KTM 400 EXC RACING manual

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.39 250 EXC RACING 400 EXC RACING 450 SX, MXC, EXC RACING 525 SX, MXC, EXC RACING BEDIENUNGSANLEITUNG 2005[...]

ENGLISH 1 IMPORTANT » 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, se[...]

ENGLISH 2 INTRODUCTION » W e would like to congratulate you on your purchase of a KTM motorcycle. Y ou 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 . Before you go for your first ride, be sure to read this manual carefully and [...]

ENGLISH 3 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION » KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations. Observance of the serv[...]

ENGLISH 4 TABLE OF CONTENTS » Page IMPOR T ANT LIMITED WARRANTY AND LIMITED GUARAN- TEE INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . .[...]

ENGLISH 5 SERIAL NUMBER LOCATIONS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1.[...]

ENGLISH 6 OPERATION INSTRUMENTS » Clutch lever The clutch lever [1] is located on the left side of the handlebar . The adjust- ing screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically . Hand decompression lever The h[...]

ENGLISH 7 OPERATION INSTRUMENTS » Headlamp switch (EXC USA) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar . The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the enti[...]

ENGLISH 8 OPERATION INSTRUMENTS » TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly dis- played in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires). Afterwards the display will ret[...]

ENGLISH 9 OPERATION INSTRUMENTS » SPEED / LAP (lap time) display mode Y ou can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds. + button Starts and stops the stop watch, lap time is not reset to 0 – button Stops th[...]

ENGLISH 10 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. T o clear all of the stored l[...]

ENGLISH 11 OPERATION INSTRUMENTS » 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. T o select the unit, select the SPEED/H mode and hold the | button for 3 sec- onds to access the SETUP menu. Press the | button u[...]

ENGLISH 12 OPERATION INSTRUMENTS » Setting the clock T o set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the | button for 3 seconds. The blinking digits can be changed using the + and - buttons. Press the | button to move to the next digit. 0- 12 will show the time in the 12-hour mode, 0-24 in the 24-hour mode.[...]

ENGLISH 13 OPERATION INSTRUMENTS » Filler cap To open the filler cap: T urn the filler cap counter -clockwise. To close the filler cap: Put the filler cap on and tighten it by turning it clockwise. Install the tank breather hose [1] without kinks. Choke If you pull the choke button [2] out as far as possible, a bore in the carbure- tor will be ope[...]

ENGLISH 14 OPERATION INSTRUMENTS » Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear . Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. Foot brake [...]

ENGLISH 15 OPERATION INSTRUMENTS » Compression damping of fork Hydraulic compression damping determines the reaction when the fork is com- pressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap [1] . T urn the adjusting screws [2] clockwise to increase damping, turn it coun[...]

ENGLISH 16 OPERATION INSTRUMENTS » Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [1] with a screwdriver . T urning in a clockwise direction will increase th[...]

ENGLISH 17 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – WEAR SUIT ABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER KTM DRIVERS AL WA YS WEAR A HELMET , BOOTS, GLOVES AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DA Y OR JUST FOR A SHOR T TRIP . THE PROTECTIVE CLOTHING SHOULD BE BRIGHTL Y COLORED SO THA T OTHER VEHICLES CAN SEE YOU[...]

ENGLISH 18 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 [...]

ENGLISH 19 DRIVING INSTRUCTIONS » Starting when the engine is cold 1 Open the fuel tap [1] . 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke [2] . 5 Leave throttle closed and kick the kickstarter briskly ALL THE W A Y or actu- ate the E-starter . – IF YOU W ANT TO ST ART THE ENGINE, MAKE SURE THA T YOU A[...]

ENGLISH 20 DRIVING INSTRUCTIONS » NOTE: Dedicated to nothing but offroad racing, 250/400/450/525 SX/MXC/EXC Racing models make no compromises in their design. As such, they do not include any radiator fan, and the size of the radiator is dimensioned for optimum ergonomics. In normal racing, the cooling system is sufficient. If you use your motorbi[...]

ENGLISH 21 PERIODIC MAINTENANCE » A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1. service after 3 hours or 20 l fuel after/every 15 hours or 100 l fuel ENGINE Change engine oil, short and long oil filters z z Clean oil screen and drain plug magnet z z Check oil lines for damage or bends z z Replace spark plug (after 30 hours) [...]

