Page 2 - ENGLISH; IMPORTANT; WARNING; Frame number; Tampering with noise control system prohibited; COMSUMER INFORMATION FOR AUSTRALIA ONLY
ENGLISH 1 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ...
Page 3 - Introduction; At the time this manual was typeset,
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 bringyou lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride,...
Page 4 - IMPORTANT LIMITED WARRANTY AND; Without this performance
ENGLISH 3 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usualwear and tear of normal use in competitions.The motorcycles comply with the regulations and categories currently ineffect with the leading international motor...
Page 5 - TABLE OF CONTENTS
ENGLISH 4 Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . ....
Page 6 - Chassis number; SERIAL NUMBER LOCATIONS; Clutch lever
ENGLISH 5 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 ofthe engine below the engine sprocket. Enter this number on...
Page 7 - Digital speedometer, indicator lamps; Electronic speedometer; SPEED/ODO display mode
ENGLISH 6 Digital speedometer, indicator lamps The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp 2 lights up when the high beam is on. Electronic speedometer The electronic speedometer display is activated as soon as th...
Page 8 - MODE; Tripmaster switch
ENGLISH 7 + – MODE Tripmaster switch The switch has three buttons: MODE, + (plus) and – (minus). WARNING D O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING . Y OUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO ANACCIDENT . Electronic speedometer functions prov...
Page 11 - OVERVIEW OF TRIPMASTER FUNCTIONS
ENGLISH 10 X X X X X X X X X X X X X X X X X X X X X no function no function starts / stops LAP figure LAP remains next figure no function no function no function no function no function increases TRP2 figure no function starts / stops STP2 Press + Display SPEED / ODO SPEED / MAX SPEED / LAP LAP / L...
Page 12 - Flasher switch
ENGLISH 11 Short circuit button (SX/MXC) The short circuit button 1 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)...
Page 13 - Filler cap; To open the filler cap:; Fuel tap; OFF; Choke; ON; SX
ENGLISH 12 Emergency OFF switch (EXC Australia) The red emergency-OFF switch 1 is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine canbe started. In this position, the E-starter and ignition circuits are interrup-ted. The E-starter cannot be actua...
Page 14 - Shift lever
ENGLISH 13 Hot start device (450/525 SX) If you pull the hot start device 1 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additionalair. The result is a „lean“ fuel-air mixture of the type needed for hot starts.To deactivate the hot start device...
Page 15 - Compression damping of fork
ENGLISH 14 Compression damping of fork Hydraulic compression damping determines the reaction when the fork iscompressed. 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 damp...
Page 16 - Steering lock; CAUTION
ENGLISH 15 Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for theMXC 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 direct...
Page 17 - Instructions for initial operation; GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE
ENGLISH 16 WARNING – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE . C LEVER KTM DRIVERS ALWAYS WEAR A HELMET , BOOTS , GLOVES AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP . T HE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COL - ORED SO THAT OTHER VEHICLES CAN SEE YOU...
Page 18 - DRIVING INSTRUCTIONS; Check the following before each start
ENGLISH 17 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 checkof your motorcycle before each start.The following checks should be performed: 1 C...
Page 19 - Starting when the engine is cold; Starting when the engine is warm; What to do when the engine is “flooded”
ENGLISH 18 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 actuate the E-starter. WARNING – I F YOU WANT TO START THE ENGINE , ...
Page 20 - Braking; Stopping and parking; Fuel
ENGLISH 19 NOTE:Dedicated to nothing but offroad racing, 250/450/525SX/MXC/EXC Racing models make no compromises in theirdesign. As such, they do not include any radiator fan, and thesize of the radiator is dimensioned for optimum ergonomics.In normal racing, the cooling system is sufficient.If you ...
Page 21 - PERIODIC MAINTENANCE SCHEDULE 2003; A clean motorcycle can be checked more quickly which saves money!
ENGLISH 20 PERIODIC MAINTENANCE SCHEDULE 2003 1. service after 3 hours or 20 l fuel after/every 15 hours or 100 l fuel IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. S ERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS OR 15 LITERS OF FUEL...
Page 22 - MPORTANT
ENGLISH 21 I MPORTANT C HECKS AND M AINTENANCE TO BE C ARRIED OUT BY THE R IDER Check oil level ● Check brake fluid level ● Check brake pads for wear ● Check lights for function ● Check horn for function ● Lubricate and adjust cables and nipples ● Bleed fork legs regularly ● Remove and clean fork du...
