OWNER’S MANUAL 2007
250 XC-F, XCF-W, EXC-F
400 XC-W, EXC RACING
450 XC, XC-W, EXC RACING
525 XC, XC-W, EXC RACING
525 XC DESERT RACING
ART. NR. 3.211.145 EN
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IMPORTANT INFORMATION »
INTENDED PURPOSE
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.
The XC and other „competition only“ labeled models are prohibited on public roads.
„On the road“ approved models are only allowed on public roads in the original homologated (throttled)
version. Without this performance restriction (i.e. de-throttled), these models are only allowed to be driven
off-road and not on public roads.
The EXC models are designed for off-road sports endurance competitions(enduro) and not suitable for
predominant motocross use.
NOTE: The above is a general statement. Specific limited warranty and limited guarantee information
may vary depending upon distribution. Please check with your local KTM dealer for limited warranty and
limited guarantee information specific to your KTM model and region.
OWNER’S MANUAL
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. 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.
In your own interest, please pay particular attention to notices that are marked as follows:
2
– Ignoring these instructions can be dangerous to life and limb!
– Ignoring these instructions may damage parts of the motorcycle or impair the motorcycle's
traffic safety!
At the time this manual was typeset, it was up-to-date with the latest state of this production series. It
cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design
upgrades of these motorcycles.This manual is an important part of your motorcycle and should be passed
on to any subsequent owner in case you decide to sell it.
SERVICE
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 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.
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IMPORTANT INFORMATION »
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.
Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding
these guidelines will significantly increase the life of your motorcycle.
WARRANTY
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.
No claims can be filed under the warranty for damage or consequential damage caused by manipulations
or conversions to the motorcycle.
AUTOMOTIVE FLUIDS
The fuels and lubricants specified in the Owner's Manual or fluids with equivalent specifications must
be used in accordance with the maintenance schedule.
3
SPARE PARTS, ACCESSORIES
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.
TRANPORT
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
ENVIRONMENT
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
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TABLE OF CONTENTS »
Page
Page
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .33
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
General information about KTM disc brakes . . . . . . . . . .35
Adjusting the free travel at the hand brake lever . . . . . . .36
Checking the brake fluid level - front brake . . . . . . . . . . .36
Refilling the front brake fluid reservoir . . . . . . . . . . . . . .36
Checking the front brake pads . . . . . . . . . . . . . . . . . . . .36
Replacing the front brake pads . . . . . . . . . . . . . . . . . . .37
Changing the basic position of the foot brake pedal . . . . .37
Checking the rear brake fluid level . . . . . . . . . . . . . . . . .37
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . .37
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .38
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . .38
Dismounting and mounting the front wheel . . . . . . . . . . .38
Dismounting and mounting the rear wheel . . . . . . . . . . .39
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .39
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Check/set distance of the magnetic sensor . . . . . . . . . . .40
Replacing the battery of the digital speedometer . . . . . . .40
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Replacing headlight lamp/parking light lamp . . . . . . . . . .42
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . .43
Bleeding the cooling system (400/450/525) . . . . . . . . . .43
Bleeding the cooling system (250-F) . . . . . . . . . . . . . . .44
Replacing the glassfiber yarn packing of the silencer . . . .44
Cleaning the spark arrester (XC-W USA) . . . . . . . . . . . . .44
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .45
Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . .45
Changing the original position of the clutch lever . . . . . . .46
Checking the oil level of the hydraulic clutch
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .2
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Short circuit button (XC) . . . . . . . . . . . . . . . . . . . . . . . . .6
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6
Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . . . . . .7
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . . .7
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . .8
Activating and deactivating display modes . . . . . . . . . . . .9
Overview of the electronic speedometer functions . . . . . .12
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Filler cap (bayonet cap) . . . . . . . . . . . . . . . . . . . . . . . . .13
Filler cap (screw cap) . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Compression damping of shock absorber
4
(XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Compression damping of shock absorber (XC-W, EXC) . . .16
Rebound damping of shock absorber . . . . . . . . . . . . . . .16
GENERAL TIPS AND WARNINGS FOR STARTING
THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Instructions for initial operation . . . . . . . . . . . . . . . . . . .17
Running in the XC/EXC models . . . . . . . . . . . . . . . . . . .17
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .18
Check the following before each start . . . . . . . . . . . . . . .18
Starting when the engine is cold . . . . . . . . . . . . . . . . . .18
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 . . . . . . .27
Changing the spring preloading of the shock absorber . . .27
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Basic suspension setup for the weight of the driver . . . . .28
Checking the shock absorber and spring . . . . . . . . . . . . .28
Determining the static sag of the shock absorber . . . . . . .28
Determining the riding sag of the shock absorber . . . . . . .28
Checking the basic setup of the telescopic fork . . . . . . . .29
Changing the spring preload on the telescopic fork
(400/450/525) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Checking the oil level of the hydraulic clutch (250-F) . . .46
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .46
Carburetor – Adjust idling (Keihin-FCRMX 37/39/41) . . . .47
Basic information on carburetor wear . . . . . . . . . . . . . . .47
Adjusting the mixture control screw . . . . . . . . . . . . . . . .47
Checking the float level (float height) . . . . . . . . . . . . . . .47
Draining the float chamber of the carburetor . . . . . . . . . .48
Oil circuit (400/450/525) . . . . . . . . . . . . . . . . . . . . . . .48
Oil circuit (250-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . .48
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .49
Changing the oil filters . . . . . . . . . . . . . . . . . . . . . . . . .50
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . .53
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . . . . . .53
TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . . . . . .54
TECHNICAL DATA – CHASSIS . . . . . . . . . . . . . . . . . . . . . .59
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . .appendix
(XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Changing the spring preload on the telescopic fork
(XC-W/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . . . .29
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .30
Cleaning the dust sleeves of the telescopic fork . . . . . . . .30
Checking and adjusting the steering head bearing . . . . .30
Changing the fork offset (caster) (XC, EXC SIXDAYS) . . . .31
How to change the handlebar position . . . . . . . . . . . . . .32
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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.
5
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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.
1
A
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").
3
B
6
Short circuit button (XC)
The short circuit button [4] turns off the engine. When pressing this button,
the ignition circuit is short-circuited.
4
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
6
5
[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
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OPERATION INSTRUMENTS »
Headlamp switch (XC-W)
In this model the headlamp is switched on with the pull switch [1].
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
7
Starter button
Pushing the black starter button [2] will actuate the E-starter.
2
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.
3
4
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.
Indicator lamps
The green control lamp [5] flashes in the same rhythm as the flash-
ing indicator when the indicator is working.
6
5
The blue control lamp [6] lights up when the high beam is on.
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OPERATION INSTRUMENTS »
Electronic speedometer
The display in the electronic speedometer is activated as soon as you press
a button on the speedometer or an impulse is received from the wheel 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.
TEST
All of the display segments briefly light up for the display function test.
8
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.
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
no function
– button
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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OPERATION INSTRUMENTS »
Activating and deactivating display modes
In the display mode SPEED/H, press and hold the | button for 3 seconds to
access the SETUP menu. The active functions will be displayed. The 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
deactivates the blinking display
– button
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
TR2
A1
tripmaster 1
tripmaster 2
average speed 1
average speed 2
stop watch 1
stop watch 2
clock
lap time
A2
S1
S2
CLK
LAP
MAX
KMH/MPH
maximum speed
display in kilometers or miles (see: Kilometers or miles)
9
If you have activated all of the display modes, they will be displayed in the
following order:
SPEED/H, SPEED/CLK, SPEED/LAP, LAP/LAP, SPEED/MAX, SPEED/ODO,
SPEED/TR1, SPEED/TR2, SPEED/A1, SPEED/A2, SPEED/S1, SPEED/S2
SPEED / CLK (time) display mode
CLK displays the time in hours, minutes and seconds.
+ button
no function
no function
– button
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“.
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
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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
no function
– button
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
no function
– button
briefly press | button changes to the next display mode
hold | button 3 secs. clears the MAX figure
10
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
no function
– button
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
decreases the TR2 figure
– button
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
no function
– button
briefly press | button changes to the next display mode
hold | button 3 secs. clears the TR1, S1, A1 figures
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OPERATION INSTRUMENTS »
SPEED / A2 display mode (average speed 2)
A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop
watch 2) figures.
The displayed figure can deviate from the actual average speed if the TR2
figure was changed manually or if S2 was not stopped after the trip.
+ button
no function
no function
– button
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
no function
– button
briefly press | button changes to the next display mode
hold | button 3 secs. clears the TR1, S1, A1 figures
11
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
no function
– button
briefly press | button changes to the next display mode
hold | button 3 secs. clears the S2 figure
Kilometers or miles
The unit (kilometers or miles) can also be changed. The ODO figure will be
retained and converted accordingly. The TR1, A1, S1, TR2 and A2 figures
will be cleared.
To select the unit, select the SPEED/H mode and hold the | button for 3 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
to activate the MPH display
– button
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
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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 +
time -
– button
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
OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS
display
SPEED / H
SPEED / CLK
briefly press + button
no function
briefly press – button
no function
briefly press | button
next display mode
next display mode
hold | button 3 secs.
displays the SETUP menu
Setting the clock menu
X
X
12
X
X
no function
no function
starts/stops LAP without
clearing LAP figure
stops LAP, stores LAP
figure, resets LAP to 0
X
SPEED / LAP
next display mode
clears all LAP figures
X
X
LAP / LAP
SPEED / MAX
SPEED / ODO
SPEED / TR1
SPEED / TR2
SPEED / A1
SPEED / A2
SPEED / S1
SPEED / S2
next figure
no function
no function
no function
no function
no function
no function
no function
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
next display mode
clears MAX
X
X
X
X
X
X
X
X
next display mode
clears TR1, S1, A1
clears TR2
X
X
X
X
X
X
increases the TR2 figure reduces the TR2 figure
no function
no function
no function
no function
no function
no function
clears TR1, S1, A1
next display mode
clears TR1, S1, A1
clears S2
no function
starts - stops S2
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.
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OPERATION INSTRUMENTS »
Filler cap (bayonet cap)
To open the filler cap: Turn the filler cap 45° counter-clockwise.
To close the filler cap: Put the filler cap on and turn it 45 ° clockwise.
Filler cap (screw 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.
1
Install the tank breather hose [1] without kinks.
13
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 XC, XC-W, EXC . . . .1.0 l (0.3 US gallons)
Reserve XC Desert Racing . .2.0 l (0.6 US gallons)
XC
EXC
Choke
2
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.
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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.
2,3,4 (5,6)
N
1
Kickstarter
The kickstarter is mounted on the right side of the engine. Its upper part can
be swivelled.
14
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
1
Steering lock
The handlebar can be locked by means of the lock located on the steering
head. To lock it, turn handlebar all the way to the right, insert key, turn it to
left, press it in, turn it to right, and remove it.
Never leave the key inserted in the steering lock. If you turn the handlebar to
the left the key could get damaged.
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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.
1
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
2
2
WP 14187C04 . . . . . . . 20 clicks
WP 14187C06 . . . . . . . 20 clicks
WP 14187C28 . . . . . . . 18 clicks
WP 14187C29 . . . . . . . .18 clicks
Rebound damping of fork
Hydraulic rebound damping determines the reaction when the fork is
rebound. By turning the adjusting screw [3] (REB), the degree of damping of
the rebound can be adjusted. Turn the knob clockwise to increase damping,
turn it counterclockwise to reduce damping during rebounding.
3
3
STANDARD ADJUSTMENT
– turn adjusting screw clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of fork
WP 14187C04 . . . . . . . 20 clicks
WP 14187C06 . . . . . . . 15 clicks
WP 14187C28 . . . . . . . 20 clicks
WP 14187C29 . . . . . . . .20 clicks
Changing the spring preload on the telescopic fork (see page 29)
15
Compression damping of shock absorber (XC, EXC SIXDAYS)
The shock absorber on these models can synchronize the compression damp-
ing 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 .
