KTM 250 EXC RACING manual

OWNERS’S MANUAL MANUALE D’USO MANUEL D’UTILISA TION MANUAL DE INSTRUCCIONES 2003 BEDIENUNGSANLEITUNG Art.Nr . 3.210.50 04/2002 250 EXC RACING, 450/525 SX, EXC, MXC RACING[...]

ENGLISH 1 IMPOR T ANT WE STRONGL Y SUGGEST THA T YOU READ THIS MANUAL CAREFULL Y AND COMPLETEL Y BEFORE GOING ON YOUR FIRST RIDE. IT CONT AINS A GREA T DEAL OF INFORMA TION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERL Y . IN YOUR OWN INTEREST , PLEASE P A Y P ARTICULAR A TTENTION TO NOTICES THA T ARE MARKED AS FOLLOWS:  WARNIN[...]

ENGLISH 2 Introduction We would like to congratulate you on your purchase of a KTM motor cycle. 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 tho[...]

ENGLISH 3 IMPOR T ANT LIMITED W ARRANTY AND LIMITED GUARANTEE INFORMA TION KTM sports motorcycles are designed and constructed to r esist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories curr ently in effect with the leading international motor cycle associations. Observance of the se[...]

ENGLISH 4 Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .5 Clutch lever . . . . . . . . . . . . . . . . [...]

ENGLISH 5 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. SERIAL NUMBER LOCA TIONS OPERA TION IN[...]

ENGLISH 6 Digital speedometer , indicator lamps The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp 2 lights up when the high beam is on. Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts[...]

ENGLISH 7 + – MODE Tr ipmaster switch The switch has three buttons: MODE, + (plus) and – (minus).  WARNING  D O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING . Y OUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT . Electronic speedometer functions provided by the T ripmaster switch The d[...]

ENGLISH 8 SPEED/CLK (clock) display mode CLK will display time in hours, minutes and seconds. + BUTTON no function – BUTTON no function press the MODE BUTTON to change to the next mode. press and hold the MODE BUTTON 3 SECONDS to set the time in the menu (see SETTING THE CLOCK) SPEED/H (hours) display mode When you stop driving and no impulses ar[...]

ENGLISH 9 SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically [...]

ENGLISH 10 X X X X X X X X X X X X X X X X X X X X X no function no function starts / stops LAP figure LAP remains next figure no function no function no function no function no function increases TRP2 figure no function starts / stops STP2 Press + Display SPEED / ODO SPEED / MAX SPEED / LAP LAP / LAP SPEED / CLK SPEED / H SPEED / TRP1 SPEED / AVS1[...]

ENGLISH 11 Short circuit button (SX/MXC) The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) 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 butt[...]

ENGLISH 12 Emergency OFF switch (EXC Australia) The red emergency-OFF switch 1 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 interrup- ted. The E-starter cannot be actuated, and the engine will not start, not even if [...]

ENGLISH 13 Hot start device (450/525 SX) If you pull the hot start device 1 out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean“ fuel-air mixture of the type needed for hot starts. To deactivate the hot start device, push the hot start button back into its ba[...]

ENGLISH 14 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap 1 . Turn the adjusting screws 2 clockwise to increase damping, turn it counter- clockwise to reduce damping[...]

ENGLISH 15 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. Turning in a clockwise direction will increase the damping, turning in a count[...]

ENGLISH 16  WARNING  –W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE . C LEVER KTM DRIVERS ALWAYS WEAR A HELMET , BOOTS , GLOVES AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP . T HE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COL - ORED SO THAT OTHER VEHICLES CAN SEE YOU AS EARLY AS POSSIBLE . –A LWAYS TURN O[...]

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 [...]

ENGLISH 18 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 WAY or actuate the E-starter.  WARNING  –I F YOU WANT TO START THE ENGINE , MAKE SURE THAT YOU ALWAYS PUT ON STURDY[...]

ENGLISH 19 NOTE: Dedicated to nothing but offroad racing, 250/450/525 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 motorbike in other conditions, plea[...]

ENGLISH 20 PERIODIC MAINTENANCE SCHEDULE 2003 1. service after 3 hours or 20 l fuel after/every 15 hours or 100 l fuel IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. S ERVICE INTERVALLS SHOULD NEVER BE EXCEEDED BY MORE THAN 2 HOURS OR 15 LITERS OF FUEL . M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSH[...]

ENGLISH 21 I MPORT ANT C HECKS AND M AINTENANCE TO BE C ARRIED OUT BY THE R IDER 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 [...]

ENGLISH 22 R ECOMMENDED INSPECTION OF THE 250/450/525 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 Check the clutch disks for wear ●●●●●● Check the length of the clutch springs ●●●●●● Chec[...]