Page 23 - EXC
ENGLISH 22 R ECOMMENDED INSPECTION OF THE 250/450/525 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP ( ADDITIONAL ORDER FOR THE KTM WORKSHOP ) a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear ● ● ● ● ● ● Check the length of...
Page 25 - MAINTENANCE WORK ON CHASSIS AND ENGINE; Checking and adjusting the steering head bearing *
ENGLISH 24 WARNING 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 SPECIALIZEDKTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED,SKILLED STAFF. ! CA...
Page 26 - Breather plug front fork; Cleaning the dust sleeves of the telescopic fork; Adjusting the spring preload on the fork (SX)
ENGLISH 25 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 wheellifted off the ground. When riding the moto...
Page 27 - Basic suspension setup for the weight of the driver; Determining the riding sag of the shock absorber
ENGLISH 26 Basic suspension setup for the weight of the driver To achieve maximum handling performance and to prevent the fork, shockabsorber, swing arm and frame from being damaged, the basic setup of thesuspension components must be suitable for your weight. At delivery,KTM's offroad motorcycles a...
Page 28 - Checking the basic setup of the telescopic fork
ENGLISH 27 According to our experience, the damping rate of the compression stagecan remain unchanged. The damping rate of the rebound stage can bereduced by a few clicks for a softer spring or increased by a few clicks for aharder spring. Checking the basic setup of the telescopic fork The precise ...
Page 29 - How to change the handlebar position; Changing the spring preloading of the shock absorber
ENGLISH 28 How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put thehandlebar in the position that is the most convenient for you. The upper tri-ple clamp 1 includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another. The bores at th...
Page 30 - Check chain tension; Correct chain tension
ENGLISH 29 Check chain tension To check the chain tension, park the motorcycle.Press the chain upward at the end of the chain sliding component. Thedistance between the chain and the swing arm should be approx. 15 mm(0.6 in). In the course of this procedure, the upper chain portion A must be taut (s...
Page 31 - Chain maintenance; Chain wear
ENGLISH 30 15 KG 33 lbs max. 272 mm 1 2 3 16 17 18 ✓ Chain maintenance For a long chain life, good maintenance is very important. Chains withoutX-rings should be cleaned in fireproof solvent regularly and afterwardstreated with hot grease or chain spray (e.g. Shell Advance Bio Chain).X-ring chains o...
Page 32 - General information about KTM disc brakes; DOT
ENGLISH 31 General information about KTM disc brakes BRAKE CALIPERS:The brake calipers of this series use a “floating” mount. This means that thebrake calipers are not solidly attached to the caliper support, which enablesthem to “float” for maximum braking contact. Secure the screws of thecaliper s...
Page 33 - Adjusting the free travel at the hand brake lever; Checking the brake fluid level - front brake; Refilling the front brake fluid reservoir *; Checking the front brake pads
ENGLISH 32 Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustmentscrew 1 . In this way, the position of the point of pressure (e.g. the resis- tance you feel on the hand brake lever when the brake pads are pressedagainst the brake ...
Page 34 - Replacing the front brake pads *; Changing the basic position of the foot brake pedal *; Checking the rear brake fluid level; Refilling the rear brake fluid reservoir *
ENGLISH 33 Replacing the front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in itsbasic position. Remove clips 1 and pull out bolt 2 . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper supportwith compressed air. Check the ...
Page 35 - Checking the rear brake pads; Replacing the rear brake pads *; Dismounting and mounting the front wheel
ENGLISH 34 Checking the rear brake pads The brake pads can be inspected from the rear. The thickness of the liningsmay not be less than 1 mm (0.04 in). WARNING A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM , OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAF...
Page 36 - Dismounting and mounting the rear wheel
ENGLISH 35 WARNING – I F YOU DON ’ T HAPPEN TO HAVE A TORQUE WRENCH AT HAND , MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE . A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE . – A FTER MOUNTING THE FRONT WHEEL , KEEP OPERATING THE HAN...
Page 37 - Checking spoke tension; Replacing the battery of the digital speedometer
ENGLISH 36 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 readyto go anywhere on your motorcycle.– Tire size can be found in the technical specifications and in the homolo- gation cert...
Page 38 - Setting the clock
ENGLISH 37 Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode.Press and hold the MODE button for 3 seconds. The blinking digits can bechanged using the + and – buttons. Press the MODE button to move to thenext digit.If no button is pressed for 20 seconds, the s...