ENGLISH 22 PERIODIC MAINTENANCE » IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use Check oil level z Check brake fluid level z Check brake pads for wear z Check lights for function z Check horn for function z Lubricate and adjust cables and nipples z Bleed fork legs regul[...]

ENGLISH 23 PERIODIC MAINTENANCE » RECOMMENDED INSPECTION OF THE 250/400/450/525 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) a 100 liter fuel consumption is equivalent to approx. 15 operating hours 15 hours 100 liter 30 hours 200 liter 45 hours 300 liter 60 hours 400 liter 90 hours 600[...]

ENGLISH 24 PERIODIC MAINTENANCE » RECOMMENDED INSPECTION OF THE 250/400/450/525 EXC ENGINE USED FOR HOBBY - ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) a 100 liter fuel consumption is equivalent to approx. 15 operating hours 30 hours 200 liter 60 hours 400 liter 90 hours 600 liter 120 hours 800 liter 180 hours [...]

ENGLISH 25 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 thr[...]

ENGLISH 26 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o 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 motorcycle[...]

ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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. Checking the basic setup of the telescopic fork The precise ridin[...]

ENGLISH 28 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. T o do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcyc[...]

ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » B A 2 1 3 2 5 4 3 4 5 2 Changing the fork offset (caster) (SX) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course. Remove the blind screw [1] to see which offs[...]

ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » 15 mm 3,5 mm 1 2 3 4 Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw . T ighten the collar screw on the lower triple clamp to 80 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 [...]

ENGLISH 31 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 8 - 10 mm (0.31 - 0.39 in). In the course of this proce[...]

ENGLISH 32 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 be[...]

ENGLISH 33 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 calip[...]

ENGLISH 34 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[...]

ENGLISH 35 MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the front brake pads * 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 [...]

ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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). A T THEIR MOST WORN POINT BRAKE P AD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE F AILURE. FOR YOUR OWN SAFETY DON’T PUT[...]

ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » – IF YOU DON’T HAPPEN TO HA VE A TORQUE WRENCH A T HAND, MAKE SURE YOU HA VE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MA Y LEAD TO AN UNST ABLE DRIVING BEHA V- IOR OF YOUR MOTORCYCLE. – AFTER MOUNTING THE FRONT WHEEL, KEEP OPERA TING THE HAND BRAKE U[...]

ENGLISH 38 MAINTENANCE WORK ON CHASSIS AND ENGINE » Tires, air pressure T ire type, tire condition, and air pressure level affect the way your motor -cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – T ire size can be found in the technical specifications and in the homolo- gation certi[...]

ENGLISH 39 MAINTENANCE WORK ON CHASSIS AND ENGINE » Battery (MXC/EXC) The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water . Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary . Removing the battery: First disconnect the [...]

ENGLISH 40 MAINTENANCE WORK ON CHASSIS AND ENGINE » Fuse (MXC/EXC) The fuse [1] is located in the starter relay of the E-starter [2] underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover [A] , you will be able to see the fuse. The following loads are connected to it: – E-starter syst[...]

ENGLISH 41 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cooling system Coolant is circulated by a water pump [1] located in the engine. When the engine is cold the coolant only circulates through the cylinder and the cylin- der head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat [2] opens and the coolant [...]

ENGLISH 42 MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. The effect of heat causes the glassfiber yarn to become loose. This may lead to a loss of performance and reduce the silencer's muffling power . By experience, the fron[...]

ENGLISH 43 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accu- mulated. T o clean, lift the filter box cover [1] (see illustration) and pull off towards the front. Detach the bottom of the filter retaining bracket [2] , tilt aside and remove the throttle ca[...]

ENGLISH 44 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the original position of the clutch lever The adjusting screw [1] can be used for individual adjustment of the original position of the clutch lever , thus allowing adjustment to an optimal position for every hand size. T urning the adjusting screw clockwise reduces the distance between [...]

ENGLISH 45 MAINTENANCE WORK ON CHASSIS AND ENGINE » CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) * Idling adjustment of the carburetor strongly affects the engine’ s starting behavior . That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly . The idl[...]

ENGLISH 46 MAINTENANCE WORK ON CHASSIS AND ENGINE » Draining the float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. W ater in the float chamber causes malfunctioning. Perform this task on a cold engine. Close th[...]

ENGLISH 47 MAINTENANCE WORK ON CHASSIS AND ENGINE » Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard. Whereas car engines req[...]

