OWNER’S MANUAL 2006 250 SX-F 250 EXC RACING 400 EXC RACING 450 SX, XC, EXC RACING 525 SX, XC, EXC RACING ENGLISH ART. NR. 3.211.
IMPORTANT » Please read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly.
INTRODUCTION » We would like to congratulate you on your purchase of a KTM motorcycle. ENGLISH 2 You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION » KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.
TABLE OF CONTENTS » Page IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION . . . . . . . . . . . . . .3 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number, engine type . . . . . . . . . . . . . . . . . . . .5 ENGLISH 4 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot start lever (250 SX-F) . . . . . . . . . . .
SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. ENGLISH Engine number, engine type 5 OPERATION INSTRUMENTS » Clutch lever The clutch lever [1] is located on the left side of the handlebar.
OPERATION INSTRUMENTS » Hot start lever (250 SX-F) 1 If you pull the red hot start lever [1] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean“ fuel-air mixture of the type needed for hot starts. Hand decompression lever (450/525 SX) 2 ENGLISH The hand decompression lever [2] is needed only if the carburetor overflows after a fall.
OPERATION INSTRUMENTS » Headlamp switch (EXC USA) In this model the headlamp is switched on with the pull switch [1]. 1 The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system.
OPERATION INSTRUMENTS » Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The | button is used to change between display modes. The + and – buttons are used to control various functions.
OPERATION INSTRUMENTS » Activating and deactivating display modes In the display mode SPEED/H, press and hold the | button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blinking function can be activated by pressing the + button and deactivated by pressing the – button. Press and hold the | button 3 seconds to store the settings. If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode.
OPERATION INSTRUMENTS » LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds. Press the + button to access the next lap time. To clear all of the stored lap times, hold the | button for 3 seconds in the SPEED/LAP mode. + button – button briefly press | button hold | button 3 secs.
OPERATION INSTRUMENTS » SPEED / A2 display mode (average speed 2) A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip. + button – button briefly press | button hold | button 3 secs.
OPERATION INSTRUMENTS » Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the | button for 3 seconds. The blinking digits can be changed using the + and - buttons. Press the | button to move to the next digit. 012 will show the time in the 12-hour mode, 0-24 in the 24-hour mode. Press and hold the | button for 3 seconds to store the settings.
OPERATION INSTRUMENTS » 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. Fuel tap In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor.
OPERATION INSTRUMENTS » Shift lever 2,3,4 (5,6) The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. N 1 Kickstarter ENGLISH The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. 14 Foot brake pedal The foot brake pedal is located in front of the right footrest.
OPERATION INSTRUMENTS » Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap [1]. Turn the adjusting screws [2] clockwise to increase damping, turn it counterclockwise to reduce damping during compression.
OPERATION INSTRUMENTS » Compression damping of shock absorber (XC, EXC) The compression damping (during compression) can be adjusted for the XC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [1] with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping. 2 STANDARD ADJUSTMENT: – turn the adjusting screw clockwise to the stop.
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – Make sure the work for the „pre-delivery inspection“ was performed 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.
DRIVING INSTRUCTIONS » Check the following before each start When you start off, the motorcycle must be in perfect technical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage.
DRIVING INSTRUCTIONS » – MAXIMAL PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. – DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV UP THE ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE. 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.
DRIVING INSTRUCTIONS » NOTE: Dedicated to nothing but offroad racing, 250/400/450/525 SX/XC/EXC Racing models make no compromises in their design. As such, they do not include any radiator fan, and the size of the radiator is dimensioned for optimum ergonomics. In normal racing, the cooling system is sufficient. If you use your motorbike in other conditions, please note that: the E-starter allows you to start XC/EXC Racing models again at any time.
