2000-2007 KTM 250-400-450-525 SX-EXC service repair manual.pdf

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REPAIRMANUAL2005
BEDIENUNGSANLEITUNGEN
OWNER’S MANUAL
MANUALE O’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
REPARATURANLEITUNG
REPAIR MANUAL
MANUALE DI REPARAZIONE
MANUEL DE REPARATION
MANUAL DE REPARACION
FEDERBEIN
SHOCK ABSORBER
AMMORTIZZATORE
AMMORTISSEUR
AMORTIGUADOR
GABEL
FORK
FORCELLA
FOURCHE
HORQUILLA
OWNER'S MANUAL
2005
250 EXC RACING
400 EXC RACING
450 SX, MXC, EXC RACING
525 SX, MXC, EXC RACING
OWNER`S MANUAL
MANUALE D`USO
MANUEL D`UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.211.39
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 !
ENGLISH
2
KTM-SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments: 1 spare parts manual chassis & engine
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION
»
KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in
competitions.
The motorcycles comply with the regulations and categories currently in effect with the leading 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
3
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 . . . . . . . . . . . . . . . . . . .
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hand decompression lever . . . . . . . . . . . . . . . . . . .
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . .
Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . .
Combination switch (EXC) . . . . . . . . . . . . . . . . . . .
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter button (EXC) . . . . . . . . . . . . . . . . . . . . . . .
Emergency OFF switch (EXC Australia) . . . . . . . . . .
Digital speedometer, indicator lamps . . . . . . . . . . . .
Electronic speedometer . . . . . . . . . . . . . . . . . . . . .
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . .
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot start device (450/525 SX) . . . . . . . . . . . . . . . .
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . .
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression damping of fork . . . . . . . . . . . . . . . . .
Rebound damping of fork . . . . . . . . . . . . . . . . . . . .
Damping action during compression of shock absorber (SX)
Compression damping of shock absorber (MXC, EXC)
Rebound damping of shock absorber (SX, MXC, EXC)
. .6
. .6
. .6
. .6
. .6
. .6
. .7
. .7
. .7
. .7
. .8
.12
.13
.13
.13
.13
.14
.14
.14
.14
.14
.15
.15
.15
.16
.16
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
MAINTENANCE WORK ON CHASSIS AND ENGINE . . .
Changing the spring preloading of the shock absorber
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic suspension setup for the weight of the driver . .
Checking the shock absorber and spring . . . . . . . . .
Determining the static sag of the shock absorber . . .
Determining the riding sag of the shock absorber . . .
Checking the basic setup of the telescopic fork . . . .
Changing the spring preload on the telescopic fork
(SX models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the spring preload on the telescopic fork
(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . .
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . .
.24
.25
.25
.26
.26
.26
.26
.27
.27
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .55
.27
.27
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .51
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . .51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .52
ENGLISH
4
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Instructions for initial operation . . . . . . . . . . . . . . . .17
Running in the Racing models . . . . . . . . . . . . . . . . .17
DRIVING INSTRUCTIONS . . . . . . . . . . . .
Check the following before each start . .
Starting when the engine is cold . . . . . .
Starting when the engine is warm . . . . .
What to do when the engine is “flooded”
Starting off . . . . . . . . . . . . . . . . . . . . .
Shifting/Riding . . . . . . . . . . . . . . . . . .
Braking . . . . . . . . . . . . . . . . . . . . . . .
Stopping and parking . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . .
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.18
.18
.19
.19
.19
.19
.19
.20
.20
.20
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .21

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