6
– unscrew the respective number of clicks for the specific type of shock absorber
in a counterclockwise direction.
WP 12187C28 . . . . . . . 15 clicks
WP 12187C29 . . . . . . . 15 clicks
4
STANDARD HIGH-SPEED SETTING:
– turn the adjusting screw [5] to the limit in a clockwise direction using a
box wrench.
– unscrew the respective number of turns for the specific type of shock absorber
in a counterclockwise direction.
WP 12187C28 . . . . . . . . . . .1 turn
WP 12187C29 . . . . . . . . . . .1 turn
5
The damping unit of the shock absorber is filled with high-compression nitro-
gen. 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).
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OPERATION INSTRUMENTS »
Compression damping of shock absorber (XC-W, EXC)
The compression damping (during compression) can be adjusted for these
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.
2
STANDARD ADJUSTMENT:
– turn the adjusting screw clockwise to the stop.
– then turn the adjusting screw counterclockwise, counting the number of
clicks that corresponds to the respective type of shock absorber.
WP 12187C04 . . . . . . . 15 clicks
1
WP 12187C06 . . . . . . . 15 clicks
The damping unit of the shock absorber is filled with high-compression nitro-
gen. 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).
16
Rebound damping of shock absorber
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.
3
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.
4
WP 12187C04 . . . . . . . 25 clicks
WP 12187C06 . . . . . . . 25 clicks
WP 12187C28 . . . . . . . 24 clicks
WP 12187C29 . . . . . . . .24 clicks
The damping unit of the shock absorber is filled with high-compression nitro-
gen. 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).
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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »
Instructions for initial operation
– Make sure the work for the „pre-delivery inspection“ was per-
– Wear suitable clothing when driving a motorcycle. Clever KTM
drivers always wear a helmet, boots, gloves and a jacket, regard-
less of whether driving all day or just for a short trip. The
protective clothing should be brightly colored so that other
vehicles can see you as early as possible.
– Always turn on the light to make sure that other drivers
become aware of you as early as possible.
– Do not drive after having consumed alcohol.
– Only use accessories recommended by KTM. For example,
front panelling can impair the driving properties of the motor-
cycle. Cases, extra tanks, etc. can alter the weight distribu-
tion and thus also impair the vehicles driving properties.
– The front and rear wheel may only be fitted with tires that
have the same profile type.
– The XC/EXC models are designed and dimensioned for 1 per-
son 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 rec-
ognized as early as possible.
– Adjust your driving speed according to the conditions and
your driving skills.
– Drive carefully on unknown roads or on unfamiliar trials.
– When driving off-road, always have a friend on a second motor-
cycle to keep you company, so that you can help each other
should difficulties arise.
formed by your authorized KTM workshop. The DELIVERY
CERTIFICATE and SERVICE MANUAL will be handed over
when you pick up your vehicle.
– Read these operating instructions carefully before your first
ride.
– Familiarize yourself with the operating elements.
– Set the clutch lever, the handbrake lever, and the footbrake
pedal to the positions that are most convenient for you.
– Get used to handling the motorcycle on an empty parking
lot or open space, before starting on a longer drive. Also try
to drive as slowly as possible and in a standing position, to
improve your feeling for the vehicle.
– Do not drive along off-road tracks which go beyond your abitily
and experience.
– Hold the handlebars with both hands and leave your feet on
the foot rests while driving.
– Remove your foot from the foot brake lever when you are not
braking. If the foot brake lever is not released the brake
pads rub continuously and the braking system is
overheated.
– Do not make any alterations to the motorcycle and always
use ORIGINAL KTM SPARE PARTS. Spare parts from other
manufacturers can impair the safety of the motorcycle.
– Motorcycles are sensitive to alterations in the distribution of
weight. If you are taking luggage with you, this should be
secured as close as possible to the middle of the vehicle;
distribute the weight evenly between the front and rear wheel.
Never exceed the maximum permissible laden weight and
the axle weights. The maximum permissible laden weight is
comprised of the following components:
– 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 XC models are not approved for use on public roads and
freeways.
– When riding your motorcycle, please bear in mind that other
people may feel molested by excessive noise.
17
– Motorcycle ready for operation and tank full
– Luggage
– Driver with protective clothing and helmet.
– Pay attention to the running-in procedure.
Running in the XC/EXC 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 XC/EXC models were uncompromisingly designed for off-
road competition purposes only. “On the road“ approved mod-
els are only allowed on public roads in the original homologated
(throttled) version. Avoid extended on-road rides at full throttle.
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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
2
3
CHECK THE OIL LEVEL
Insufficient oil results in premature wear and consequently to engine
damage.
B
A
FUEL
Check that there is sufficient fuel in the tank; when closing the filler cap,
check that the tank venting hose is free of kinks.
CHAIN
A loose chain can fall from the chain wheels; an extremely worn chain can
tear, and insufficient lubrication can result in unnecessary wear to the chain
and chain wheels. 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
5
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.
18
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
7
8
CABLES
Check correct setting and easy running of all control cables.
COOLING FLUID
Check the level of the cooling fluid when the engine is cold.
ELECTRICAL SYSTEM
Check correct functioning of headlamps, tail-lights, brake lights, indica-
tors, control lamps and horn while the engine is running.
9
LUGGAGE
If you are taking luggage with you, check that this is securely fastened.
Starting when the engine is cold
1
2
3
4
5
Open the fuel tap [1].
Swing up the side stand or center stand.
Put the gear in neutral.
Operate the choke [2].
Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actu-
ate the E-starter.
– 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 kick-
starter, or the engine may kick back and propel your foot upward with great
force.
1
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DRIVING INSTRUCTIONS »
– Always kick the kickstarter briskly all the way without opening the throt-
tle. If you do not Kick hard enought, with an open throttle grip, the kick-
back hazard will be higher.
– Do not start the engine and allow it to idle in a closed area. Exhaust fumes
are poisonous and can cause loss of consciousness and death. Always pro-
vide 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.
2
– Maximal period for continuous starting: 5 seconds. Wait at least 5 sec-
onds 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 cylin-
der and can cause engine damage.
NOTE: If you have trouble starting the motorcycle, this could be due to old
fuel in the float chamber. The easily inflammable components of the
new fuels evaporate during longer periods of standstill.When the
motorcycle has been out of operation for more than a week, it is there-
fore recommended to drain the old fuel from the float chamber. The
engine will immediately start off when the float chamber is filled with
new fuel.
19
Starting when the engine is warm
1
2
3
4
Open the fuel tap [1].
Swing up the side stand.
Put the gear in neutral.
Leave throttle closed and kick the kickstarter briskly ALL THE WAY or
actuate the E-starter.
What to do when the engine is „flooded“
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.
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DRIVING INSTRUCTIONS »
NOTE:
the fuel tap to the OFF position, park on an area where the ground
Dedicated to nothing but offroad racing, XC/EXC models make no is firm, and lock the motorcycle.
compromises in their design. As such, they do not include any radi-
ator fan, and the size of the radiator is dimensioned for optimum
ergonomics.
Motorcycle engines produce a great amount of heat while running.
In normal racing, the cooling system is sufficient.
If you use your motorbike in other conditions, please note that:
The engine, exhaust pipe, muffler, brake rotors, and shock absorbers
can become very hot. Do not touch any of these parts after operating
the E-starter allows you to start XC/EXC models again at any time. the motorcycle, and take care to park it where pedestrians are not
Therefore, turn off the engine if you intend to run your motorcycle likely to touch it and get burned.
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).
– 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 car-
burettor can flood and fuel will enter the engine.
– Never park your motorcycle in places where there are fire haz-
ards due to dry grass or other easily flammable materials.
– After falling with the motorcycle, check all functions thoroughly
before starting up operations again.
– A twisted handlebar must always be replaced. Do not adjust
the handlebar, it will lose stability.
– High rpm rates when the engine is cold have an adverse effect
on the life of your engine. We recommend you run the engine
in a moderate rpm range for a few miles giving it a chance to
warm up. After that no further precautions in this respect need
to be taken. The engine has reached its operating temperature
as soon as the radiators become warm.
20
– 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 eas- NOTE REGARDING THE SIDE STAND:
ily get out of control.
Use your foot to kick side stand forward up to the stop and lean
– If any abnormal vibrations occur while driving, check that the the motorcycle sideways. Make sure that the ground is solid and
engine fastening bolts are tight.
that your motorcycle is standing securely. Just in case, you can
– In the event that, while riding on your motorcycle, you notice shift into first gear.
any unusual operation-related noise, stop immediately, turn the
engine off, and contact an authorized KTM dealer.
The side stand is designed to bear only the load of the motorcycle.
Braking
The side stand and/or the frame can be damaged and the motor-
cycle can fall over if you mount the motor-cycle, thus putting an
additional load on the side stand.
Close throttle and apply the hand and foot brakes at the same time.
When driving on sandy, wet or slippery ground use mainly the rear
wheel brake. Always brake with feeling, blocking wheels can cause
you to skid or fall. Always finish braking before you enter a curve.
Also change down to lower gears depending on your speed.
Fuel
The engine needs unleaded fuel with at least RON 95 (USA =
When driving down hill, use the braking effect of the engine. Premium PON 91).
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.
Use leaded or unleaded premium grade gasoline (95 octanes). Never
use gasoline having less than 95 octanes because it may damage
the engine.
– In case of rain, after washing the motorcycle, after rides through
water and in case of rides on wet off-road tracks, humid or dirty
brake discs can delay the braking effect. The brakes must be Gasoline is highly flammable and poisonous. Extreme caution should
pulled until they are dry or clean. be used when handling gasoline. Do not refuel the motorcycle near
Rides on salt-strewed or dirty roads can also delay the braking effect. open flames or burning cigarettes. Always switch off the engine before
The brakes must be pulled until they are clean. refuelling. Be careful not to spill gasoline on the engine or exhaust
– Dirty brake discs cause increased tear of brake pads and brake pipe while the engine is hot. Wipe up spills promptly. If gasoline is
–
discs.
swallowed or splashed in the eyes, seek a doctor’s advice immedi-
– When you brake, the brake discs, brake pads, brake caliper and ately.
brake fluid heat up. The hotter these parts get, the weaker the
breaking effect. In extreme cases, the entire braking system Fuel expands when its temperature rises. Therefore do not fill the
can fail.
tank to the top (see fig.).
– If the resistance in the hand brake lever or foot brake pedal
feels “spongy” (too much play), this is an indication that some-
thing is wrong with the brake system. Don’t ride your motorcy-
cle anymore without first having the brake system looked over
by a KTM dealer.
35 mm
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
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PERIODIC MAINTENANCE »
1st service
after 3 hours
or 20 l fuel
every
20 hours
or 140 l fuel
or 1 race
250-F 2007
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
z
z
z
Change engine oil, oil filter
z
Clean oil screen and drain plug magnet
Replace spark plug (after 30 hours)
z
z
z
z
z
z
z
z
z
z
z
z
z
Check and adjust valve clearance
Check engine mounting bolts for tightness
Clean the spark-plug connector and check for a tight fit
Check the screws on the kick starter and shift lever for a tight fit
Check carburetor connection boot for cracks and leaks
Check idle speed setting
z
z
z
Check vent hoses for damage or bends
Check cooling system for leaks, check quantity of antifreeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation and bends,
adjust and lubricate
z
z
z
z
z
z
z
Check fluid level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
21
Check function of electric systems (low high beam, brake light, indicator lamps,
speedometer illumination, horn, emergency OFF switch or button
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check brake fluid level, lining thickness, brake discs
Check brake lines for damage and leaks
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
Check the screws and guide bolts on the brake system for a tight fit
Check shock absorber and fork for leaks and function
Clean fork dust bellows
Bleed fork legs
Check swing arm bearings
z
z
Check/adjust steering head bearings
Check tightness of chassis screws (triple clamps, fork leg axle passage,
swingarm, shock aborber)
z
z
z
z
z
z
z
z
z
z
z
Check/adjust steering head bearings
Check tires and air pressure
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
Check clearance of wheel bearings
250-F 2007
ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER
at least
once a year
every
2 years
z
Complete maintenance of fork
z
Complete maintenance of shock absorber
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
z
z
z
z
z
z
z
Treat battery connections with contact grease
Treat electric contacts and switches with contact spray
Change hydraulic clutch fluid
Change brake fluid
Clean Sparkarrestor (XC-W USA)
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.