PERIODIC MAINTENANCE » 250 SX-F 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Change engine oil, oil filter z Check and adjust valve clearance z z Check engine mounting bolts for tightness z z Clean the spark-plug connector and check for a tight fit z z Check the screws on the kick starter and shift lever for a tight fit z z Replace spark plug (after 30 hours) z Check carburetor connection boot for cracks and leaks Check idle speed setting z z Check vent hoses fo
PERIODIC MAINTENANCE » 250 SX-F 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start Check oil level z Check brake fluid level z Check brake pads for wear z After every cleaning For crosscountry use z Lubricate and adjust cables and nipples Bleed fork legs regularly z Remove and clean fork dust bellows regularly z z Clean and lubricate chain, check tension and adjust if necessary z z Clean air filter and filter box ENGLISH 22 at least once a year Check ti
PERIODIC MAINTENANCE » WHEELS CHASSIS BRAKES ADD- ON PARTS CARBURETOR ENGINE A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 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) 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 Verg
PERIODIC MAINTENANCE » 250/400/450/525 SX/XC/EXC 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start Check oil level z Check brake fluid level z Check brake pads for wear z Check lights for function z Check horn for function z For crosscountry use ENGLISH Bleed fork legs regularly z Remove and clean fork dust bellows regularly z z Clean and lubricate chain, check tension and adjust if necessary z z Clean air filter and filter box Check tires for pressure
PERIODIC MAINTENANCE » 250/400/450/525 SX/XC/EXC 2006 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP) Check the clutch disks for wear every 30 hours 200 liter z Check the length of the clutch springs every 45 hours 300 liter z z z z Check the cylinder and piston for wear z Check the groove on the piston pin retainer for wear (visual check) z Check the camshaft for wear (visual check) z Replace the cams
PERIODIC MAINTENANCE » 250/400/450/525 SX/XC/EXC 2006 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR HOBBY USE (ADDITIONAL ORDER FOR THE KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx.
MAINTENANCE WORK ON CHASSIS AND ENGINE » – 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver AA To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing).
MAINTENANCE WORK ON CHASSIS AND ENGINE » WP12187B06 WP12187B26 250/400/450/525XC/EXC 450/525 XC USA 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.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the fork offset (caster) (SX) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the handling to match the race course. A 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.
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 10 Nm in 3 stages. Adjust the steering head bearing without clearance (see: Checking and adjusting the steering head support) and tighten the clamp screws on the upper triple clamp to 17 Nm in 3 stages.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 8 - 10 mm (0.31 - 0.39 in). In the course of this procedure, the upper chain portion [A] must be taut (see drawing). If necessary, correct the chain tension.
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).
MAINTENANCE WORK ON CHASSIS AND ENGINE » General information about KTM disc brakes BRAKE CALIPERS: The brake calipers of this series use a „floating“ mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to „float“ for maximum braking contact. Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm. FRONT: TOSHIBA H 38 (SINTERED) – harder to dose, good brake performance, long life, for wet slippery terrain.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the free travel at the hand brake lever 1 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the front brake pads * 1 Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips [1] and pull out bolt [2]. Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and grease guide bolts if necessary. Mount the right brake pad and fix it with the bolt.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the rear brake pads min. 1 mm The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in). AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.
MAINTENANCE WORK ON CHASSIS AND ENGINE » – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE. – AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS. – IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Tires, air pressure Tire type, tire condition, and air pressure level affect the way your motor-cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in the homologation certificate – Tire condition has to be checked every time you want to ride your motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Battery (XC, EXC) 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 service life. TOPLITE TO REMOVE THE BATTERY: First disconnect the negative pole, then the positive pole from the battery.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Fuse (XC/EXC) A 2 The fuse [1] is located in the starter relay of the E-starter [2] underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover [A], you will be able to see the fuse. The following loads are connected to it: – E-starter system – horn – flasher lights – electronic speedometer The starter relay also contains a (10 amp) spare fuse [3]. Replace a blown fuse only with an equivalent one.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 250 SX-F 1 2 1 Cooling system Coolant is circulated by a water pump [1] located in the engine. When the engine is cold the coolant only circulates through the cylinder and the cylinder head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat [2] opens and the coolant is also pumped through both aluminum radiators. Air blowing in through the radiators cools the coolant.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Bleeding the cooling system (250 SX-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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accumulated. To clean, lift the filter box cover [1] (see illustration) and pull off towards the front. Detach the bottom of the filter retaining bracket [2], tilt aside and remove the throttle cap [3] and the air filter [4] and filter support [5] from the filter box. The SX models do not have a throttle cap.
