User manual KTM 250 XCF-W

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 (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 ENGLISH 4 . . .15 . . .16 . . .16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 .17 .17 .18 .18 .18 .19 .19 .19 .19 .20 .20 .20 .21 .27 .27 .27 .28 .28 .28 .28 .29 . . .29 . . . . . . . . . . . . . . .29 .29 .30 .30 .30 .31 .32 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 ENGLISH 5 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 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"). ENGLISH 6 B 3 Short circuit button (XC) 4 The short circuit button [4] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) 6 5 The light switch has 2, respectively 3 switch positions. [A] = Light off (this function is not available in all models) [B] = Low beam on [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 OPERATION INSTRUMENTS » Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [1]. 1 Flasher switch Flasher left Flasher right 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. 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. 3 4 Pushing the black starter button [4] will actuate the E-starter. Indicator lamps 6 The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on. 5 ENGLISH 7 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. TEST All of the display segments briefly light up for the display function test. ENGLISH 8 WS (wheel size) The display changes and the circumference of the front wheel is briefly displayed 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 motorcycles, 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 ­ button briefly press button hold button 3 secs. no function no function changes to the next display mode 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). 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. + button ­ button briefly press hold activates the blinking display deactivates the blinking display changes to the next display without changing any settings starts the SETUP stores the settings and changes to the SPEED/H mode button button 3 secs. The following display modes can be activated: TR1 tripmaster 1 TR2 tripmaster 2 A1 average speed 1 A2 average speed 2 S1 stop watch 1 S2 stop watch 2 CLK clock LAP lap time MAX maximum speed KMH/MPH display in kilometers or miles (see: Kilometers or miles) 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 ­ button briefly press button hold button 3 secs. no function no function changes to the next display mode 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 ­ button Starts and stops the stop watch, lap time is not reset to 0 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 continues to run after you press the - button, all 10 memory 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. Changes to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. Clears all LAP figures briefly press hold button button 3 secs. ENGLISH 9 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. changes to the next lap time no function changes to the next display mode changes to the next display mode SPEED / MAX display mode (maximum speed) MAX displays the maximum speed traveled and is always active. ENGLISH 10 + button ­ button briefly press button hold button 3 secs. no function no function changes to the next display mode clears the MAX figure SPEED / TR1 display mode (tripmaster 1) The TR1 tripmaster is always active and counts to 999.9. It is used to measure 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 activated 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 ­ button briefly press button hold button 3 secs. no function no function changes to the next display mode 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 useful function for trips taken according to a roadbook. + button ­ button briefly press button hold button 3 secs. increases the TR2 figure decreases the TR2 figure changes to the next display mode 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 ­ button briefly press button hold button 3 secs. no function no function changes to the next display mode clears the TR1, S1, A1 figures 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. no function no function changes to the next display mode changes to the next display mode SPEED / S1 display mode (stop watch 1) + button ­ button briefly press button hold button 3 secs. no function no function changes to the next display mode clears the TR1, S1, A1 figures 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 ­ button briefly press button hold button 3 secs. starts and stops the stop watch no function changes to the next display mode 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 seconds 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 display returns to the SPEED/H mode. If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode. + button ­ button briefly press hold button to access the menu to activate the KMH display to activate the MPH display changes to the next mode changes from the menu to the SETUP menu stores and closes the SETUP menu button 3 secs. ENGLISH 11 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 activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received. 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. If no button is pressed for 20 seconds, the settings will be stored automatically and the display will return to the SPEED/CLK mode. + button ­ button briefly press button hold button 3 secs. time + time changes to the next digit starts the SETUP menu stores the time and changes to the SPEED/CLK display mode Motorcycle is driving Motorcycle is standing ENGLISH 12 OVERVIEW OF THE ELECTRONIC SPEEDOMETER FUNCTIONS display SPEED / H briefly press + button no function no function starts/stops LAP without clearing LAP figure next figure no function no function no function increases the TR2 figure no function no function no function starts - stops S2 briefly press ­ button no function no function stops LAP, stores LAP figure, resets LAP to 0 no function no function no function no function reduces the TR2 figure no function no function no function no function briefly press button hold button 3 secs. X X X X X X X X X X X X X X X X X X X X X 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 next display mode next display mode displays the SETUP menu Setting the clock menu clears all LAP figures next display mode clears MAX next display mode clears TR1, S1, A1 clears TR2 clears TR1, S1, A1 next display mode clears TR1, S1, A1 clears S2 SPEED / CLK SPEED / LAP LAP / LAP SPEED / MAX SPEED / ODO SPEED / TR1 SPEED / TR2 SPEED / A1 SPEED / A2 SPEED / S1 SPEED / 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. 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) Install the tank breather hose [1] without kinks. 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 2 Choke If you pull the choke button [2] out as far as possible, a bore in the carburetor 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. ENGLISH 13 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. OPERATION INSTRUMENTS » Shift lever 2,3,4 (5,6) N 1 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. Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. ENGLISH 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 1 Push the side stand to the ground with your foot and load it with the motorcycle. Make sure that you put your bike on solid ground and in a secure position. For off-road riding, you can use the rubber band [1] to additionally secure the center stand in its folded-up position 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. OPERATION INSTRUMENTS » Compression damping of fork 1 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. 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 14187C28 . . . . . . . 18 clicks WP 14187C06 . . . . . . . 20 clicks WP 14187C29 . . . . . . . .18 clicks 2 2 Rebound damping of fork 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 14187C28 . . . . . . . 20 clicks WP 14187C06 . . . . . . . 15 clicks WP 14187C29 . . . . . . . .20 clicks Changing the spring preload on the telescopic fork (see page 29) Compression damping of shock absorber (XC, EXC SIXDAYS) The shock absorber on these models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression 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 compression 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. 6 STANDARD LOW-SPEED SETTING: ­ turn the adjusting screw [4] to the limit in a clockwise direction using a screwdriver . ­ 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 nitrogen. 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). ENGLISH 15 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. 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. 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 WP 12187C06 . . . . . . . 15 clicks The damping unit of the shock absorber is filled with high-compression nitrogen. 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). 2 1 ENGLISH 16 Rebound damping of shock absorber 3 4 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 counterclockwise to reduce damping during rebounding. 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 . . . . . . . 25 clicks WP 12187C28 . . . . . . . 24 clicks WP 12187C06 . . . . . . . 25 clicks WP 12187C29 . . . . . . . .24 clicks The damping unit of the shock absorber is filled with high-compression nitrogen. 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). GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for initial operation ­ 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. ­ 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: ­ Motorcycle ready for operation and tank full ­ Luggage ­ Driver with protective clothing and helmet. ­ Pay attention to the running-in procedure. ­ Wear suitable clothing when driving a motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regardless 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 motorcycle. Cases, extra tanks, etc. can alter the weight distribution 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 person 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 recognized 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 motorcycle to keep you company, so that you can help each other should difficulties arise. ­ 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. Running in the XC/EXC models Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding 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 offroad competition purposes only. "On the road" approved models are only allowed on public roads in the original homologated (throttled) version. Avoid extended on-road rides at full throttle. ENGLISH 17 DRIVING INSTRUCTIONS » Check the following before each start When you start off, the motorcycle must be in perfect technical condition. For safety reasons, you should make a habit of performing an overall 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. 2 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. 3 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 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. 5 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 complete 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 CABLES Check correct setting and easy running of all control cables. 7 COOLING FLUID Check the level of the cooling fluid when the engine is cold. 8 ELECTRICAL SYSTEM Check correct functioning of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running. 9 LUGGAGE If you are taking luggage with you, check that this is securely fastened. B A ENGLISH 18 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 actuate the E-starter. 1 ­ 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 kickstarter, or the engine may kick back and propel your foot upward with great force. DRIVING INSTRUCTIONS » ­ Always kick the kickstarter briskly all the way without opening the throttle. If you do not Kick hard enought, with an open throttle grip, the kickback 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 provide 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. ­ 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.When the motorcycle has been out of operation for more than a week, it is therefore 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. 2 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 throttle 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. ENGLISH 19 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. Therefore, turn off the engine if you intend to run your motorcycle 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). ­ 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. ­ 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 easily get out of control. ­ If any abnormal vibrations occur while driving, check that the engine fastening bolts are tight. ­ In the event that, while riding on your motorcycle, you notice any unusual operation-related noise, stop immediately, turn the engine off, and contact an authorized KTM dealer. the fuel tap to the OFF position, park on an area where the ground is firm, and lock the motorcycle. Motorcycle engines produce a great amount of heat while running. The engine, exhaust pipe, muffler, brake rotors, and shock absorbers can become very hot. Do not touch any of these parts after operating the motorcycle, and take care to park it where pedestrians are not likely to touch it and get burned. ­ 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 carburettor can flood and fuel will enter the engine. ­ Never park your motorcycle in places where there are fire hazards due to dry grass or other easily flammable materials. ENGLISH 20 NOTE REGARDING THE SIDE STAND: Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways. Make sure that the ground is solid and that your motorcycle is standing securely. Just in case, you can shift into first gear. The side stand is designed to bear only the load of the motorcycle. The side stand and/or the frame can be damaged and the motorcycle can fall over if you mount the motor-cycle, thus putting an additional load on the side stand. Braking 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. When driving down hill, use the braking effect of the engine. 