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PERIODIC MAINTENANCE »
250-F 2007
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Before
each
start
After
For cross- at least
every
country
use
once
cleaning
a year
z
Check oil level
z
z
z
z
Check brake fluid level
Check brake pads for wear
Check lights for function
Check horn for function
z
z
Lubricate and adjust cables and nipples
Bleed fork legs regularly
z
z
z
z
Remove and clean fork dust bellows regularly
Clean and lubricate chain, check tension and adjust if necessary
Clean air filter and filter box
z
z
z
Check tires for pressure and wear
Check cooling fluid level
Check fuel lines for leaks
z
z
Drain and clean float chamber
Check all control elements for smooth operation
Check brake performance
z
z
z
z
z
Treat blank metal parts (with the exception of brake and exhaust system)
with wax-based anti corrosion agent
22
Treat ignition and steering locks and light switches with contact spray
Check tightness of screws, nuts and hose clamps regularly
z
250-F 2007
IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE
RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP)
COMPETITIVE every 10 hours every 20 hours every 40 hours every 80 hours
A 100 liter fuel consumption
is equivalent to approx. 15 operating hours
RACING 70 liter
140 liter
270 liter
540 liter
HOBBY-USE every 20 hours every 40 hours
–––
every 80 hours
540 liter
140 liter
270 liter
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check the clutch disks for wear
z
Check the length of the clutch springs
Check the clutch drive for indentations
Check the outer clutch hub for indentations
Check the cylinder and piston for wear
Check the groove on the piston pin retainer for wear (visual check)
Check the camshaft for wear (visual check)
Check the spring cap for wear
Check the eccentricity of the valve disk
Check the valve guides for wear
Replace the valves
z
z
z
z
z
Replace the valve springs
Check the function of the timing chain tensioner
Check the eccentricity of the crankshaft journal
Replace the conrod bearings
Check piston pin bearing
Replace the crankshaft main bearings
z
z
z
z
Check the entire transmission including the roller and bearings for wear
Check the length of the bypass valve spring
Replace the glass-fiber yarn filling in the silencer
Replace the sealing cup for the foot brake cylinder
Replace the throttle slide, jet needle and main jet holder (every 200 hours)
z
z
z
NOTE:
If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
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PERIODIC MAINTENANCE »
1st service
after 3 hours
or 20 l fuel
every
15 hours
or 100 l fuel
or 1 race
400/450/525 2007
A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!
z
z
z
z
z
z
Change engine oil, short and long oil filters
Clean oil screen and drain plug magnet
Check oil lines for damage or bends
Replace spark plug (after 30 hours)
z
z
z
z
z
z
z
z
z
z
z
z
z
Check and adjust valve clearance
Check engine mounting bolts for tightness
Clean the spark-plug connector and check for a tight fit
Check the screws on the kick starter and shift lever for a tight fit
Check carburetor connection boot for cracks and leaks
Check idle speed setting
z
z
z
Check vent hoses for damage or bends
Check cooling system for leaks, check quantity of antifreeze
Check exhaust system for leaks and fitment
Check cables for damage, smooth operation and bends
adjust and lubricate
z
z
z
z
z
z
z
Check fluid level of the clutch master cylinder
Clean air filter and filter box
Check electric wires for damage and bends
Check headlamp setting
23
Check function of electric systems (low high beam, brake light, indicator lamps,
speedometer illumination, horn, emergency OFF switch or button
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check brake fluid level, lining thickness, brake discs
Check brake lines for damage and leaks
Check/function smooth operation and adjust free travel of handbrake/foot brake lever
Check the screws and guide bolts on the brake system for a tight fit
Check shock absorber and fork for leaks and function
Clean fork dust bellows
Bleed fork legs
Check swing arm bearings
z
z
Check/adjust steering head bearings
Check tightness of chassis screws
(triple clamps, fork leg axle passage, swingarm, shock aborber)
z
z
z
z
z
z
z
z
z
z
z
Check spoke tension and rim joint
Check tires and air pressure
Check chain, chain joint, rear sprockets and chain guides for wear, fit and tension
Lubricate chain, clean and grease the adjusting screws on the chain tensioner
Check clearance of wheel bearings
400/450/525 2007
ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER
at least
once a year
every
2 years
z
Complete maintenance of fork
z
Complete maintenance of shock absorber
Clean and grease steering head bearings and gasket elements
Clean and adjust carburetor
z
z
z
z
z
z
z
Treat electric contacts and switches with contact spray
Treat battery connections with contact grease
Change hydraulic clutch fluid
Change hydraulic clutch fluid
Clean Sparkarrestor (XC-W USA)
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.
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PERIODIC MAINTENANCE »
400/450/525 2007
IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER
Before
each
start
After
For cross- At least
every
country
use
once
cleaning
a year
z
Check oil level
z
z
z
z
Check brake fluid level
Check brake pads for wear
Check lights for function
Check horn for function
z
z
Lubricate and adjust cables and nipples
Bleed fork legs regularly
z
z
z
z
Remove and clean fork dust bellows regularly
Clean and lubricate chain, check tension and adjust if necessary
Clean air filter and filter box
z
z
z
Check tires for pressure and wear
Check cooling fluid level
Check fuel lines for leaks
24
z
z
Drain and clean float chamber
Check all control elements for smooth operation
Check brake performance
z
z
z
z
z
Treat blank metal parts (with the exception of brake and exhaust system)
with wax-based anti corrosion agent
Treat ignition and steering locks and light switches with contact spray
Check tightness of screws, nuts and hose clamps regularly
z
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PERIODIC MAINTENANCE »
400/450/525 2007
IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE
RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP)
COMPETITIVE every 15 hours every 30 hours every 45 hours
RACING 100 liter
200 liter
300 liter
A 100 liter fuel consumption is equivalent to approx. 15 operating hours
HOBBY-USE every 30 hours every 60 hours every 90 hours
200 liter
400 liter
600 liter
z
z
z
Check the clutch disks for wear
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Check the length of the clutch springs
Check the cylinder and piston for wear
Check the groove on the piston pin retainer for wear (visual check)
Check the camshaft for wear (visual check)
Replace the camshaft bearings
Check the length of the valve springs
Check the spring cap for wear
Check the eccentricity of the valve disk
Check the valve guides for wear
Check the radial clearance of the rocker arm rollers
Check the elongation of the timing chain
Check the chain tensioner tooting for damage (visual check)
Check the eccentricity of the crankshaft journal
Replace the conrod bearings
z
25
Check piston pin bearing
Replace the balancer shaft bearings
Replace the crankshaft main bearings
Check the entire transmission including the roller and bearings for wear
Check the length of the bypass valve spring
Replace the glass-fiber yarn filling in the silencer
Replace the sealing cup for the foot brake cylinder
Replace the throttle slide, jet needle and main jet holder (every 210 hours)
z
z
NOTE:
If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
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26
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Maintenance and adjusting work marked with an asterisk (*) requires expert skills and technical know-how. For your own safety, always
have such work performed by a specialized KTM dealer where your motorcycle will be optimally serviced by appropriately qualified,
skilled staff.
– If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc. The high
pressure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear.
– 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 contam-
inates 1,000,000 liters of water.
27
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 mm (0.04 in).
2
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.
1
After readjusting the clamping screw [2], tighten it to 8 Nm.
ADJUSTMENT VALUES
Spring preload A.......5 mm (0,2 in)
A
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.
3
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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 75 - 85 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.
A
A
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.
B
B
28
– 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
C
C
– 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) . . . . . . . . . . . . . .– 500 mm
Riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm
The riding sag should lie between 95 and 105 mm.
If the riding sag is less than 95 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).
WP12187C06, WP12187C29
WP12187C04, WP12187C28
84/250
80/250
The spring rate is written on the outside of the spring (e.g. 80/250). 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.
80/250
76/250
After installing a different spring, readjust the static sag to 35 mm (± 2 mm).
76/250
72/250
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.
65
70
75
80
85
90
95
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
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
(XC, EXC SIXDAYS)
29
The telescopic forks of these 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).
Turning in a clockwise direction will increase the prestress, turning in a coun-
terclockwise direction will decrease the prestress.
Changing the spring preload will not affect the rebound damping adjustment.
Generally, if the spring preload is higher, the rebound damping should also
be set higher.
NOTE:
Always turn the adjusting screws the same distance on both fork legs. Different
spring preloads on the fork legs will reduce the telescopic fork's response.
Changing the spring preload on the telescopic fork (XC-W/EXC)
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, 5 and 10 mm (see spare parts catalog). The fork springs
may not be pretensioned by more than 20 mm.
The preload adjuster used in the XC models can easily be retrofitted for the
telescopic forks of the XC-W/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
WP14187C29
If you weigh less than 75 kg or more than 85 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.
4,8 N/mm
4,6 N/mm
4,4 N/mm
WP14187C06, WP14187C28
WP14187C04
4,6 N/mm
4,4 N/mm
4,2 N/mm
If you are uncertain which spring to use, contact your KTM workshop.
4,4 N/mm
4,2 N/mm
4,0 N/mm
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.
65
70
75
80
85
90
95
RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather
plugs [1] a few turns in order to relieve excess pressure from the inside of the
fork. To do this, place the motorcycle on a stand with the front wheel lifted
off the ground. When riding the motorcycle mainly on the road, it will suffice
to have this job performed in the course of the periodical maintenance
service.
1
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 hav-
ing the seals replaced.
Cleaning the dust sleeves of the telescopic fork
The dust-protection bellows [2] are to remove dust and coarse dirt particles
from the fork tube. However, after some time, dirt may also get in behind the
dust-protection bellows. If this dirt is not removed, the oil sealing rings located
behind it may start to leak.
Use a screwdriver to lift the dust-protection bellows out of the outer tubes
and slide them downward.
2
30
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 consider-
ably 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]
and [5] of the top triple clamp and turn steering stem bolt clockwise [4] until
there is no more play. Don’t tighten the steering stem bolt all the way, other-
wise the bearings will be damaged. With a plastic hammer, lightly tap on the
triple clamp to release tension. Retighten the five pinch bolts.
4
XC, EXC SIXDAYS . . . . . . . . . . . . . . . . . . . . . . . . .17 Nm (pinch bolts 3)
XC, EXC SIXDAYS . . . . . . . . . . . . . . .Loctite 243 + 17 Nm (pinch bolt 5)
XC-W, EXC . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Nm (pinch bolts 3 + 5)
3
3
5
– If the steering head bearing is not adjusted to be free of play, the motor-
cycle will exhibit unsteady driving characteristics and can get out of
control.
– XC, EXC SIXDAYS: Be sure to lock the thread on the pinch bolt [5] with
Loctite 243.
If you drive with play in the steering head bearing for longer periods, the bear-
ings and subsequently the bearing seats in the frame will be destroyed.
The steering head bearings should be regreased at least once a year
(e.g. Motorex Long Term 2000).
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Changing the fork offset (caster)
(XC, EXC SIXDAYS) *
The fork offset [A] in these 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.
A
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.
B
The offset is set to 20 mm in the condition at delivery.
1
5
2
3
4
31
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.