Page 39 - Check/set distance of the magnetic sensor; Wheel circumference with standard tires = 2205 mm
ENGLISH 38 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 . mm x 3.14 KMH: WS = mm x 3.14 MPH: WS = (mm x 3.14...
Page 40 - Charging the battery; VOLT
ENGLISH 39 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. Simplykeep the battery poles clean and slightly grease them with an acid-freegrease if necessary.Removing the battery:First disconnect the...
Page 41 - Replacing headlight lamp/parking light lamp
ENGLISH 40 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 protectioncover A , you will be able to see the fuse. The following loads are connected to it:– E-starter system–...
Page 42 - Cooling system; Checking the coolant level; Bleeding the cooling system
ENGLISH 41 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 (about70°C, 158°F), the thermostat 2 opens and the coolant ...
Page 43 - Replacing the glassfiber yarn packing of the silencer *
ENGLISH 42 Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. The effectof heat causes the glassfiber yarn to become loose. This may lead to a lossof performance and reduce the silencer's muffling power. By experience,the front...
Page 44 - Cleaning the air filter *; Adjusting the throttle cables *; bk
ENGLISH 43 Cleaning the air filter * A dirty air filter impairs the air-flow rate, reduces the engine performance,and increases the fuel consumption. In extreme cases, dirt may even getinto the engine and cause damage. Therefore, change the air filter in regular intervals.For this purpose, rotate th...
Page 45 - Changing the original position of the clutch lever; Checking the oil level of the hydraulic clutch; Bleeding of the hydraulic clutch
ENGLISH 44 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 positionfor every hand size.Turning the adjusting screw clockwise reduces the distance betwee...
Page 46 - Basic information on carburetor wear; Adjusting the mixture control screw *
ENGLISH 45 CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) * Idling adjustment of the carburetor strongly affects the engine’s startingbehavior. That is, an engine whose idling speed is adjusted correctly will beeasier to start than one whose idling speed has not been adjusted correctly.The idle ...
Page 47 - Draining the float chamber of the carburetor; Oil circuit; Checking the engine oil level; bm
ENGLISH 46 Draining the float chamber of the carburetor Following every wet cleaning procedure, the float chamber of thecarburetor should be drained in order to remove any water that may havepenetrated into it. Water in the float chamber causes malfunctioning.Perform this task on a cold engine.Close...
Page 48 - Engine oil; Changing the engine oil *; TEMPERATURE
ENGLISH 47 Engine oil Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or sur-passing the quality requirements of API classes SG or SH (see specificationson the container). ! CAUTION ! I NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE . Changing the e...
Page 50 - TROUBLESHOOTING
ENGLISH 49 TROUBLESHOOTING If you had the specified maintenance work on your motorcycle carried out, disturbances can hardly be expected. Should an error occurnevertheless, we advise you to use the troubleshooting chart in order to find the cause of error.We would like to point out that many operati...
Page 52 - USE AFTER A PERIOD OF STORAGE; STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION
ENGLISH 51 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 co...
Page 54 - Six Days; Six Days
ENGLISH 53 BASIC CARBURATOR SETTING Type Keihin FCR-MX 37 Keihin FCR-MX 37 Keihin FCR-MX 39 Keihin FCR-MX 41 Carburator-setting number 3700A 3700A 3900A 4122A Main jet 160 160 178 185 Jet needle OBETP OBEKT OBDVR OBDTP Idling jet 42 42 42 40 Main air jet 200 200 200 200 Idling air jet 100 100 100 10...
Page 56 - DCC; STANDARD ADJUSTMENT-SHOCK ABSORBER
ENGLISH 55 WP 5018 PDS WP 5018 PDS DCC MCC 1218X760 1218X761 Compression adjuster 15 LS (low speed) 17 2 HS (high speed) Rebound adjuster 26 26 Spring 76-95/260 71-90/260 Spring preload 6 mm (0.24 in) 8 mm (0.32 in) STANDARD ADJUSTMENT-SHOCK ABSORBER WP4860MXMA WP4860MXMA 1418X727 1418X737 Compressi...
Page 57 - HEAD WORD INDEX
ENGLISH 56 Page Adjusting the free travel at the hand brake lever .................32 Adjusting the mixture control screw ....................................45 Adjusting the spring preload on the fork (SX)......................25 Adjusting the throttle cables ..........................................
