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 ENGLISH 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 Engine number Key number Stamp of dealer All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. © 2006 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only. COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. In accordance with the international quality management ISO 9001 standard, KTM uses quality assurance processes that lead to the highest possible product quality. ENGLISH 1 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 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. 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: ENGLISH 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. IMPORTANT INFORMATION » We expressly point out that work marked with an asterisk in the chapter ,,Maintenance work on the chassis 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 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. 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. 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 ENGLISH 3 TABLE OF CONTENTS » INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . Engine number, engine type . . . . . . . . . . . . . . . . . . Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . Short circuit button (XC) . . . . . . . . . . . . . . . . . . . . . Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . . Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency OFF switch (EXC Australia) . . . . . . . . . . . Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . Activating and deactivating display modes . . . . . . . . Overview of the electronic speedometer functions . . . Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . Filler cap (bayonet cap) . . . . . . . . . . . . . . . . . . . . . . Filler cap (screw cap) . . . . . . . . . . . . . . . . . . . . . . . Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression damping of fork . . . . . . . . . . . . . . . . . Rebound damping of fork . . . . . . . . . . . . . . . . . . . . Compression damping of shock absorber (XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . Compression damping of shock absorber (XC-W, EXC) Rebound damping of shock absorber . . . . . . . . . . . . GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . Instructions for initial operation . . . . . . . . . . . . . . . . Running in the XC/EXC models . . . . . . . . . . . . . . . . DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Check the following before each start . . . . . . . . . . . . Starting when the engine is cold . . . . . . . . . . . . . . . Starting when the engine is warm . . . . . . . . . . . . . . What to do when the engine is ,,flooded" . . . . . . . . . Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . Changing the spring preloading of the shock absorber Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic suspension setup for the weight of the driver . . Checking the shock absorber and spring . . . . . . . . . . Determining the static sag of the shock absorber . . . . Determining the riding sag of the shock absorber . . . . Checking the basic setup of the telescopic fork . . . . . Changing the spring preload on the telescopic fork (XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . Changing the spring preload on the telescopic fork (XC-W/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . Cleaning the dust sleeves of the telescopic fork . . . . . Checking and adjusting the steering head bearing . . Changing the fork offset (caster) (XC, EXC SIXDAYS) . How to change the handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page . . .1 . . .2 . . .5 . . .5 . . .5 . . .6 . . .6 . . .6 . . .6 . . .6 . . .7 . . .7 . . .7 . . .7 . . .7 . . .8 . . .9 . .12 . .12 . .13 . .13 . .13 . .13 . .14 . .14 . .14 . .14 . .14 . .15 . .15 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 . . . . . ...