3
4
2
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. Apply Loctite 243 to the thread of the collar screw [2]
and turn all the way in.
5
– Be sure to lock the thread on the collar screw [2] with Loctite 243.
– Do not confuse the collar screw with the blind screw [1].
Grease the steering head bearing and sealing elements.
2
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Mount the lower triple clamp, upper steering head bearing, protection ring,
O-ring, upper triple clamp and the blind screw.
Tighten the collar screw on the lower triple clamp to 60 Nm.
Mount the fork legs and tighten the clamp screws on the lower triple clamp
to 12 Nm in 3 stages.
Adjust the steering head bearing without clearance (see: Checking and adjust-
ing the steering head support). Apply Loctite 243 to the thread of the mid-
dle clamp screw. Tighten the clamp screws on the upper triple clamp to 17
Nm in 3 stages.
The middle clamp screw must be secured with loctite 243.
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).
Tighten all screws and nuts to the specified torques using a torque wrench.
Screws or nuts that are not tightened enough can become loose and cause
the motorcycle to go out of control while driving. Screws or nuts tightened too
firmly can damage the thread and components.
32
How to change the handlebar position
The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar in the position that is the most convenient for you. The upper triple
clamp [1] includes 2 bores arranged at a distance of 15 mm (0.6 in) from
one another. The bores at the handlebar support [2] are offset from the cen-
ter by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws [3] of the handlebar clamps and screws [4]
of the handlebar support. Position the handlebar support, and tighten screws
[4] to 40 Nm (30 ft.lbs). Mount the handlebar and handlebar clamps, and
tighten screws [3] to 20 Nm (15 ft.lbs). The gap between the handlebar sup-
port and the handlebar clamps should be the same size in the front and in
the rear.
3
4
2
The screws [4] must be secured with loctite 243.
3,5 mm
1
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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.
A
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 compo-
nents of the secondary drivetrain (chain, bearings of transmission and rear
wheel). Aside from resulting premature wear, if worst comes to worst the
chain may rupture or the countershaft of the transmission may break.
– Too much slack in the chain, on the other hand, can result in the chain
jumping off the chain wheels. If this happens, the chain could also block
the rear wheel or damage the engine.
– In either case the operator is likely to lose control of the motorcycle.
33
Correct chain tension
Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting
screws [3] equally far. Tighten lock nuts.
3
B
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.
Clean and grease the adjusting screws regularly (Motorex Long Term Grease
2000). Before tightening the collar nut, verify that the chain adjusters [4] are
sitting close to the adjusting screws and that the rear wheel has been aligned
with the front wheel.
2
1
Tighten collar nut [1] to 80 Nm.
4
– If you don’t happen to have a torque wrench at hand, make sure you have
the tightening torque corrected by a KTM dealer as soon as possible. A
loose axle may lead to an unstable driving behavior of your motorcycle.
– Tighten the collar nut with the required torque. A loose wheel spindle may
lead to an unstable behavior of your motorcycle.
B
2
4
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°.
3
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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.
34
Chain wear
To check the chain wear, observe the following indications:
Shift the gear into idling and pull the upper chain strand with approx. 10-15
Kilograms (33 lb) upwards (see figure). Now one can measure a space of 18
chain reels at the lower chain strand. The chain should be replaced at the
latest when a space of 272 mm (10.70 in) is measured. Chains do not always
wear off evenly, therefore repeat the measurement at different places on the
chain.
15 KG
33 lbs
NOTE:
If you mount a new chain, the sprockets should also be replaced. New chains
wear faster if used on old used sprockets.
Secure the screws of the chain wheel by applying Loctite and fasten them in
a crosswise order.
Tightening torque for nuts: 35 Nm.
Tightening torque for screws: 50 Nm.
max. 272 mm
1
2
3
16 17 18
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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 HHB sintered lining at the
front and TOYO B 143 FF sintered lining at the back. These linings provide
an optimal combination of dosing, brake performance and life cycle. The lin-
ing type is stated on the back of the brake pad and also recorded in the homolo-
gation papers.
35
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
2.50 mm (front) / 3.50 mm (rear) thick at the thinnest point [A]. Check the
thickness of the brake disk at several points.
A
– A brake disk worn down to less than 2.50 mm (front) / 3.50 mm (rear) is
a safety risk. Have the brake disk replaced as soon as it reaches the serv-
ice limit.
– Have any repairs on the brake system be performed by a KTM dealer.
1
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 motor-
cycle often, the brake fluid should be changed even more frequently. Brake
fluid tends to absorb water. Therefore, vapor pockets may form in "old" brake
fluids even at low temperatures, causing the brake system to fail.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Adjusting the free travel at the hand brake lever
Free travel at the hand brake lever may be readjusted by using adjustment
screw [1]. In this way, the position of the point of pressure (i.e. the resis-tance
you feel on the hand brake lever when the brake pads are pressed against the
brake disc) can be adjusted for any hand size.
When you press the hand brake lever forwards, you should have at least
3 mm free travel. Turn the adjusting screw [1] if necessary.
min. 3 mm
1
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 author-
ized KTM dealer immediately.
36
Refilling the front brake fluid reservoir *
Loosen screws [2] and remove lid [3] and membrane [4].
3
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.
2
– 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.
4
– 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.
5 mm
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.
min.
1 mm
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.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Replacing the front brake pads *
1
Press the brake caliper toward the brake disk, to put the brake piston in its
basic position. Remove clips [1] and pull out bolt [2]. Remove brake pads
from the brake caliper. Clean the brake caliper and the brake caliper support
with compressed air. Check the sleeves of the guide bolts for damage, and
grease guide bolts if necessary.
1
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].
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 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.
4
3
2
2
1
37
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].
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 sys-
tem when driving, causing the rear wheel to brake.The braking system over-
heats and may even fail completely in extreme cases.
3-5mm
5
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 author-
ized KTM dealer immediately.
A
Refilling the rear brake fluid reservoir *
Add brake fluid as soon as a bubble is visible in inspection glass [A].
To top up, remove screw [7]. Fill DOT5.1 brake fluid (e.g. Motorex Brake Fluid
DOT 5.1) up to the mark [B] on the inside of the reservoir and remount the
screw. Spilled brake fluid must be rinsed off with water.
B
– 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.
7
– 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.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Checking the rear brake pads
min.
The brake pads can be inspected from the rear. The thickness of the linings
may not be less than 1 mm (0.04 in).
1 mm
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.
1
38
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].
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.
3
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.
4
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).
5
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.
Before remounting the front wheel, clean and grease the shaft seal rings [A]
and the bearing surface [B] of the distance bushings and mount the distance
bushing.
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).
A
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 15 Nm
6
B
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
– If you don’t happen to have a torque wrench at hand, make sure you have
the tightening torque corrected by a KTM dealer as soon as possible. A
loose axle may lead to an unstable driving behavior of your motorcycle.
– After mounting the front wheel, keep operating the hand brake until the
pressure point returns.
7
– It is very important to keep the brake disk free from oil and fatty matters,
otherwise the braking effect would be strongly reduced.
Dismounting and mounting the rear wheel
Jack the motorcycle up on its frame so that the rear wheel no longer
touches the ground.
Remove the collar nut [1], remove the chain tensioner [2] and pull out the
wheel spindle [3] until you can push the rear wheel forwards.
Take the chain off the rear sprocket, pull out the wheel spindle and carefully
remove the rear wheel from the swing arm.
2
– 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 col-
lar nut thoroughly and apply a new coat of grease to prevent the thread
from jamming.
1
39
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 behavior of your motorcycle.
– After mounting the rear wheel, keep operating the rear brake until the pres-
sure point returns.
3
– 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 overloading.The
spokes must be tensioned to 5 Nm.
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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.
TIRES-AIR PRESSURE
front
1,0 bar
– 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.
rear
Off road
1,0 bar
2,0 bar
Road driver only 1,5 bar
– If air pressure is too low, abnormal wear and overheating of the tire can
result.
40
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].
1
2
1
3
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.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Battery
The battery is located under the seat and is maintenance-free.
Maintenance-free means you will not need to check the acid level. Clean the
battery terminals regularly and grease with acid-free grease if necessary. The
charge condition and type of charge are very important for the battery's serv-
ice life.
1
TO REMOVE THE BATTERY:
First disconnect the negative pole, then the positive pole from the battery.
Remove the filter box cover and detach both rubber bands [1].
Remove the battery.
Install the battery as described for the specific type of battery (see illustra-
tion). Connect the minus pole to the battery last.
– If electrolyte (sulphuric acid) leaks from the battery, proceed with great
care. The electrolyte can cause severe burns.
– In the case of skin contact rinse thoroughly with water.
– In the case of contact with the eyes, thoroughly rinse eyes with water for
at least 15 minutes. Immediately consult a doctor.
– The battery is a closed model but can nevertheless emit explosive gases.
Avoid sparks and open fire near the battery.
– Defective batteries must be stored out of the reach of children. Ensure
proper disposal of discarded batteries.
Never remove the closure [2] since it will be damaged
41
STORAGE:
If the motorcycle is being immobilized for longer periods of time, remove and
charge the battery. Storage temperature 0 - 35°C, avoid direct sunlight.
Charge the battery every 3 months.
Charging the battery
The battery discharges every day, even if it is not used.
Always disconnect the battery when charging. Charge the battery as described
in the instructions [3] on the battery housing. Do not exceed the amperage
and charging time. Quick charging at a high amperage has an adverse effect
on the service life.
2
3
Always use special charging devices to charge maintenance-free batteries, e.g.
the KTM charging device (item no. 58429074000). You can also use this
charging device to test the off-load voltage and startability of the battery and
generator. It is impossible to overcharge the battery with this device.
Charge the battery immediately if it is empty when you start the motorcycle.
If left to stand in an uncharged condition for a longer period of time, the bat-
tery will run down and sulfatize, destroying the battery.
Recharge the battery every 3 months if it is being stored for a longer period
of time.
– Never remove the closure [2] since it will be damaged.
– To avoid damage to the on-board electronic system, always disconnect the
minus pole before you charge the battery.
– To charge, connect the battery to the battery charger before you switch on
the battery charger. When the battery is charged, switch off the battery
charger before you disconnect the battery.
VOLT
– Provide adequate ventilation when charging the battery in a closed room;
the battery emits explosive gases when charging.
– Electrolytes will escape through the safety valves if the battery is charged
too long or at an excessive voltage or amperage. This will reduce battery
capacity.
– Try to avoid quick charges.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Fuse
The fuse [1] is located in the starter relay of the E-starter [2] underneath the
left side paneling.
A
2
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.
1
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 damage the whole elec-
trical installation.
3
42
Replacing headlight lamp/parking light lamp
5
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.
6
4
5
Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out
of the socket.
To mount the lamp reverse the worksteps indicated above.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Cooling system
400/450/525
250-F
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.
1
2
1
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 pressure. Caution - scalding
hazard!
– Do not detach any radiator hoses while the engine is hot. The escaping
hot coolant and the steam may cause serious burns.
– In case you get burnt, hold the affected part of your body under running
cold water right away.
– Coolant is toxic. Keep the coolant out of the reach of children.
– In case coolant is ingested, consult a doctor immediately.
– If coolant gets into your eyes, rinse them out with water immediately and
consult doctor.
3
A mixture of 50% antifreeze liquid and 50% destilled water is used as coolant.
However, the antifreeze protection must be at least -25° C (-13° F). This mix-
ture offers antifreeze protection but also good corrosion protection and should
therefore not be replaced by pure water.
43
– The cooling system must be bled after draining the cooling liquid or after
adding more than 0.25 l (0.06 US gallons) cooling liquid.(see below).
– For the cooling system, use only high-grade antifreeze (e.g. Motorex Anti
Freeze). Using lower-grade antifreeze agents can cause corrosion and
coolant foaming.