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. ­ 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 pulled until they are dry or clean. ­ Rides on salt-strewed or dirty roads can also delay the braking effect. The brakes must be pulled until they are clean. ­ Dirty brake discs cause increased tear of brake pads and brake discs. ­ When you brake, the brake discs, brake pads, brake caliper and brake fluid heat up. The hotter these parts get, the weaker the breaking effect. In extreme cases, the entire braking system can fail. ­ If the resistance in the hand brake lever or foot brake pedal feels "spongy" (too much play), this is an indication that something is wrong with the brake system. Don't ride your motorcycle anymore without first having the brake system looked over by a KTM dealer. Fuel The engine needs unleaded fuel with at least RON 95 (USA = Premium PON 91). Use leaded or unleaded premium grade gasoline (95 octanes). Never use gasoline having less than 95 octanes because it may damage the engine. Gasoline is highly flammable and poisonous. Extreme caution should be used when handling gasoline. Do not refuel the motorcycle near open flames or burning cigarettes. Always switch off the engine before refuelling. Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot. Wipe up spills promptly. If gasoline is swallowed or splashed in the eyes, seek a doctor's advice immediately. Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.). 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 PERIODIC MAINTENANCE » 250-F 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! Change engine oil, oil filter Clean oil screen and drain plug magnet ENGINE 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 CARBURETOR Check carburetor connection boot for cracks and leaks Check idle speed setting Check cooling system for leaks, check quantity of antifreeze Check exhaust system for leaks and fitment ADD-ON PARTS Check cables for damage, smooth operation and bends, adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems (low high beam, brake light, indicator lamps, speedometer illumination, horn, emergency OFF switch or button Check brake fluid level, lining thickness, brake discs BRAKES 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 CHASSIS Bleed fork legs Check swing arm bearings Check/adjust steering head bearings Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber) Check/adjust steering head bearings WHEELS 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 Check vent hoses for damage or bends 1st service after 3 hours or 20 l fuel every 20 hours or 140 l fuel or 1 race ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor 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. every 2 years 250-F 2007 ENGLISH 21 PERIODIC MAINTENANCE » 250-F 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start 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 level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance 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 After every cleaning For crosscountry use at least once a year ENGLISH 22 250-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 RACING 70 liter 140 liter 270 liter 540 liter is equivalent to approx. 15 operating hours HOBBY-USE every 20 hours every 40 hours ­­­ every 80 hours 140 liter 270 liter 540 liter Check the clutch disks for wear 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 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 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) NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. PERIODIC MAINTENANCE » 400/450/525 2007 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 Check carburetor connection boot for cracks and leaks Check idle speed setting 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 Check fluid level of the clutch master cylinder Clean air filter and filter box Check electric wires for damage and bends Check headlamp setting Check function of electric systems (low high beam, brake light, indicator lamps, speedometer illumination, horn, emergency OFF switch or button 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 Check/adjust steering head bearings Check tightness of chassis screws (triple clamps, fork leg axle passage, swingarm, shock aborber) 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 1st service after 3 hours or 20 l fuel every 15 hours or 100 l fuel or 1 race CARBURETOR ENGINE ADD- ON PARTS WHEELS CHASSIS BRAKES 400/450/525 2007 ADDITIONAL SERVICE WORK THAT MUST BE PERFORMED UNDER A SEPARATE ORDER at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor 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. every 2 years ENGLISH 23 PERIODIC MAINTENANCE » 400/450/525 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start 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 After every cleaning For crosscountry use At least once a year ENGLISH 24 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 level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance 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 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 Check the clutch disks for wear 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 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 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) NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. Check the length of the valve springs ENGLISH 25 ENGLISH 26 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. 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). 1 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 counterclockwise will reduce the preload, turning it clockwise will increase the preload. 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 Tefloncoated 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 highpressure spray directly at the pivot bearing. 3 ENGLISH 27 ­ 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 contaminates 1,000,000 liters of water. 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 (wearing 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 accordingly. 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. SPRING RATE ENGLISH 28 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. ­ 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." B B C C Determining the riding sag of the shock absorber ­ 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). 