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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) * The idle speed is controlled by means of the adjusting wheel [1] and the mixture control screw [2]. The adjusting wheel is used to adjust the basic setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system. Clockwise turning reduces the fuel quantity (lean mixture), counterclockwise turning increases the fuel quantity (rich mixture).
MAINTENANCE WORK ON CHASSIS AND ENGINE » Draining the float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes malfunctioning. Perform this task on a cold engine. Close the fuel tap and put one end of the hose [1] into a collecting vessel.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Engine oil JASO T903 MA TEMPERATUR 0°C 32°F 5W/40 10W/50 Automobile engine oil used to be used for four-stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four-stroke motorcycles - the JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines require a higher power output at higher speeds.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the oil filters 2 1 Remove the screw [1] and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws [2] and dismount the two oil filter covers. 2 2 ENGLISH Using circlip pliers, pull the oil-filter inserts [3] out of the housing. Clean the oil filter cover, the sealing surfaces of the O-rings and the engine casing.
TROUBLESHOOTING » TROUBLE Engine doesn’t crank (E-starter). CAUSE Operating errror REMEDY Turn on the emergency-OFF switch (Australia only) Blown fuse Dismount the left paneling and the filter box cover and replace the fuse in the starter relay. Discharged battery. Recharge the battery and investigate the causes for discharging; contact a KTM dealer. Low outside temperature Start the engine with the kickstarter Engine cranks but doesn’t start (E- Operating error starter).
TROUBLESHOOTING » TROUBLE Engine does not rev high CAUSE REMEDY Carburetor fuel level too high because float Dismount carburetor and check if worn out needle valve is dirty or worn out Loose carburetor jets Tighten jets Electronic ignition timing faulty Have ignition system checked Engine will not reach full power Fuel supply partially interrupted or carbu- Clean and check fuel system as well as carburetor retor dirty Replace the float Air filter very dirty Clean or replace air filter Exhaust system
CLEANING » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. – You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should also be cleaned with the help of a paint brush.
TECHNICAL DATA – ENGINE » ENGINE 250 SX-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.8 : 1 Fuel unleaded fuel with at least RON 95 Valve timing 4 valves controlled by finger levers and 2 camshafts, driven by a pair of spur gears and a tooth-type chain ENGLISH 54 Camshaft 05 Valve diameter Intake 30.9 mm Valve diameter Exhaust 26.5 mm Valve clearence cold Intake 0.10 - 0.20 mm (0.004 - 0.
TECHNICAL DATA – ENGINE » 10 Nm Oil drain plug M12x1.5 20 Nm Allen head plug, oil screen short M16x1.5 Oil + 10 Nm Hexagon plug, oil screen long M20x1.5 15 Nm Collar screw for oil filter cover M5 6 Nm Plug pressure valve M12x1.
TECHNICAL DATA – ENGINE » ENGLISH 56 ENGINE 250 EXC 400 EXC 450 SX Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 250 cc Bore/Stroke 75 / 56.5 mm 89 / 64 mm 95 / 63.4 mm 95 / 63.
TECHNICAL DATA – ENGINE » BASIC CARBURATOR SETTING 400 EXC RACING EU 400 EXC-G RACING USA 450 EXC RACING EU Type Keihin FCR-MX 3700B Keihin FCR-MX 3900D Keihin FCR-MX 3900D Keihin FCR-MX 3900E Main jet 160 178 178 178 Jet needle OBEKT OBDVR OBDVR OBDVR Idling jet 42 42 42 42 Main air jet 200 200 200 200 Idling air jet 100 100 100 100 Needle position 3rd from top 1st from top 1st from top 3rd from top Starting jet 85 85 85 85 Mixture control screw open 0,75 1,25 1,2
TECHNICAL DATA – ENGINE » TIGHTENING TORQUES – ENGINE 250/400/450/525 SX/XC/EXC ENGLISH 58 Hexagon collar screw, engine case, clutch cover, ignition cover M6 10 Nm Oil drain plug M12x1.5 20 Nm Allan head plug, oil screen short M16x1.5 Oil + 10 Nm Hexagon plug, oil screen long M20x1.5 15 Nm Collar screw for oil filter cover M5 6 Nm Plug pressure valve M12x1.