– Extreme climate conditions or stop and go traffic may cause overheating
problems. To avoid this, an electric blower [4] is offered (ask your KTM
Dealer).
4
Checking the coolant level
The coolant should be 10 mm (0.4 in) above the radiator fins when the engine
is cold (see diagram). In the event of the coolant being drained, always fill
and bleed the system.
10 mm
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.
when engine is cold
Caution - scalding hazard!
Bleeding the cooling system (400/450/525)
By removing the screw [5] at the front end of the cylinder you can drain the
coolant.
To bleed the cooling system, fill in approx. 0.8 liters (0.2 US gallons) of coolant
and remove the bleeder screw [6]. Do not reinstall the bleeder screw until
coolant escapes at the bore without any bubbles.
Then, fill in the coolant until it reaches a level about 10 mm above the
radiator fins.
After a short ride, check the coolant level once more.
6
5
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Bleeding the cooling system (250-F)
2
By removing the screw [1] at the water pump cover you can drain the coolant.
To bleed the cooling system, fill in approx. 1.0 liter (0.25 US gallons) of coolant
and remove the bleeder screw [2]. Do not reinstall the bleeder screw until
coolant escapes at the bore without any bubbles.
Then, fill in the coolant until it reaches a level about 10 mm above the
radiator fins.
After a short ride, check the coolant level once more.
1
Replacing the glassfiber yarn packing of the silencer *
XC
Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the
filling checked regularly by an authorized KTM workshop (see Lubrication and
Service Chart). The insulating material fibers escape through the holes in the
perforated pipe with time, causing the silencer to „burn out“. In addition to
causing a higher noise-level, it will also affect the power characteristic. The
insulating material suitable for your exhaust is available from your authorized
KTM workshop.
3
5
C
7
By experience, the front glassfiber yarn packing [3] needs to be replaced more
often than the rear silencing mat [4].
For this purpose, remove the silencer from the vehicle and dismount the front
cap [5]. Pull the front glassfiber yarn packing together with the inner exhaust
pipe [6] out of the silencer. Clean the front inner exhaust pipe.
To facilitate the mounting procedure, you can make a mounting tool [7] out
of wood, plastic, or metal. Insert the mounting tool into the inner pipe and
mount the glassfiber packing. Push the inner pipe containing the packing into
the silencer such that the slot engages the web [A]. Use a blunt ended object
to stuff the glassfiber yarn packing all the way into the silencer, and mount
the front cap.
6
44
5
EXC
To change the rear silencing mat, start by removing the front packing and the
inner exhaust pipe. Then, drill open the rivets and remove the end cap [C].
C
3
7
NOTE:
In every exhaust repair procedure, the O-rings must be replaced by new ones.
Glass fiber yarn packings are available from your licensed KTM
mechanic.
4
6
Make sure the caps are screwed on tightly. Mount the muffler stress-free before
tightening the fixing screws.
A
The exhaust system becomes very hot while the motorcycle is running. to avoid
burns do not start work on the exhaust system until it has properly cooled
down.
EXC-F
Cleaning the spark arrester (XC-W 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.
B
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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 XC models do not have a throttle cap.
1
– Do not clean foam filter with fuel or petroleum since these damage the
foam. KTM recommends the products of the company Motorex for air fil-
ter maintenance (Bio Dirt Remover and Liquid Bio Power).
– Never start your motorcycle without any air filters. Otherwise, dust and
dirt may penetrate and cause damage and increased wear.
– Dust and dirt can accumulate and damage the engine if the air filter is
not mounted correctly.
3
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.
2
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.
45
5
4
3
2
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
11
10
Be sure not to pinch the throttle cables when mounting the tank. Afterwards,
check the throttle cables for easy action.
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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 counterclockwise reduces the distance between
the clutch lever and the handlebar. Turning the adjusting screw clockwise
increases the distance between the clutch lever and the handlebar.
1
Adjustment of the clutch lever position is only possible within certain limits.
Only turn the adjusting screw manually and never apply excessive force.
Checking the oil level of the hydraulic clutch (400/450/525)
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.
2
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).
3
4
KTM uses biodegradable, hydraulic mineral oil to actuate the hydraulic
clutch. Do not mix this oil with any other hydraulic oil. Always use
original KTM hydraulic oil (available from your authorized KTM workshop) to
make sure your clutch operates smoothly.
46
Never refill with brake fluid.
Checking the oil level of the hydraulic clutch (250-F)
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, add DOT 5.1 brake fluid (Motorex Brake Fluid 5.1).
Brembo clutch fittings are installed in the 250-F models and filled with DOT
5.1 brake fluid. To make sure the clutch operates smoothly, never add hydraulic
oil to these systems.
Bleeding of the hydraulic clutch *
If the clutch lever starts to feel unresponsive, the clutch control system needs
to be bled. You will need to use a bleeding syringe (special tool). Please note
that Motorex 75 clutch fluid must be used for the 400/450/525 models and
Motorex DOT. 5.1 brake fluid for the 250-F models.
Turn the handlebar until the master cylinder is in a horizontal position, remove
the screws [2], the cover [3] and the rubber boot [4].
6
Fill the bleeder syringe [6] with a suitable fluid (see Technical Specifications
- Engine). Remove the bleeder screw [5] from the slave cylinder and mount
the bleeder syringe.
5
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 cylin-
der 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).
7
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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).
1
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)
Warm up the engine
2
3
4
Use the adjusting wheel [1] to set the normal idle speed (1400 - 1500 rpm).
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;
2
47
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.
Then, use the adjusting wheel to set the desired idle speed.
In cases of greater changes in the outside temperature and extremely
different altitudes, the idling speed should be readjusted.
3
5
6
Basic information on carburetor wear
As a result of engine vibrations, the throttle valve, jet needle, and needle jet
are subjected to increased wear. This wear may cause the carburetor to mal-
function (e.g., overly rich mixture). Therefore, these parts should be replaced
after approx. 200 hours.
Adjusting 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).
4
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.
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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.
2a
400/450/525: Close the fuel tap and put one end of the hose [1] into a col-
lecting vessel. Open the drain plug [2a] (turning it counterclockwise) by ser-
val turns, and drain the fuel from the float chamber. Then, retighten the drain
plug and open the fuel tap.
2b
250-F: Close the fuel tap, and place a cloth under the carburetor, which is
capable of absorbing the leaking fuel. Unscrew the plug [2b] and clean it with
compressed air. Then, mount the plug together with the gasket, open the fuel
tap, and check the float chamber for leaks.
1
– Fuel is easily flammable and toxic. When handling fuel, be sure to exer-
cise 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 eas-
ily flammable. In case you ingested fuel or fuel splashed into your eyes,
consult a doctor immediately.
– Dispose of the fuel properly.
5
6
9
8
48
7
Oil circuit (400/450/525)
10
13
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].
12
3
15
14
11
4
Oil circuit (250-F)
The oil pump [20] sucks engine oil from the transmission oil sump through
the long oil screen [21] and conveys it to the oil filter [22] where any con-
tamination is filtered out. The cleaned engine oil is pumped past the bypass
valve [23] to the conrod bearing [24] and sprayed onto the pistons from below
through a jet [25].
Two other oil ducts lead into the cylinder head. One duct supplies the hydraulic
chain tensioner [26], the other duct leads to the camshaft bearing support
[27], where the camshaft bearings and the cam lever are supplied with oil
(via spraying nozzles).
27
25
26
30
24
The second oil pump [28] sucks the engine oil out of the crankcase through
the short oil screen [29] and uses it to grease the transmission gears [30].
28
20
29
22
21
23
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].
B
A
Replenish the engine oil, if necessary.
Insufficient amounts of or low-grade engine oil lead to premature wear in the
engine.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Engine oil
JASO T903 MA
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).
250-F:
400/450/525:
10W/50
+
10W/50
5°C
41°F
0°C
32°F
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity or 5W/40
viscosity (see table).
5W/40
5W/40
–
Insufficient oil or poor quality oil results in premature wear of the engine.
Changing the engine oil *
Note: When changing the engine oil, it is necessary to clean the short and
long oil screens and to replace both oil filters (250-F: only one oil filter).
Engine oil has be changed with the engine at an operating temperature.
1
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.
49
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.
2
3
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 (oiled) 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.
4
To mount the long oil screen [5], place it on an approx. 300 mm (12 in) long
pin-type key or a similar tool. Insert the pin-type key through the opening into
the bore of the opposite engine casing wall. Then, push the oil screen into
the engine casing as far as possible. Remove the pin-type key, mount the plug
and tighten it to 15 Nm.
5
The oil screen is mounted slightly downwards, incorrectly fitted, the screen
looses its function and this can cause increased engine wear.
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MAINTENANCE WORK ON CHASSIS AND ENGINE »
Changing the oil filters
2
Place a receptacle underneath the engine to collect the drained oil. Remove
the 4 screws [2] and dismount the two oil filter covers.
2
2
Using circlip pliers, pull the oil-filter inserts [3] out of the housing.
Clean the oil filter cover, the sealing surfaces of the O-rings and the engine
casing. Check the O-rings of the oil filter covers for damage and, if necessary,
replace them.
3
3
50
NOTE:
The 250-F engine only has one oil filter insert [3].
3
Put the motorcycle on its side and fill the oil filter housings about halfway
with engine oil. Fill oil filter with oil, place the long oil filter in the front and
the short filter in the back of the filter box.
Grease the O-rings [4] of the oil filter covers and mount the covers. Mount
the screws and tighten them to 6 Nm.
4
Return the motorcycle to an upright position.
Remove the oil dipstick [5] at the clutch cover and fill in 1.2 liters
(250-F: 1.1 liters) of fully synthetic engine oil (Motorex Power Synt 4T
10W/50).
5
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.
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TROUBLESHOOTING »
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.
TROUBLE
CAUSE
REMEDY
Engine doesn’t crank (E-starter). Operating errror
Turn on the emergency-OFF switch (Australia only)
Blown fuse
Dismount the left paneling and the filter box cover and
replace the fuse in the starter relay.
Discharged battery.
Recharge the battery and investigate the causes for
discharging; contact a KTM dealer.
Low outside temperature
Start the engine with the kickstarter
Engine cranks but doesn’t start (E- Operating error
starter).
Open fuel tap, tank fuel, actuate choke. Pay attention to
starting information (see driving instructions).
Engine will not start (Kickstarter). The motorcycle has been out of opera- The easily inflammable components of the new fuels evap-
tion for a longer period of time. Therefore orate during longer periods of standing still.
old fuel has accumulated in the float When the motorcycle has been out of operation for more
chamber
than a week, it is therefore recommended to drain the old
fuel from the float chamber. The engine will immediately
start when the float chamber is filled with new fuel.
Fuel supply interrupted
Close fuel tap, loosen fuel hose at carburetor, lead into a
basin and open fuel tap
51
–
–
if fuel leaks out, the carburetor may need cleaning
if no fuel leaks out, check tank ventilation, i.e. clean
fuel tap
Flooded engine
In order to "pump the engine free", pull the hand 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.
Sooty or wet spark plug
Electrode gap too large
Clean and dry the spark plug or exchange it, respectively
Adjust spark plug electrode gap to 0.6 mm
Spark plug connector or spark plug Dismount spark plug, connect ignition cable, hold to
faulty
ground (blank place on engine) and actuate starter, a
strong spark must be produced at the spark plug
–
–
If no spark is created replace the spark plug.
If the new spark plug doesn't produce a spark either,
disconnect the spark plug connector from the ignition
cable, hold it a distance of approx. 5 mm from ground
and start.
–
–
If a spark now occurs, replace spark plug cap
If no spark is produced, control ignition system
Short circuit cable scored in wiring har- Dismount the fuel tank, disconnect the black/yellow cable
ness, emergency OFF switch or short cir- from the cable of the emergency-OFF switch and the short-
cuit button faulty
circuit button, respectively, and check the ignition spark.
