KTM 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 manuel d'utilisation
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Un bon manuel d’utilisation
Les règles imposent au revendeur l'obligation de fournir à l'acheteur, avec des marchandises, le manuel d’utilisation KTM 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. Le manque du manuel d’utilisation ou les informations incorrectes fournies au consommateur sont à la base d'une plainte pour non-conformité du dispositif avec le contrat. Conformément à la loi, l’inclusion du manuel d’utilisation sous une forme autre que le papier est autorisée, ce qui est souvent utilisé récemment, en incluant la forme graphique ou électronique du manuel KTM 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 ou les vidéos d'instruction pour les utilisateurs. La condition est son caractère lisible et compréhensible.
Qu'est ce que le manuel d’utilisation?
Le mot vient du latin "Instructio", à savoir organiser. Ainsi, le manuel d’utilisation KTM 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 décrit les étapes de la procédure. Le but du manuel d’utilisation est d’instruire, de faciliter le démarrage, l'utilisation de l'équipement ou l'exécution des actions spécifiques. Le manuel d’utilisation est une collection d'informations sur l'objet/service, une indice.
Malheureusement, peu d'utilisateurs prennent le temps de lire le manuel d’utilisation, et un bon manuel permet non seulement d’apprendre à connaître un certain nombre de fonctionnalités supplémentaires du dispositif acheté, mais aussi éviter la majorité des défaillances.
Donc, ce qui devrait contenir le manuel parfait?
Tout d'abord, le manuel d’utilisation KTM 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 devrait contenir:
- informations sur les caractéristiques techniques du dispositif KTM 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
- nom du fabricant et année de fabrication KTM 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
- instructions d'utilisation, de réglage et d’entretien de l'équipement KTM 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
- signes de sécurité et attestations confirmant la conformité avec les normes pertinentes
Pourquoi nous ne lisons pas les manuels d’utilisation?
Habituellement, cela est dû au manque de temps et de certitude quant à la fonctionnalité spécifique de l'équipement acheté. Malheureusement, la connexion et le démarrage KTM 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 ne suffisent pas. Le manuel d’utilisation contient un certain nombre de lignes directrices concernant les fonctionnalités spécifiques, la sécurité, les méthodes d'entretien (même les moyens qui doivent être utilisés), les défauts possibles KTM 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 et les moyens de résoudre des problèmes communs lors de l'utilisation. Enfin, le manuel contient les coordonnées du service KTM en l'absence de l'efficacité des solutions proposées. Actuellement, les manuels d’utilisation sous la forme d'animations intéressantes et de vidéos pédagogiques qui sont meilleurs que la brochure, sont très populaires. Ce type de manuel permet à l'utilisateur de voir toute la vidéo d'instruction sans sauter les spécifications et les descriptions techniques compliquées KTM 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, comme c’est le cas pour la version papier.
Pourquoi lire le manuel d’utilisation?
Tout d'abord, il contient la réponse sur la structure, les possibilités du dispositif KTM 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, l'utilisation de divers accessoires et une gamme d'informations pour profiter pleinement de toutes les fonctionnalités et commodités.
Après un achat réussi de l’équipement/dispositif, prenez un moment pour vous familiariser avec toutes les parties du manuel d'utilisation KTM 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. À l'heure actuelle, ils sont soigneusement préparés et traduits pour qu'ils soient non seulement compréhensibles pour les utilisateurs, mais pour qu’ils remplissent leur fonction de base de l'information et d’aide.
Table des matières du manuel d’utilisation
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Page 1
KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 5/2006 FOTO: MITTERBAUER 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 OWNER’S MANUAL 2007 ART. NR. 3.211.145 EN ENGLISH[...]
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Page 2
ENGLISH 1 INTRODUCTION » 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,[...]
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ENGLISH 2 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 interna- tional motorcycle associations. The XC and other „competition only“ labe[...]
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ENGLISH 3 IMPORTANT INFORMATION » W e expressly point out that work marked with an asterisk in the chapter „Maintenance work on the chas- sis 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 sho[...]
