . . . .26

Determining the static sag of the shock absorber . . . .26

Digital speedometer, indicator lamps . . . . . . . . . . . . . .7

Dismounting and mounting the front wheel . . . . . . . .36

Dismounting and mounting the rear wheel . . . . . . . . .37

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

58

ANHANG – APPENDICE

APPENDIX – APÉNDICE

1

SCHALTPLAN »WIRING DIAGRAMM

ANHANG – APPENDICE

APPENDIX – APÉNDICE

2

SCHALTPLAN »WIRING DIAGRAMM

ANHANG – APPENDICE

APPENDIX – APÉNDICE

3

SCHALTPLAN »WIRING DIAGRAMM

ANHANG – APPENDICE

APPENDIX – APÉNDICE

4

SCHALTPLAN »WIRING DIAGRAMM

ENGLISH DEUTSCH ITALIANO

Battery Batterie Batteria

Cooling fan Lüftermotor Motorino ventola

Driving light lamp Fernlichtkontrolle spia abbagliante

Flasher control lamp Blinkerkontrolle spia lampeggiatori

Flasher relay Blinkerrelais Relè indicatori

Front brake switch vorderer Bremslichtschalter Interruttore luce ant. di stop

Generator Generator Generatore

Handle bar switch for multi-func.-digital-speedometer Lenkerschalter für Kombiinstrument Interruttore sul manubrio per tachimetro multifunzione

Headlight Scheinwerfer Faro anteriore

High / low beam switch Auf-Abblendschalter Commutatore abbagliante/anabbagliante

Horn Hupe Avvisatore acustico

Ignition coil Zündspule Bobina d‘accensione

Ignition switch Zündschloss Interruttore d‘accensione

Left front flasher linker vorderer Blinker Indicatore ant. sx

Left rear flasher linker hinterer Blinker Indicatore post. sx

Multi-func.-digital-speedometer Multifunktionsdigitaltacho Tachimetro digitale multifunzione

Pick up Impulsgeber Pick up

Position light Standlicht Luce di posizione

Rear brake switch hinterer Bremslichtschalter Interruttore luce post. di stop

Rear light / brakelight hinteres Begrenzungslicht / Bremslicht Luce post. di posizione/stop

Regulator-rectifier Regelgleichrichter Regolatore-raddrizzatore

Right front flasher rechter vorderer Blinker Indicatore ant. dx

Right rear flasher Rechter hinterer Blinker Indicatore post. dx

Speed sensor Geschwindigkeitssensor Sensore velocità

Start button Starttaster Pulsante d´avviamento

Start relay Startrelais Relè d‘avviamento

Starter motor Startermotor Motorino d‘avviamento

Stop button Not-Aus-Schalter Interrutore di aresto dèmergenza

Throttle position sensor (TPS) Vergaserpotentiometer Potenziometro carburatore (sensore TPS)

CABLE COLOURS KABELFARBEN CAVO COLORATO

bl: black bl: blau bl: nero

ye: yellow ye: gelb ye: giallo

bu: blue bu: blau bu: blu

gn: green gn: grün gn: verde

re: red re: rot re: rosso

wh: white wh: weiß wh: bianco

br: brown br: braun br: marrone

or: orange or: orange or: arancione

pi: pink pi: rosa pi: rosa

gr: grey gr: grau gr: grigio

pu: purple pu: violett pu: violetto

ANHANG – APPENDICE

APPENDIX – APÉNDICE

5

SCHALTPLAN »WIRING DIAGRAMM

ENGLISH FRANCAIS ESPANIOL

Battery Batterie Batería

Cooling fan Ventilateur Motor del ventilador

Driving light lamp temoin feu route lampara aviso luces largas

Flasher relay Relais de clignotants Relé de la luz intermitente

Flasher control lamp temoin de clignoteur lampara aviso intermitentes

Front brake switch Contacteur de frein avant Interruptor de luz del freno delantero

Generator Alternateur Generador

Handle bar switch for multi-func.-digital-speedometer Contacteur au guidon pour ordinateur de bord Interruptor de manillar para instrumento combinado

Headlight Phare Faro

High / low beam switch Contacteur code/phare Interruptor de encender/apagar la luz larga

Horn Avertisseur sonore Cláxon

Ignition coil Bobine d’allumage Bobina de encendido

Ignition switch Contacteur d’allumage Cerradura de encendido

Left front flasher Clignotant avant gauche Luz intermitente izquierda delantera

Left rear flasher Clignotant arrière gauche Luz intermitente izquierda trasera

Multi-func.-digital-speedometer Ordinateur de bord Velocímetro digital multifuncional

Pick up Capteur d’allumage Generador de impulsos

Position light feu de position luz de posicion

Rear brake switch Contacteur de frein arrière Interruptor de luz del freno trasero

Rear light / brakelight Feu rouge/stop Luces de parqueo traseras /luces de freno

Regulator-rectifier Régulateur/redresseur Regulador rectificador

Right front flasher Clignotant avant droit Luz intermitente derecha delantera

Right rear flasher Clignotant arrière droit Luz intermitente derecha trasera

Speed sensor Capteur de vitesse Sensor de velocidad

Start button bouton de démarrage botón de arranque

Start relay Relais de démarreur Relé del arranque

Starter motor Démarreur Motor de arranque eléctrico

Stop button bouton d´arrêt d`urgence interruptor de parada de emergencia

Throttle position sensor (TPS) Capteur d’ouverture de carburateur Potenciómetro del carburador

CABLE COLOURS COULEUR DE CABLE COLOR DE CABLE

bl: black bl: noir bl: negro

ye: yellow ye: jaune ye: amarillo

bu: blue bu: bleu bu: azul

gn : green gn: vert gn: verde

re: red re: rouge re: rojo

wh: white wh: blanc wh: blanco

br: brown br: brun br: marron

or: orange or: orange or: naranja

pi: pink pi: rose pi: rosado

gr: grey gr: gris gr: gris

pu: purple pu: violet pu: violeta

ANHANG – APPENDICE

APPENDIX – APÉNDICE

6

KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

OWNER`S MANUAL

MANUALE D`USO

MANUEL D`UTILISATION

MANUAL DE INSTRUCCIONES

ART. NR. 3.211.39

250 EXC RACING

400 EXC RACING

450 SX, MXC, EXC RACING

525 SX, MXC, EXC RACING

BEDIENUNGSANLEITUNG2005