If a spark is generated, look for the problem in the short-
circuit circuit.
The plug connection of the CDI-unit, the Remove the seat and the fuel tank. Clean the plug con-
pulse generator or the ignition coil has nection and treat it with contact spray
oxydized
Water in carburetor or jets blocked
Glogged idling jet
Dismount and clean the carburetor
Engine fails to idle
Disassemble the carburetor and clean the jets
Incorrect adjustment of adjusting Have the carburetor adjusted
screws on carburetor
Defective spark plug
Replace the spark plug
Defective ignition system
Have the ignition system checked
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TROUBLESHOOTING »
TROUBLE
CAUSE
REMEDY
Engine does not rev high
Carburetor fuel level too high because float Dismount carburetor and check if worn out
needle valve is dirty or worn out
Loose carburetor jets
Tighten jets
Electronic ignition timing faulty
Have ignition system checked
Engine will not reach full power Fuel supply partially interrupted or carbu- Clean and check fuel system as well as carburetor
retor dirty
Float leaks
Replace the float
Air filter very dirty
Clean or replace air filter
Exhaust system is not tight, deformed, or Check if exhaust is damaged, replace glasfiber yarn in
the silencer does not contain enough glass- exhaust silencer
fiber yarn
Valve gap too small
Adjust valve gap
Loss of compression because hand decom- Check setting of the hand decompression cable
pressor has no play
Electronic ignition timing faulty
Have ignition system checked
Engine stops or splutters in Insuffient fuel
Clean and check fuel system and carburettor
Check rubber sleeve and carburetor for tight fit
carburetor
52
Engine takes air out of control
Insufficient cooling liquid
Engine gets too hot
Refill cooling liquid (see maintenace work), check cooling
system for leaks
Not enough air stream
Drive on briskly (electric fan can be retrofitted)
Bleed cooling system
Cooling system has not been bled
Radiators very dirty
Clean radiators with water jet
Foam formation in cooling system
Bent cooling hose
Replace cooling liquid, use antifreeze liquid with brand name
Shorten or replace cooling hose
Thermostat defective
Dismount and check thermostat (opening temperature
70°C, (158°F) or replace it
Blown fan fuse (XC Desert)
Replace fuse and check if fan operates properly (see
below)
Defect thermoswitch (XC Desert)
Fan defective (XC Desert)
Contact a KTM dealer
Check if fan operates properly. To do this, start the
engine, then bypass the connections to the thermoswitch
(bottom right radiator), contact a KTM dealer
High oil consumption
Hose of engine ventilation is bent
Engine oil level too high
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“
Motor oil too thin (viscosity)
All switched on lamps blown Capacitor or voltage regulator faulty
out
Dismount seat and fuel tank and check connections, have
capacitor and voltage regulator checked
Horn, flasher lights and Blown fuse in the starter relay
E-starter do not work
Dismount left side paneling and filter box cover, replace
fuse
The battery is discharged
The battery isn’t charged by the generator Remove seat and fuel tank and check voltage regulator con-
because
nections; voltage regulator and generator should be checked
by a KTM dealer.
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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.
If using a power washer, do not point the water jet at the electric components, plugs, cables, bearings, carburetor, etc. The high pres-
sure will cause water to penetrate into the components and can cause them to malfunction or lead to premature wear.
– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should also be cleaned with the help
of a paint brush.
– Before cleaning with water, plug the exhaust pipe to prevent water ingress
– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber
of the carburetor. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warm-
ing these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.
– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of
the motorcycle is allowed to evaporate.
– Once the motorcycle has cooled down, oil or grease all sliding and bearing points. Treat the chain with a chain spray. Also oil the
fuel tap.
– To avoid any failures in of the electric system, you should treat the emergency-OFF switch, short-circuit button, light switch and
socket connectors with a contact spray.
CONSERVATION FOR WINTER OPERATION »
In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take 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.
53
Keep the anti-corrosion agent from getting into contact with the brake discs, otherwise this will significantly reduce the braking power.
After rides on salted roads, clean motorcycle thoroughly with cold water and let it dry well.
STORAGE »
Should you wish to make a pause over a longer space of time, please observe the following instructions:
– Clean motorcycle thoroughly (see chapter: CLEANING)
– Change engine oil, short and long oil filters (old engine oil contains aggressive contaminants).
– Check antifreeze and amount of cooling liquid.
– Warm up the engine once again, close the fuel cock and wait until the engine dies. Then open the drain plug of the float chamber
to remove the remaining fuel.
– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in
order to distribute the oil onto the cylinder walls and mount the spark plug.
– Set piston to compression so that the valves will be closed (slowly operate the kickstarter until you can hear the automatic
decompressor click (release))
– Let fuel flow out of tank into an appropriate container.
– Correct tire pressure.
– Lubricate pivot points of the control levers, foot rests, etc. as well as the chain.
– Service the shock absorber linkage
– Disassemble and charge battery (see chapter: BATTERY).
– The storage place should be dry and not subjected to excessive temperature fluctuations.
– Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use airtight materials as a possible humidity might not be
able to escape and could cause corrosion.
It would be very bad to let the engine run for a short time during the storage period. The engine would not get warmed up enough and
the thus developed steam would condense during the combustion process and cause the valves and exhaust to rust.
USE AFTER A PERIOD OF STORAGE
– Mount the charged battery (regard polarity).
– Set the time in the speedometer.
– Fill up tank with fresh fuel.
– Check motorcycle as before each start (see driving instructions).
– Take a short, careful test ride first.
NOTE: Before you put your motorcycle away for the winter, you should check all parts for their function and wear. Should any service
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.
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TECHNICAL DATA – ENGINE »
ENGINE
250 XC-F
250 XCF-W, EXC-F
Design
Liquid-cooled single cylinder 4-stroke engine
Displacement
Bore/Stroke
Ratio
249.51 ccm
76 / 55 mm
12.8 : 1
Fuel
unleaded fuel with at least RON 95 (USA = Premium PON 91)
4 valves controlled by finger levers and 2 camshafts,
driven by a pair of spur gears and a tooth-type chain
Intake: 770.36.009.100 / Exhaust: 770.36.110.100
30.9 mm
Valve timing
Camshaft
Valve diameter Intake
Valve diameter Exhaust
26.5 mm
Valve clearence cold Intake 0.10 - 0.20 mm (0.004 - 0.008 in)
Valve clearence cold Exhaust 0.12 - 0.22 mm (0.005 - 0.009 in)
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston
2 cylinder roller bearings
needle bearing
bronze bushing
alluminium alloy forged
Piston rings
1 compression ring, 1 oil scraper ring
pressure circulation lubrication with 2 rotor pumps
full synthetic oil (Motorex Power Synt 4T 10W/50)
1.1 liters
Engine lubrication
Engine oil
54
Quantity of engine oil
Primary drive
Clutch
22:68
multiple disc clutch in oil bath, hydraulically operated (brake fluid DOT 5.1)
Transmission claw shifted
1st gear
6-speed
13:32
15:30
17:28
19:26
21:25
22:24
6-speed
13:33
17:33
19:29
23:28
23:23
26:22
2nd gear
3rd gear
4th gear
5th gear
6th gear
Ignition system
Generator
contactless DC-CDI ignition with digital advanced system by KOKUSAN
12 V 150 W
Spark plug
NGK CR 9 EBK
Cooling system
Cooling liquid
Starting equipment
liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
1.2 liters, 50% antifreeze, 50% destilled water, at least -25° (-13° F)
kick - electric starter
Engine oil
JASO T903 MA
250-F:
Only use fully synthetic engine oils that meet the JASO MA quality require-
ments (see information on the can).
KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem-
peratures over 5°C, 41°F) or 5W/40 (for temperatures under 5°C, 41°F).
+
10W/50
5°C
41°F
Poor oil quality or minor quantity cause early engine-wear.
5W/40
–
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TECHNICAL DATA – ENGINE »
TIGHTENING TORQUES – ENGINE 250-F
Hexagon collar screw, engine case, clutch cover, ignition cover, water pump cover M6
10 Nm
Oil drain plug
M12x1.5
20 Nm
Allen head plug, oil screen short
Hexagon plug, oil screen long
Collar screw for oil filter cover
Plug pressure valve
M16x1.5
M20x1.5
M5
Oil + 10 Nm
15 Nm
6 Nm
M12x1.5
M5
20 Nm
Screws, oil pump cover
Loctite 222 + 6 Nm
10 Nm
Hexagon collar screw, cylinder / cylinder head
Cylinder head screw
M6
M10
M6
Oil + 40/50 Nm
Loctite 243 + 10 Nm
10 Nm
Hexagon collar screw, exhaust flange
Valve cover screws
M6
Camshaft screw
M12x1
M7
Loctite 243 + 80 Nm
Oil + 18 Nm
Collar screw/nut camshaft bearing support
Hexagon nut, primary gear
M18x1.5 left
M18x1.5
M6
Loctite 243 + 150 Nm
Loctite 243 + 120 Nm
10 Nm
Nut for inner clutch hub
Hexagon collar screw, clutch spring
Allan head screw, shift roller locking piece
Hexagon collar screw, locking lever
Locking screw for shift roller bearing
Locking screw for main shaft bearing
HH collar screw clip/tensioning rail
Plug for chain tensioner
M6
Loctite 243 + 10 Nm
Loctite 243 + 6 Nm
Loctite 243 + 6 Nm
Loctite 243 + 6 Nm
Loctite 243 + 10 Nm
25 Nm
M5
55
M6
M6
M6
M24x1.5
M6
Hexagon collar screw, stator XC, EXC
Hexagon collar screw, E-starter
Hexagon collar screw, pulser coil
Hexagon collar nut, flywheel
Hexagon collar screw, bump part kickstarter
Cable retaining bracket (ignition)
Allan head screw, kickstarter
Hexagon collar screw, shift lever
Hexagon screw, engine sprocket
Spark plug
Loctite 243 + 8 Nm
10 Nm
M6
M5
Loctite 243 + 6 Nm
60 Nm
M12x1
M6
Loctite 243 + 10 Nm
Loctite 243 + 6 Nm
Loctite 243 + 25 Nm
Loctite 243 + 10 Nm
Loctite 243 + 60 Nm
10-12 Nm
M6
M8
M6
M10
M10
BASIC CARBURATOR SETTING
250 XC-F USA
250 XCF-W USA
250 EXC-F
250 EXC-F SIXDAYS
Type
Keihin FCR-MX 3900G Keihin FCR-MX 3900G Keihin FCR-MX 3900G Keihin FCR-MX 3900G
Main jet
168
168
168
172
Jet needle
OBETP
OBEKT
OBEKT
40
OBETP
Idling jet
40
40
40
Main air jet
200
200
200
200
Idling air jet
Needle position
Starting jet
100
100
100
100
5th from top
2nd from top
2nd from top
85
5th from top
85
85
85
Mixture control screw open
Slide
1.25
0.75
0.75
1.25
15
15
15
15
Performance restrictor
Stop pump membrane
–
–
Slide stop
858 / 2,15 mm
–
858 / 2,15 mm
858 / 2,15 mm
858 / 2,15 mm
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TECHNICAL DATA – ENGINE »
ENGINE
400 XC-W, EXC
450 XC
450 XC-W, EXC
525 XC
525 XC-W, EXC
Design
Liquid-cooled single cylinder 4-stroke engine with balancer shaft
Displacement
398 cc
449 cc
448 cc
510 cc
Bore/Stroke
89 / 64 mm
11 : 1
95 / 63,4 mm
12 : 1
89 / 72 mm
11 : 1
95 / 72 mm
11 : 1
Ratio
Fuel
unleaded fuel with at least RON 95 (USA = Premium PON 91)
4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain
Valve timing
Camshaft
595/0121
35 mm
590/5521
590/5521
590/5521
Valve diameter Intake
Valve diameter Exhaust
Valve clearence cold Intake
Valve clearence cold Exhaust
Crank shaft bearing
Connecting rod bearing
Top end bearing
Piston alluminium alloy
Piston rings
30 mm
0.10 - 0.15 mm (0,004 - 0,006 in)
0.10 - 0.15 mm (0,004 - 0,006 in)
2 cylinder roller bearing
needle bearing
bronze bushing
cast
forged
cast
forged
1 compression ring, 1 oil scraper ring
Engine lubrication
Engine oil
pressure circulation lubrication with two rotor pumps
full synthetic oil (Motorex Power Synt 4T 10W/50)
1.25 liters
56
Quantity of engine oil
Primary ratio
Primary ratio
Clutch
multiple disc clutch in oil bath, hydraulically operated (Motorex Kupplungsfluid 75)
Transmission claw shifted
6-speed
6-speed
6-speed
6-speed
6-speed
Gear ratio
1st Gear
14:34
17:31
14:34
17:31
14:34
17:31
16:32
18:30
14:34
17:31
2nd Gear
3rd Gear
19:28
22:26
24:23
26:21
20:28
22:26
24:24
21:18
19:28
22:26
24:23
26:21
20:28
22:26
24:24
21:18
19:28
22:26
24:23
26:21
4th Gear
5th Gear
6th Gear
Ignition system
Generator
contactless DC-CDI ignition with digital advanced system by KOKUSAN
12V 150W
Spark plug
NGK DCPR 8 E
0.6 mm (0.02367 in)
Spark plug gap
Cooling system
Cooling liquid
Starting equipment
liquid cooled, permanent rotation of cooling liquid through mechanically driven water pump
1 liter, 50% antifreeze, 50% destilled water, at least -25° (-13° F)
kick - electric starter
Engine oil
JASO T903 MA
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).