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Page 5
TABLE OF CONTENTS » ENGLISH 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . . .5 Engine number , engine type . . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . .[...]
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Page 6
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 5[...]
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Page 7
A B C OPERATION INSTRUMENTS » 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"). Combination switch (EXC) The light switch has 2, respectively 3 switch position[...]
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Page 8
OPERATION INSTRUMENTS » Headlamp switch (XC-W) 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 entire turn indic[...]
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Page 9
OPERATION INSTRUMENTS » ENGLISH 8 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[...]
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Page 10
OPERATION INSTRUMENTS » ENGLISH 9 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[...]
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OPERATION INSTRUMENTS » ENGLISH 10 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[...]
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Page 12
OPERATION INSTRUMENTS » ENGLISH 11 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[...]
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Page 13
OPERATION INSTRUMENTS » ENGLISH 12 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.[...]
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Page 14
OPERATION INSTRUMENTS » ENGLISH 13 1 2 XC EXC Filler cap (bayonet cap) To open the filler cap: T urn 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) To open the filler cap: T urn the filler cap counter -clockwise. To close the filler cap: Put the filler cap[...]
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OPERATION INSTRUMENTS » ENGLISH 14 2,3,4 (5,6) 1 N 1 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 swiv[...]
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1 2 2 3 3 5 6 4 OPERATION INSTRUMENTS » ENGLISH 15 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 dampi[...]
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Page 17
OPERATION INSTRUMENTS » ENGLISH 16 2 1 4 3 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 . T urning in a clockwise direction will increase the[...]
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Page 18
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » ENGLISH 17 – W ear suitable clothing when driving a motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regard- less 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 ear[...]
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Page 19
1 DRIVING INSTRUCTIONS » ENGLISH 18 A B 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 re[...]
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2 DRIVING INSTRUCTIONS » ENGLISH 19 – Always kick the kickstarter briskly all the way without opening the throt- tle. If you do not Kick hard enought, with an open throttle grip, the kick- back 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 consciousnes[...]
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Page 21
DRIVING INSTRUCTIONS » ENGLISH 20 35 mm NOTE: Dedicated to nothing but offroad racing, XC/EXC models make no compromises in their design. As such, they do not include any radi- ator 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 conditi[...]
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Page 22
PERIODIC MAINTENANCE » ENGLISH 21 250-F 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20 l fuel every 20 hours or 140 l fuel or 1 race ENGINE Change engine oil, oil filter z z Clean oil screen and drain plug magnet z z Replace spark plug (after 30 hours) Check and adjust valve clearance z z Che[...]
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Page 23
PERIODIC MAINTENANCE » ENGLISH 22 NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced. 250-F 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use at least once a year Check oil level z Check brake fluid[...]
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Page 24
PERIODIC MAINTENANCE » ENGLISH 23 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 . 400/450/525 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20 l f[...]
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Page 25
PERIODIC MAINTENANCE » ENGLISH 24 400/450/525 2007 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use At least once a year 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 cabl[...]
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Page 26
PERIODIC MAINTENANCE » ENGLISH 25 400/450/525 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 RACING A 100 liter fuel consumption is equivalent to approx. 15 operating hours HOBBY-USE every 15 hours[...]
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Page 27
ENGLISH 26[...]
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Page 28
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 27 A 3 1 2 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 [...]
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Page 29
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 28 A B B C 65 SPRING RA TE 70 75 80 85 90 95 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 80/250 76/250 84/250 80/250 76/250 72/250 WP12187C06, WP12187C29 WP12187C04, WP12187C28 A B C Basic suspension setup for the weight of the driver T o achieve maximum handling performance and to prevent the fork, s[...]
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Page 30
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 29 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 fre[...]
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Page 31
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 30 1 5 4 3 3 2 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 [...]
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Page 32
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 31 B A 2 1 3 2 5 4 3 4 5 2 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 han- dling to match the race course. Remove the blind screw [1] to se[...]
