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 ENGLISH ART. NR. 3.211.145 EN 5/2006 FOTO: MITTERBAUER KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.
INTRODUCTION » We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below Frame number ENGLISH Engine number Key number 1 Stamp of dealer All information contained is without obligation.
IMPORTANT INFORMATION » ENGLISH 2 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 international 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.
IMPORTANT INFORMATION » WARRANTY The service work specified in the „Lubrication and Maintenance Schedule“ must be performed and service 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.
TABLE OF CONTENTS » ENGLISH 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . Engine number, engine type . . . . . . . . . . . . . . . . . . Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand brake lever . . .
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.
OPERATION INSTRUMENTS » Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting 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 ENGLISH The hand brake lever [3] is mounted on the handlebars on the right and actuates the front wheel brake.
OPERATION INSTRUMENTS » Headlamp switch (XC-W) 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 (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. 1 To open the filler cap: Turn the filler cap counter-clockwise. To close the filler cap: Put the filler cap on and tighten it by turning it clockwise. Install the tank breather hose [1] without kinks. ENGLISH Filler cap (screw cap) 13 Fuel tap OFF In this position the fuel tap is closed.
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-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, 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, XC/EXC 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 models again at any time.
PERIODIC MAINTENANCE » 250-F 2007 every 20 hours or 140 l fuel or 1 race z Change engine oil, oil filter z Clean oil screen and drain plug magnet z 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
PERIODIC MAINTENANCE » 250-F 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start ENGLISH 22 Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid leve
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 Chec
PERIODIC MAINTENANCE » 400/450/525 2007 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 and wear z
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.
ENGLISH 26
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 75 - 85 kg (wearing full protective clothing).
MAINTENANCE WORK ON CHASSIS AND ENGINE » Checking the basic setup of the telescopic fork ENGLISH 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.
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) (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 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 12 Nm in 3 stages. Adjust the steering head bearing without clearance (see: Checking and adjusting the steering head support). Apply Loctite 243 to the thread of the middle clamp screw.
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 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 lining type is stated on the back of the brake pad and also recorded in the homologation papers. ENGLISH BRAKE CALIPERS: The brake calipers of this series use a „floating“ mount.
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 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 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. 1 – If electrolyte (sulphuric acid) leaks from the battery, proceed with great care. The electrolyte can cause severe burns.
MAINTENANCE WORK ON CHASSIS AND ENGINE » Fuse 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-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-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 XC 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. 400/450/525: 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 250-F: 10W/50 5W/40 400/450/525: + 5°C 41°F 0°C 32°F – 10W/50 5W/40 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.
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 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. Check the O-rings of the oil filter covers for damage and, if necessary, replace them.
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 XC-F Design Liquid-cooled single cylinder 4-stroke engine 250 XCF-W, EXC-F Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.8 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91) Valve timing 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 Valve diameter Intake 30.9 mm Valve diameter Exhaust 26.
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 » 400 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 95 / 63,4 mm 89 / 72 mm 95 / 72 mm Ratio 11 : 1 12 : 1 11 : 1 11 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91) Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft 595/0121 Valve diameter Intake 35 mm Valve diameter Exhaust 30 mm V
TECHNICAL DATA – ENGINE » BASIC CARBURATOR SETTING 400 EXC RACING EU Type Keihin FCR-MX 3900D Keihin FCR-MX 3900E Main jet 178 178 Jet needle OBDVR OBDVR Idling jet 42 42 Main air jet 200 200 Idling air jet 100 100 Needle position 1st from top 1st from top Starting jet 85 85 Mixture control screw open 1.25 1.25 Slide 15 15 Performance restrictor – Slide stop Stop pump membrane 858 / 2.15 mm 858 / 2.
TECHNICAL DATA – ENGINE » TIGHTENING TORQUES – ENGINE 400/450/525 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 250/400/450/525 Frame Central tube chrome-moly-steel frame Fork WP Suspension – 4860 MXMA / MXMA + PA Wheel travel front/rear 300/335 mm Rear suspension WP Suspension – 5018 PDS MCC / DCC, 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 » STANDARD ADJUSTMENT – FORK ENGLISH 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 14187C28 WP 4860 MXMA + PA 14187C29 Compression adjuster 20 20 18 18 Rebound adjuster 20 15 20 20 Spring 4.2 N/mm 4.4 N/mm 4.4 N/mm 4.
Activating and deactivating display modes . . . . . . . . . . . Adjusting the free travel at the hand brake lever . . . . . . . Adjusting the mixture control screw . . . . . . . . . . . . . . . . Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . . Basic information on carburetor wear . . . . . . . . . . . . . . . Basic suspension setup for the weight of the driver . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding of the hydraulic clutch .
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flasher control lamp right f ront f lasher br pu bl bl M wh gn br re ye ye-bl bu br wh-re bl G ye-re 10 A start rel ay 3 ye wh generator re-wh start butt on starter motor cooling fan wh-re re-bl flasher switch re flasher relay ye-re or G pu high/low beam switch horn switch stop button horn ye-re br black bl bl handle bar switch (optional) ye-re re or gn re br-bl ye-re br ye-bl bl bu wh br bl ye-bl gn pick up batt ery rear brake switch br ye-re wh ye bl
SCHALTPLAN » WIRING DIAGRAM multi-func.-digital-speedometer handle bar switch (optional) stop switch light switch M gn wh-re black bl br 10 A start rel ay 3 ye G ye-re wh generator re-wh start butt on starter motor wh-re re-bl re wh wh ye-bl bu cooling fan pick up br batt ery ye-re br wh ye main harness 594.11.075.100 wh br regulator-rectifier U 0 8. 04 .
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 4 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.
BEDIENUNGSANLEITUNG 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 DEUTSCH ART. NR. 3.211.145 DE 5/2006 FOTO: MITTERBAUER KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.