400/450/525:
+
10W/50
Poor oil quality or minor quantity cause early engine-wear.
0°C
32°F
5W/40
–
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TECHNICAL DATA – ENGINE »
BASIC CARBURATOR SETTING
400 XC-W
USA
400 EXC RACING
EU
Type
Keihin FCR-MX 3900D Keihin FCR-MX 3900E
Main jet
178
178
Jet needle
OBDVR
OBDVR
42
Idling jet
42
Main air jet
200
200
Idling air jet
Needle position
Starting jet
100
100
57
1st from top
1st from top
85
85
Mixture control screw open
Slide
1.25
1.25
15
15
Performance restrictor
Stop pump membrane
–
Slide stop
858 / 2.15 mm
858 / 2.15 mm
BASIC CARBURATOR SETTING
57
450 XC, XC-W
USA
450 EXC RACING
EU / AUS
450 EXC RACING
SIXDAYS
EU
Type
Keihin FCR-MX 3900E Keihin FCR-MX 3900E Keihin FCR-MX 3900E
Main jet
178
178
182
Jet needle
OBDVR
OBDVR
42
OBDTR
Idling jet
42
42
Main air jet
200
200
200
Idling air jet
Needle position
Starting jet
100
100
100
3rd from top
3rd from top
85
4th from top
85
85
Mixture control screw open
Slide
1.25
1.25
2.0
15
15
15
Performance restrictor
Stop pump membrane
–
Slide stop
858 / 2.15 mm
–
858 / 2.15 mm
858 / 2.15 mm
BASIC CARBURATOR SETTING
525 XC, XC-W
USA
525 EXC RACING EU
525 EXC RACING AUS
525 EXC RACING
SIXDAYS
525 XC DESERT RACING EU EU
Type
Keihin FCR-MX 3900F Keihin FCR-MX 3900F Keihin FCR-MX 3900F
Main jet
178
178
182
Jet needle
OBDVT
OBDVT
42
OBDTR
Idling jet
42
42
Main air jet
200
200
200
Idling air jet
Needle position
Starting jet
100
100
100
3rd from top
3rd from top
85
5th from top
85
85
Mixture control screw open
Slide
1.25
1.25
2.0
15
15
15
Performance restrictor
Stop pump membrane
–
Slide stop
858 / 2.15 mm
–
858 / 2.15 mm
858 / 2.15 mm
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TECHNICAL DATA – ENGINE »
TIGHTENING TORQUES – ENGINE 400/450/525
Hexagon collar screw, engine case, clutch cover, ignition cover
Oil drain plug
M6
10 Nm
M12x1.5
M16x1.5
M20x1.5
M5
20 Nm
Allan head plug, oil screen short
Hexagon plug, oil screen long
Oil + 10 Nm
15 Nm
Collar screw for oil filter cover
6 Nm
Plug pressure valve
M12x1.5
M8
20 Nm
Jet screw and hollow screw, oil line
Screws, oil pump cover
10 Nm
M5
Loctite 222 + 6 Nm
10 Nm
Hexagon collar screw, cylinder head top section
Hex.collar screw, cylinder head top section, water pump cover
Hexagon collar screw, exhaust flange
Cylinder head screw
M6
M6
10 Nm
M6
Loctite 243 + 10 Nm
Oil + 40/50 Nm
Loctite 243 + 28 Nm
6 Nm
M10
M8
Allan head screw, camshaft gear
Allan head screw, cap rocker arm
Counter nuts, valve adjustment screw
Allan head screw, primary gear, free wheel
Hexagon nut, primary gear
M5
M6x0.75
M6
11 Nm
Loctite 648 + 16 Nm
Loctite 243 + 150 Nm
Loctite 243 + 10 Nm
Loctite 243 + 120 Nm
Loctite 243 + 8 Nm
Loctite 243 + 10 Nm
Loctite 243 + 6 Nm
Loctite 243 + 6 Nm
Loctite 243 + 6 Nm
Loctite 243 + 6 Nm
10 Nm
M20x1.5 left
M6
Allan head screw, balancer shaft gear
Nut for inner clutch hub
M18x1.5
M6
58
Hexagon collar screw, clutch spring
Allan head screw, shift roller locking piece
Hexagon collar screw, locking lever
Hexagon collar screw, shift roller
Hexagon collar screw securing guide, chain guide, chain tensioner
Hexagon collar screw, clip
M6
M5
M5
M6
M5
Hexagon collar screw, chain adjuster
Hexagon collar screw, stator XC/EXC
Hexagon collar screw, pulser coil
Hexagon collar nut, flywheel
M6
M6
Loctite 243 + 10 Nm
Loctite 243 + 6 Nm
60 Nm
M5
M12x1
M6
Hexagon collar screw, bump part kickstarter
Hexagon collar screw, spring hanger kickstarter
Hexagon collar screw E-starter
Loctite 243 + 10 Nm
Loctite 243 + 10 Nm
10 Nm
M6
M6
Hexagon collar screw, hanger vent hose
Allan head screw, kickstarter
M6
Loctite 243 + 10 Nm
Loctite 243 + 25 Nm
Loctite 243 + 10 Nm
Loctite 243 + 60 Nm
10-12 Nm
M8
Hexagon collar screw, shift lever
Hexagon screw, engine sprocket
Spark plug
M6
M10
M10
M12x1.25
Spark plug
20 Nm
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TECHNICAL DATA – CHASSIS »
CHASSIS
250/400/450/525
Frame
Central tube chrome-moly-steel frame
Fork
WP Suspension – 4860 MXMA / MXMA + PA
300/335 mm
Wheel travel front/rear
Rear suspension
Front brake
Rear brake
Brake disc
Front tires
WP Suspension – 5018 PDS MCC / DCC, aluminium swing arm
Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated
Disk brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated
Wear limit max. 2,5 mm front and 3,5 mm rear
XC, XC-F, XC-W, XCF-W
80/100-21“
EXC, EXC-F
90/90-21“
Air pressure offroad
Air pressure road
1,0 bar
1,5 bar
Rear tires
250 XC-F, XCF-W
100/100-18“
250 EXC-F
120/90-18“
400/450/525 XC, XC-W
110/100-18“
400/450/525 EXC
140/80-18“
Air pressure offroad
Air pressure road
1,0 bar
2,0 bar
Fuel tank capacity
Final drive ratio
Chain
250 XC-F, XCF-W
250 EXC-F AUS
250 EXC-F EU
400/450/525
EXC EU
450/525 XC, XC-W 525 XC
450/525 EXC AUS DESERT RACING
9.5 liters (2.5US gal) 13 liters (3.5 US gal)
8,5 liters (2.2 US gal) 7 liters (2 US gal)
8 liters (2.1 US gal)
250 XC-F
13:48
250 XCF-W
13:52
250 EXC-F
14:38
400/450/525
XC, XC-W
14:50
400/450/525 EXC
525 XC DES. RAC.
15:45
59
5/8 x 1/4“
Available final sprockets 38, 40, 42, 45, 48, 49, 50, 51, 52
Bulbs (EXC)
headlight
12V 35/35W (socket BA20D)
12V 5W (socket W2, 1x9,5d)
12V 21/5W (socket BaY15d)
12V 10W (socket Ba15s)
parking light
brake - rear light
flasher light
Battery
maintenance-free battery 12V 4Ah
63.5°
Steering head angle
Wheel base
250: 1475 ± 10 mm (58 ± 0.4 in)
925 mm (36.5 in)
400/450/525: 1481 ± 10 mm (58.3 ± 0.4 in)
400/450/525: approx. 113 kg (248.6 lbs)
Seat height, unloaded
Ground clearance, unloaded 380 mm (15.1 in)
Weight (without fuel) 250: approx. 107 kg (235.4 lbs)
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TECHNICAL DATA – CHASSIS »
STANDARD ADJUSTMENT – FORK
250 XCF-W
250 EXC-F
400/450/525 XC-W
400/450/525 EXC
525 XC DESERT RACING
250 XC-F
250 EXC-F SIXDAYS
450/525 XC
450/525 EXC SIXDAYS
WP 4860 MXMA
14187C04
WP 4860 MXMA
14187C06
WP 4860 MXMA + PA WP 4860 MXMA + PA
14187C28
14187C29
Compression adjuster
Rebound adjuster
Spring
20
20
18
18
20
15
20
20
4.2 N/mm
–
4.4 N/mm
–
4.4 N/mm
2 turns
110 mm
SAE 5
4.6 N/mm
2 turns
110 mm
SAE 5
Spring preload
Air chamber length
Fork oil
110 mm
SAE 5
110 mm
SAE 5
STANDARD ADJUSTMENT – SHOCK ABSORBER
250 XCF-W
250 EXC-F
400/450/525 XC-W
400/450/525 EXC
525 XC DESERT RACING
250 XC-F
250 EXC-F SIXDAYS
450/525 XC
450/525 EXC SIXDAYS
WP 5018 PDS MCC
12187C04
15
WP 5018 PDS MCC
12187C06
15
WP 5018 PDS DCC
12187C28
WP 5018 PDS DCC
12187C29
Compression adjuster
15 LS (low speed)
1.0 HS (high speed)
15 LS (low speed)
1.0 HS (high speed)
60
Rebound adjuster
Spring
25
25
24
24
76/250
5 mm
80/250
5 mm
76/250
5 mm
80/250
5 mm
Spring preload
TIGHTENING TORQUES – CHASSIS
Collar screw, front wheel spindle
Brake caliper, front
M24x1,5
M8
40 Nm
Loctite 243 + 25 Nm
Loctite 243 + 40 Nm
14 Nm
Brake caliper, FTE radial front
Brake disks
M10x1,25
M6
Clamping screws, upper fork bridge XC-W, EXC
Clamping screws, lower fork bridge XC-W, EXC
Clamping screws, upper fork bridge XC, EXC SIXDAYS
Clamping screw, steering stem XC, EXC SIXDAYS
Clamping screws, lower fork bridge XC, EXC SIXDAYS
Clamping screws, fork stubs
M8
20 Nm
M8
15 Nm
M8
17 Nm
M8
Loctite 243 + 17 Nm
12 Nm
M8
M8
15 Nm
Hexagon nut, swing arm bolt
M16x1,5
M8
100 Nm
Hexagon collar screw, handlebar clamp
Allan head srew, handlebar support
Shock absorber, top
20 Nm
M10
M12
M12
M20x1,5
M8
Loctite 243 + 40 Nm
Loctite 243 + 70 Nm
Loctite 243 + 70 Nm
80 Nm
Shock absorber, bottom
Collar nut, swing arm bolt
Sprocket Screws
Loctite 243 + 35 Nm
10 Nm
Ball joint for push rod
M6
Engine mounting bolt
M10
M8
60 Nm
Engine brace
33 Nm
Spoke nipple
M4,5 / M5
M6
5 Nm
Screw adjusting ring spring preload shock abs.