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Page 33
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 32 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 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 12 Nm in 3 [...]
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Page 34
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 33 8-10 mm / 0.3-0.4 in A 2 3 1 4 B 2 B 3 4 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 (0.3[...]
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Page 35
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 34 15 KG 33 lbs max. 272 mm 1 2 3 16 17 18 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 oth[...]
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Page 36
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 35 A 1 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 c[...]
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Page 37
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 36 5 mm min. 3 mm 1 3 2 4 min. 1 mm 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 a[...]
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Page 38
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 37 3-5mm 1 1 2 2 1 2 4 3 6 5 A B 7 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 [...]
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Page 39
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 38 min. 1 mm 1 2 3 4 5 6 A B 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[...]
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Page 40
MAINTENANCE WORK ON CHASSIS AND ENGINE » 3 ENGLISH 39 7 1 2 – 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 un[...]
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Page 41
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 40 1 2 3 1 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- gati[...]
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Page 42
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 41 VOL T 2 3 1 Battery The battery is located under the seat and is maintenance-free. Maintenance-free means you will not need to check the acid level. Clean the battery terminals regularly and grease with acid-free grease if necessary . The charge condition and type of charge are very important for[...]
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Page 43
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 42 2 A 1 3 4 6 5 5 Fuse 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-starte[...]
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Page 44
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 43 when engine is cold 10 mm 3 4 5 6 1 1 2 400/450/525 250-F 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[...]
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Page 45
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 44 XC EXC C 6 5 3 7 3 7 5 C 4 6 A B 2 1 EXC-F Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart). The insulating material fibe[...]
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Page 46
MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the throttle cables * The throttle grip should always provide for a backlash of 3-5mm. Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. T o adjust the throttle cables, dismount the seat and the tank together with spoiler[...]
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Page 47
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 46 1 2 4 3 6 5 7 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 counterclockwise reduces [...]
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Page 48
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 47 1 2 3 4 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 .[...]
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Page 49
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 48 3 4 5 6 7 8 9 10 11 12 13 15 14 28 20 22 21 23 24 25 26 29 30 27 A B 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 chambe[...]
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Page 50
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 49 1 2 3 4 5 JASO T903 MA 5°C 41°F 0°C 32°F + – 10W/50 10W/50 5W/40 5W/40 250-F: 400/450/525: 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 separat[...]
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Page 51
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 50 2 2 2 3 3 4 5 3 Changing the oil filters 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. Clean the oil filter cover , the sealing surfaces[...]
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Page 52
TROUBLESHOOTING » ENGLISH 51 If you had the specified maintenance work on your motorcycle carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the troubleshooting chart in order to find the cause of error . W e would like to point out that many operations cannot be performed by yourself. In cas[...]
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Page 53
TROUBLESHOOTING » ENGLISH 52 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[...]
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Page 54
ENGLISH 53 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. If using a power washer , do not point [...]
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Page 55
TECHNICAL DATA – ENGINE » ENGLISH 54 JASO T903 MA 5°C 41°F + – 10W/50 5W/40 250-F: TEMPERA TUR ENGINE 250 XC-F 250 XCF-W, EXC-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.8 : 1 Fuel unleaded fuel with at least RON 95 (USA = Premium PON 91) V alve timing 4 valves controlled by [...]
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Page 56
TECHNICAL DATA – ENGINE » ENGLISH 55 BASIC CARBURATOR SETTING 250 XC-F USA 250 XCF-W USA 250 EXC-F 250 EXC-F SIXDAYS T ype Keihin FCR-MX 3900G Keihin FCR-MX 3900G Keihin FCR-MX 3900G Keihin FCR-MX 3900G Main jet 168 168 168 172 Jet needle OBETP OBEKT OBEKT OBETP Idling jet 40 40 40 40 Main air jet 200 200 200 200 Idling air jet 100 100 100 100 N[...]