TECHNICAL DATA – CHASSIS » CHASSIS 250 SX-F, 450/525 SX Frame Central tube chrome-moly-steel frame 250/400/450/525 XC/EXC 450/525 XC, EXC USA Fork WP 4860 MA/PA Wheel travel front/rear 300/335 mm Rear suspension WP Progressive Damping System shock absorber, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated Brake disc Wear limit max.
TECHNICAL DATA – CHASSIS » TIGHTENING TORQUES – CHASSIS ENGLISH 60 Collar screw, front wheel spindle M24x1,5 40 Nm Brake caliper, front M8 Loctite 243 + 25 Nm Brake caliper, FTE radial front M10x1,25 Loctite 243 + 40 Nm Brake disks M6 Loctite 243 + 14 Nm Clamping screws, upper fork bridge EXC M8 20 Nm Clamping screws, lower fork bridge EXC M8 15 Nm Clamping screws, upper fork bridge SX M8 17 Nm Clamping screws, lower fork bridge SX M8 12 Nm Clamping screws, fork stubs M8 15 Nm H
Page 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 (XC, EXC) . . . . . . . . . . . . . . . . . . . . . . . . . .41 Bleeding of the hydraulic clutch . . . . . . . . . . .
ENGLISH 62
ANHANG – APPENDICE APPENDIX – APÉNDICE SCHALTPLAN » WIRING DIAGRAM 1 black stop button brown ignition coil yellow-black blue-white 250 SX-F 2005/06 generator 3 gr een red CDI harness - 594.39.032.000 I G red-white red-black C D pick up 20.02.
SCHALTPLAN » WIRING DIAGRAM ANHANG – APPENDICE APPENDIX – APÉNDICE black 2 stop button brown yellow-black blue-white SX 450-525 2005-06 ignition coil generator 3 gr een red CDI harness - 594.39.032.000 I G red-white red-black C D pick up 20.02.
flasher control lamp right front flasher pu bl bl flasher switch re M wh gn re ye br ye-bl bu br wh-re bl start relay 10 A ye G ye-re start button starter motor c o o l in g f an 3 re-wh f lasher relay ye-re or G pu high/low beam switch horn switch stop button horn ye-re br black bl bl h and l e ba r sw itch ( op t i o n al ) re ye-re or gn re wh br-bl ye-re br ye-bl bl bu br bl wh-re re-bl wh generator battery ye-re br wh ye br bl wh gn-wh br br pu 59
SCHALTPLAN » WIRING DIAGRAM multi-func.-digital-speedometer re h and l e ba r sw itch ( op t i o n al ) stop switch light switch starter motor gn wh-re black bl br 10 A start relay 3 ye G ye-re wh generator re-wh start button M wh-re re-bl bu wh c o o l i n g f an p i c k up br main h arn ess battery br ye-re wh ye wh br 594.11.075.100 regulator-rectifier U 2 5. 02 .
ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Front brake switch Generator DEUTSCH Batterie Lüftermotor Fernlichtkontrolle Blinkerkontrolle Blinkerrelais vorderer Bremslichtschalter Generator Handle bar switch for multi-func.
SCHALTPLAN » WIRING DIAGRAM ANHANG – APPENDICE APPENDIX – APÉNDICE 6 ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Front brake switch Generator FRANCAIS Batterie Ventilateur temoin feu route Relais de clignotants temoin de clignoteur Contacteur de frein avant Alternateur Handle bar switch for multi-func.
5/2005 FOTO: MITTERBAUER KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.