Other screws on chassis
8 Nm
M6
M8
M10
M6
M8
10 Nm
25 Nm
45 Nm
15 Nm
30 Nm
50 Nm
Other collar nuts on chassis
M10
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HEAD WORD INDEX »
Page
Page
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . . . .5
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Filler cap (bayonet cap) . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Filler cap (screw cap) . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
General information about KTM disc brakes . . . . . . . . . . . .35
General tips and warnings for starting the motorcycle . . . . . .17
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . . . . . . . .7
How to change the handlebar position . . . . . . . . . . . . . . . .32
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Instructions for initial operation . . . . . . . . . . . . . . . . . . . . .17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Kilometers or miles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Maintenance work on chassis and engine . . . . . . . . . . . . . .27
Oil circuit (250-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Oil circuit (400/450/525) . . . . . . . . . . . . . . . . . . . . . . . . .48
Operation instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Overview of the electronic speedometer functions . . . . . . . .12
Periodic maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . . .15
Rebound damping of shock absorber . . . . . . . . . . . . . . . . .16
Refilling the front brake fluid reservoir . . . . . . . . . . . . . . . .36
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . . . .37
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Replacing headlight lamp/parking light lamp . . . . . . . . . . . .42
Replacing the battery of the digital speedometer . . . . . . . . .40
Replacing the front brake pads . . . . . . . . . . . . . . . . . . . . .37
Replacing the glassfiber yarn packing of the silencer . . . . . .44
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . . . .38
Running in the XC/EXC models . . . . . . . . . . . . . . . . . . . . .17
Serial number locations . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Short circuit button (XC) . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Starting when the engine is cold . . . . . . . . . . . . . . . . . . . .18
Starting when the engine is warm . . . . . . . . . . . . . . . . . . . .19
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Technical Data – Chassis . . . . . . . . . . . . . . . . . . . . . . . . . .59
Technical Data – Engine . . . . . . . . . . . . . . . . . . . . . . . . . .54
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Use after a period of storage . . . . . . . . . . . . . . . . . . . . . . .53
What to do when the engine is „flooded“ . . . . . . . . . . . . . .19
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .appendix
WS (wheel size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Activating and deactivating display modes . . . . . . . . . . . . . .9
Adjusting the free travel at the hand brake lever . . . . . . . . .36
Adjusting the mixture control screw . . . . . . . . . . . . . . . . . .47
Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . . . .45
Basic information on carburetor wear . . . . . . . . . . . . . . . . .47
Basic suspension setup for the weight of the driver . . . . . . .28
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . . . . .46
Bleeding the cooling system (250-F) . . . . . . . . . . . . . . . . .44
Bleeding the cooling system (400/450/525) . . . . . . . . . . . .43
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Carburetor – Adjust idling (Keihin-FCRMX 37/39/41) . . . . . .47
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Changing the basic position of the foot brake pedal . . . . . . .37
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Changing the fork offset (caster) (XC, EXC SIXDAYS) . . . . . .31
Changing the oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Changing the original position of the clutch lever . . . . . . . . .46
Changing the spring preload on the telescopic fork
(XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Changing the spring preload on the telescopic fork
61
(XC-W/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Changing the spring preloading of the shock absorber . . . . .27
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Check the following before each start . . . . . . . . . . . . . . . . .18
Check/set distance of the magnetic sensor . . . . . . . . . . . . .40
Checking and adjusting the steering head bearing . . . . . . . .30
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Checking the basic setup of the telescopic fork . . . . . . . . . .29
Checking the brake fluid level - front brake . . . . . . . . . . . . .36
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . . . .43
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . .48
Checking the float level (float height) . . . . . . . . . . . . . . . . .47
Checking the front brake pads . . . . . . . . . . . . . . . . . . . . . .36
Checking the oil level of the hydraulic clutch (250-F) . . . . .46
Checking the oil level of the hydraulic clutch (400/450/525) . .46
Checking the rear brake fluid level . . . . . . . . . . . . . . . . . . .37
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . . . .38
Checking the shock absorber and spring . . . . . . . . . . . . . . .28
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Cleaning the dust sleeves of the telescopic fork . . . . . . . . . .30
Cleaning the spark arrester (XC-W USA) . . . . . . . . . . . . . . .44
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . . . .6
Compression damping of fork . . . . . . . . . . . . . . . . . . . . . . .15
Compression damping of shock absorber
(XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Compression damping of shock absorber (XC-W, EXC) . . . . .16
Conservation for winter operation . . . . . . . . . . . . . . . . . . . .53
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Determining the riding sag of the shock absorber . . . . . . . . .28
Determining the static sag of the shock absorber . . . . . . . . .28
Dismounting and mounting the front wheel . . . . . . . . . . . . .38
Dismounting and mounting the rear wheel . . . . . . . . . . . . .39
Draining the float chamber of the carburetor . . . . . . . . . . . .48
Driving instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . . . . .7
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62
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SCHALTPLAN » WIRING DIAGRAM
headlight
multi-func.-digital-speedometer
driving light lamp
flasher control lamp
front
brake switch
1
wh
bu
gn
ye
re
br
ye-bl
br
bl-wh
ye-re
br
ye-re
br
ye-re
or
bu-wh
br
C
D
I
ye-bl
re-wh
re-bl
gn
or
pu
bl
re
bu
ye
bl
ye-bl
ye-re
wh-re
br
bl
bl
black
ye
bu
br
re
ye-re
br
gn
bl
re-bl
wh-re
re-wh
ye-re
ye
wh
ye
wh-gn
rear light/brakelight
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SCHALTPLAN » WIRING DIAGRAM
headlight
multi-func.-digital-speedometer
2
br
ye-bl
bl-wh
bu-wh
br
C
ye-bl
wh
ye
re-wh
re-bl
gn
D
re
bu
ye
I
bl
ye-re
wh-re
bl
black
ye
bu
br
re
ye-re
br
gn
br
re-bl
wh-re
re-wh
ye-re
ye
wh
rear light/brakelight
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SCHALTPLAN » WIRING DIAGRAM
ENGLISH
DEUTSCH
ITALIANO
Battery
Batterie
Batteria
Cooling fan
Lüftermotor
Motorino ventola
Driving light lamp
Flasher control lamp
Flasher relay
Front brake switch
Generator
Fernlichtkontrolle
Blinkerkontrolle
Blinkerrelais
vorderer Bremslichtschalter
Generator
spia abbagliante
spia lampeggiatori
Relè indicatori
Interruttore luce ant. di stop
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
Horn
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Multi-func.-digital-speedometer
Pick up
Auf-Abblendschalter
Hupe
Zündspule
Commutatore abbagliante/anabbagliante
Avvisatore acustico
Bobina d‘accensione
Interruttore d‘accensione
Indicatore ant. sx
Indicatore post. sx
Tachimetro digitale multifunzione
Pick up
3
Zündschloss
linker vorderer Blinker
linker hinterer Blinker
Multifunktionsdigitaltacho
Impulsgeber
Position light
Standlicht
Luce di posizione
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Speed sensor
hinterer Bremslichtschalter
hinteres Begrenzungslicht / Bremslicht
Regelgleichrichter
rechter vorderer Blinker
Rechter hinterer Blinker
Geschwindigkeitssensor
Starttaster
Interruttore luce post. di stop
Luce post. di posizione/stop
Regolatore-raddrizzatore
Indicatore ant. dx
Indicatore post. dx
Sensore velocità
Start button
Start relay
Pulsante d´avviamento
Relè d‘avviamento
Startrelais
Starter motor
Stop button
Throttle position sensor (TPS)
Startermotor
Not-Aus-Schalter
Vergaserpotentiometer
Motorino d‘avviamento
Interrutore di aresto dèmergenza
Potenziometro carburatore (sensore TPS)
CABLE COLOURS
bl: black
ye: yellow
bu: blue
KABELFARBEN
bl: schwarz
ye: gelb
CAVO COLORATO
bl: nero
ye: giallo
bu: blau
bu: blu
gn: green
re: red
gn: grün
re: rot
gn: verde
re: rosso
wh: white
br: brown
or: orange
pi: pink
wh: weiß
br: braun
or: orange
pi: rosa
wh: bianco
br: marrone
or: arancione
pi: rosa
gr: grey
gr: grau
gr: grigio
pu: purple
pu: violett
pu: violetto
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SCHALTPLAN » WIRING DIAGRAM
ENGLISH
FRANCAIS
ESPANOL
Battery
Batterie
Batería
Cooling fan
Ventilateur
Motor del ventilador
Driving light lamp
Flasher relay
Flasher control lamp
Front brake switch
Generator
temoin feu route
Relais de clignotants
temoin de clignoteur
Contacteur de frein avant
Alternateur
lampara aviso luces largas
Relé de la luz intermitente
lampara aviso intermitentes
Interruptor de luz del freno delantero
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
Horn
Ignition coil
Ignition switch
Left front flasher
Left rear flasher
Multi-func.-digital-speedometer
Pick up
Contacteur code/phare
Avertisseur sonore
Interruptor de encender/apagar la luz larga
Cláxon
Bobina de encendido
Cerradura de encendido
Luz intermitente izquierda delantera
Luz intermitente izquierda trasera
Velocímetro digital multifuncional
Generador de impulsos
4
Bobine d’allumage
Contacteur d’allumage
Clignotant avant gauche
Clignotant arrière gauche
Ordinateur de bord
Capteur d’allumage
feu de position
Position light
luz de posicion
Rear brake switch
Rear light / brakelight
Regulator-rectifier
Right front flasher
Right rear flasher
Speed sensor
Contacteur de frein arrière
Feu rouge/stop
Régulateur/redresseur
Clignotant avant droit
Clignotant arrière droit
Capteur de vitesse
Interruptor de luz del freno trasero
Luces de parqueo traseras /luces de freno
Regulador rectificador
Luz intermitente derecha delantera
Luz intermitente derecha trasera
Sensor de velocidad
Start button
Start relay
Starter motor
Stop button
bouton de démarrage
Relais de démarreur
Démarreur
bouton d´arrêt d`urgence
Capteur d’ouverture de carburateur
botón de arranque
Relé del arranque
Motor de arranque eléctrico
interruptor de parada de emergencia
Potenciómetro del carburador
Throttle position sensor (TPS)
CABLE COLOURS
bl: black
COULEUR DE CABLE
bl: noir
COLOR DE CABLE
bl: negro
ye: yellow
bu: blue
ye: jaune
bu: bleu
ye: amarillo
bu: azul
gn : green
re: red
wh: white
br: brown
or: orange
pi: pink
gn: vert
gn: verde
re: rojo
re: rouge
wh: blanc
br: brun
or: orange
pi: rose
wh: blanco
br: marron
or: naranja
pi: rosado
gr: gris
gr: grey
gr: gris
pu: purple
pu: violet
pu: violeta
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KTM Group Partner
KTM-Sportmotorcycle AG
A–5230 Mattighofen
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