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. After installing a different spring, readjust the static sag to 35 mm (± 2 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. WP12187C06, WP12187C29 WP12187C04, WP12187C28 80/250 76/250 76/250 72/250 84/250 80/250 65 70 75 80 85 90 95 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 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) 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 counterclockwise 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 various 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 WP14187C06, WP14187C28 WP14187C04 SPRING RATE 4,6 N/mm 4,4 N/mm 4,2 N/mm 4,4 N/mm 4,2 N/mm 4,0 N/mm 4,8 N/mm 4,6 N/mm 4,4 N/mm If you weigh less than 75 kg or more than 85 kg, you should install the respective fork springs. The correct spring rate is shown in the illustrations. The standard 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. If you are uncertain which spring to use, contact your KTM workshop. 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 ENGLISH 29 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. 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 having the seals replaced. 1 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. ENGLISH 30 2 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 considerably reduce the tire's road grip and the braking effect of the front brake. Checking and adjusting the steering head bearing * 4 Check steering head bearing for play periodically. To check, put the motorcycle 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, otherwise the bearings will be damaged. With a plastic hammer, lightly tap on the triple clamp to release tension. Retighten the five pinch bolts. 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) ­ If the steering head bearing is not adjusted to be free of play, the motorcycle 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 bearings 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). 3 5 3 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 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 1 The offset is set to 20 mm in the condition at delivery. 4 3 5 2 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). 3 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 protection ring [4]. Tap gently on the lower triple clamp with a rubber hammer to loosen the steering stem [5] out of the bearing seat. Take the lower triple clamp with the steering stem out of the steering head. 4 2 5 Remove the collar screw from the lower triple clamp and pull out the steering 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. ­ 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 ENGLISH 31 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. 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 Mount Mount Mount the the the the front wheel fender and tighten the screws to 10 Nm. hand brake cylinder and tighten the screws to 10 Nm. staring number plate. front wheel (see: Dismounting and mounting the front wheel). ENGLISH 32 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. 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 center by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in 4 different positions. 3 4 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 support and the handlebar clamps should be the same size in the front and in the rear. The screws [4] must be secured with loctite 243. mm 15 2 3,5 mm 1 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check chain tension A 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. ­ 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 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. 8-1 0m m/ 0.30.4 in Correct chain tension B 1 3 2 Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting screws [3] equally far. Tighten lock nuts. 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. Tighten collar nut [1] to 80 Nm. ­ 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. 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°. 4 2 4 B 3 ENGLISH 33 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. ENGLISH 34 Chain wear 15 KG 33 lbs 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. 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 123 16 17 18 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. A 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 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 service limit. ­ Have any repairs on the brake system be performed by a KTM dealer. 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 necessary to top up the brake fluid. If the brake fluid level drops below the minimum 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 motorcycle 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. 1 ENGLISH 35 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. 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. 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. 1 min. 3 mm Checking the brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar 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 authorized KTM dealer immediately. ENGLISH 36 3 2 Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4]. Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir 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. ­ 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. ­ 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. 4 5 mm min. 1 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. 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. MAINTENANCE WORK ON CHASSIS AND ENGINE » 1 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. 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]. ­ 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. 2 3 4 2 2 1 Changing the basic position of the foot brake pedal * 6 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]. Measured on the outside, the foot brake pedal must have 3-5 mm (0.12­0.20 in) of free play before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). 3-5mm 5 If this free play is not present, then pressure can build up in the brake system when driving, causing the rear wheel to brake.The braking system overheats and may even fail completely in extreme cases. Checking the rear brake fluid level The reservoir for the rear brake disk is located on the right side of the motorcycle 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 authorized 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 7 ­ 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. ­ 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. ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » min. 1 mm Checking the rear brake pads 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. 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 * 1 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. ENGLISH 38 2 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]. ­ 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 4 To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. 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). 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. 5 A 6 B 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). 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 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. 7 Dismounting and mounting the rear wheel 2