ENGLISH 48 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the oil filters Remove the screw [1] and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws [2] and dismount the two oil filter covers. Using circlip pliers, pull the oil-filter inserts [3] out of the housing[...]

ENGLISH 49 TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine doesn’t crank (E-starter). Operating errror Blown fuse Discharged battery . Low outside temperature T urn on the emergency-OFF switch (Australia only) Dismount the left paneling and the filter box cover and replace the fuse in the starter relay . Recharge the battery and investigate the ca[...]

ENGLISH 50 TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine does not rev high Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition timing faulty Dismount carburetor and check if worn out T ighten jets Have ignition system checked Engine will not reach full power Fuel supply partially[...]

ENGLISH 51 CLEANING » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH[...]

ENGLISH 52 TECHNICAL DATA - ENGINE » TYPE 250 EXC 400 EXC 450 SX 450 MXC 450 EXC 525 SX 525 MXC-G 525 EXC 525 MXC DESERT Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 250 cm 3 398 cm 3 449 cm 3 448 cm 3 510 cm 3 Bore/Stroke 75 / 56,5 mm 89 / 64 mm 95 / 63,4 mm 89 / 72 mm 95 / 72 mm Ratio 12 : 1 11 : 1 Fuel u[...]

ENGLISH 53 TECHNICAL DATA - ENGINE » BASIC CARBURATOR SETTING 250 EXC RACING EU / AUS 11 kW 400 EXC RACING EU / AUS 12 kW 400 EXC-G RACING USA 450 EXC RACING EU / AUS 12 kW T ype Keihin FCR-MX 3700A Keihin FCR-MX 3900C Keihin FCR-MX 3900C Keihin FCR-MX 3900A Main jet 160 178 178 178 Jet needle OBEKT OBDVR OBDVR OBDVR Idling jet 42 42 42 42 Main ai[...]

ENGLISH 54 TECHNICAL DATA - ENGINE » Engine oil Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). POOR OIL QUALITY OR MINOR QUANTITY CAUSE EA[...]

ENGLISH 55 TECHNICAL DATA - CHASSIS » CHASSIS 450/525 SX 250/400/450/525 EXC/MXC DESERT 450/525 MXC-G, EXC-G USA Frame Central tube chrome-moly-steel frame Fork 4860 P A/MA WP Up Side Down 4860 MA Wheel travel front/rear 300/335 mm Rear suspension WP Progressive Damping System shock absorber , aluminium swing arm Front brake Disk brake with carbon[...]

ENGLISH 56 TECHNICAL DATA - CHASSIS » TIGHTENING TORQUES - CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm Brake caliper , FTE radial front M10x1,25 Loctite 243 + 40 Nm Brake disk M6 Loctite 243 + 10 Nm Clamping screws, upper fork bridge EXC M8 20 Nm Clamping screws, lower fork bridge EXC M8 15[...]

ENGLISH 57 HEAD WORD INDEX » Activating and deactivating display modes . . . . . . . . .9 Adjusting the free travel at the hand brake lever . . . . .34 Adjusting the mixture control screw . . . . . . . . . . . . .45 Adjusting the throttle cables . . . . . . . . . . . . . . . . . . .43 Basic suspension setup for the weight of the driver . . .26 Bat[...]

ENGLISH 58[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAMM[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAMM[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAMM[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 4 SCHALTPLAN » WIRING DIAGRAMM ENGLISH DEUTSCH IT ALIANO Battery Batterie Batteria Cooling fan Lüftermotor Motorino ventola Driving light lamp Fernlichtkontrolle spia abbagliante Flasher control lamp Blinkerkontrolle spia lampeggiatori Flasher relay Blinkerrelais Relè indicatori Front brake switch vord[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 5 SCHALTPLAN » WIRING DIAGRAMM ENGLISH FRANCAIS ESP ANIOL Battery Batterie Batería Cooling fan V entilateur Motor del ventilador Driving light lamp temoin feu route lampara aviso luces largas Flasher relay Relais de clignotants Relé de la luz intermitente Flasher control lamp temoin de clignoteur lampa[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 6[...]

KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART. NR. 3.211.39 250 EXC RACING 400 EXC RACING 450 SX, MXC, EXC RACING 525 SX, MXC, EXC RACING BEDIENUNGSANLEITUNG 2005[...]