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Page 57
TECHNICAL DATA – ENGINE » ENGLISH 56 ENGINE 400 XC-W, EXC 450 XC 450 XC-W, EXC 525 XC 525 XC-W, EXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 cc 449 cc 448 cc 510 cc Bore/Stroke 89 / 64 mm 95 / 63,4 mm 89 / 72 mm 95 / 72 mm Ratio 11 : 1 12 : 1 11 : 1 11 : 1 Fuel unleaded fuel with at least RON 95 ([...]
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Page 58
TECHNICAL DATA – ENGINE » 57 ENGLISH 57 BASIC CARBURATOR SETTING 400 XC-W USA 400 EXC RACING EU T ype Keihin FCR-MX 3900D Keihin FCR-MX 3900E Main jet 178 178 Jet needle OBDVR OBDVR Idling jet 42 42 Main air jet 200 200 Idling air jet 100 100 Needle position 1st from top 1st from top Starting jet 85 85 Mixture control screw open 1.25 1.25 Slide [...]
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Page 59
TECHNICAL DATA – ENGINE » ENGLISH 58 TIGHTENING TORQUES – ENGINE 400/450/525 Hexagon collar screw , engine case, clutch cover , ignition cover M6 10 Nm Oil drain plug M12x1.5 20 Nm Allan head plug, oil screen short M16x1.5 Oil + 10 Nm Hexagon plug, oil screen long M20x1.5 15 Nm Collar screw for oil filter cover M5 6 Nm Plug pressure valve M12x[...]
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Page 60
TECHNICAL DATA – CHASSIS » ENGLISH 59 CHASSIS 250/400/450/525 Frame Central tube chrome-moly-steel frame Fork WP Suspension – 4860 MXMA / MXMA + P A Wheel travel front/rear 300/335 mm Rear suspension WP Suspension – 5018 PDS MCC / DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper [...]
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TECHNICAL DATA – CHASSIS » ENGLISH 60 STANDARD ADJUSTMENT – FORK 250 XCF-W 250 EXC-F 400/450/525 XC-W 400/450/525 EXC 525 XC DESERT RACING 250 XC-F 250 EXC-F SIXDAYS 450/525 XC 450/525 EXC SIXDAYS WP 4860 MXMA 14187C04 WP 4860 MXMA 14187C06 WP 4860 MXMA + P A 14187C28 WP 4860 MXMA + P A 14187C29 Compression adjuster 20 20 18 18 Rebound adjuste[...]
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Page 62
HEAD WORD INDEX » ENGLISH 61 Activating and deactivating display modes . . . . . . . . . . . . . .9 Adjusting the free travel at the hand brake lever . . . . . . . . .36 Adjusting the mixture control screw . . . . . . . . . . . . . . . . . .47 Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . . . .45 Basic information on carbur[...]
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ENGLISH 62[...]
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Page 64
ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAM 7 0 - 6 0 0 2 g n i c a R C X E m m a r g a i d g n i r i w s s e n r a h n i a m 0 5 1 . 5 7 0 . 1 1 . 4 9 5 6 0 0 2 . 4 0 . 8 0 h c t i w s r e h s a l f p u k c i p h c t i w s e k a r b r a e r r e h s a l f t n o r f t f e l r e h s a l f t n o r f t h g i r r e h s a l[...]
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ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAM 7 0 - 5 0 0 2 W - C X , C X m m a r g a i d g n i r i w s s e n r a h n i a m 6 0 0 2 . 4 0 . 8 0 0 0 1 . 5 7 0 . 1 1 . 4 9 5 p u k c i p l i o c n o i t i n g i G 3 r o t a r e n e g rear light /brake light v r o s n e s d e e p s h c t i w s r a b e l d n a h ) l a n o i t[...]
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ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAM 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 vorde[...]
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ANHANG – APPENDICE APPENDIX – APÉNDICE 4 SCHALTPLAN » WIRING DIAGRAM ENGLISH FRANCAIS ESP ANOL 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 lampara[...]
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 5/2006 FOTO: MITTERBAUER 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 BEDIENUNGSANLEITUNG 2007 ART. NR. 3.211.145 DE DEUTSCH[...]