ENGLISH 23 R ECOMMENDED INSPECTION OF THE 250/450/525 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 Check the clutch disks for wear ●●●●●● Check the length of the clutch springs ●●●●●● Che[...]

ENGLISH 24  WARNING  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. ! CAUTION ! –W HEN CLEANING THE MOTORCYCLE[...]

ENGLISH 25 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 hav[...]

ENGLISH 26 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 70[...]

ENGLISH 27 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 riding sag of the telescopic fork cannot be det[...]

ENGLISH 28 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 tri- ple 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 cen- t[...]

ENGLISH 29 Check chain tension To check the chain tension, park the motorcycle. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 15 mm (0.6 in). In the course of this procedure, the upper chain portion A must be taut (see illustration). If necessary, correct the cha[...]

ENGLISH 30 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. Shell Advance Bio Chain). X-ring chains on the other hand are very simple to clean. Th[...]

ENGLISH 31 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[...]

ENGLISH 32 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 (e.g. 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. ! CAUTI[...]

ENGLISH 33 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 sleeves of the guide bolts for damage, and greas[...]

ENGLISH 34 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).  WARNING  A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM , OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAFETY DON ’ T PUT OFF HAVING YOUR BRAKE P[...]

ENGLISH 35  WARNING  –I F 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 . –A FTER MOUNTING THE FRONT WHEEL , KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETUR[...]

ENGLISH 36 Ti res, air pressure Tire type, tire condition, and air pressure level affect the way your motor- cycle rides and must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in the homolo- gation certificate – Tire condition has to be checked[...]

ENGLISH 37 Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the MODE button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the MODE button to move to the next digit. If no button is pressed for 20 seconds, the settings will be stored automati- cally and t[...]

ENGLISH 38 Check/set distance of the magnetic sensor The distance between magnet 2 and sensor 1 must be 2-4 mm (0,08-0,16 in), otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing in or off the sensor 1 . mm x 3.14 KMH: WS = mm x 3.14 MPH: WS = (mm x 3.14) : 1.61 1 2 Wheel circumference with standar d ti[...]

ENGLISH 39 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 negative and then the positive pole of the b[...]

ENGLISH 40 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 system – horn – flasher lights The starter relay[...]

ENGLISH 41 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 is also pumped through both aluminum radiators[...]

ENGLISH 42 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 front glassfiber yarn packing 1 needs to be rep[...]

ENGLISH 43 Cleaning the air filter * A dirty air filter impairs the air-flow rate, reduces the engine performance, and increases the fuel consumption. In extreme cases, dirt may even get into the engine and cause damage. Therefore, change the air filter in regular intervals. For this purpose, rotate the two quick-release fasteners 1 counter-clock- [...]

ENGLISH 44 Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning th[...]

ENGLISH 45 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 idle speed is controlled by means of the adjusti[...]

ENGLISH 46 Draining the float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes malfunctioning. Perform this task on a cold engine. Close the fuel tap and put one end of the hose 1 in[...]

ENGLISH 47 Engine oil Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or sur- passing the quality requirements of API classes SG or SH (see specifications on the container). ! CAUTION ! I NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE . Changing the engine oil * NOTE: W HEN CHANGING THE ENGINE OIL [...]

ENGLISH 48 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. Clean the oil filter cover, the sealing surfac[...]

ENGLISH 49 TROUBLESHOOTING 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. We would like to point out that many operations cannot be performed by yourself. In case of [...]

ENGLISH 50 TROUBLE Engine does not rev high Engine will not reach full power Engine stops or splutters in carburetor Engine gets too hot High oil consumption All switched on lamps blown out Horn, flasher lights and E-starter do not work The battery is discharged CAUSE Carburetor fuel level too high because float needle valve is dirty or worn out Lo[...]

ENGLISH 51 Should you wish to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil, short and long oil filters (old engine oil contains aggressive contaminants). – Check antifreeze and amount of cooling liquid. – Warm up the engine once[...]

ENGLISH 52 Type 250 EXC 450 SX 450 MXC 450 EXC 525 SX 525 MXC 525 EXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 250 cc 449 cc 448 cc 510 cc Bore/Stroke 75 / 56.5 mm 95 / 63.4 mm 89 / 72 mm 95 / 72 mm Ratio 12 : 1 11 : 1 Fuel unleaded premium gasoline with at least RON 95 Valve timing 4 valves over rocker [...]

ENGLISH 53 BASIC CARBURA TOR SETTING Type Keihin FCR-MX 37 Keihin FCR-MX 37 Keihin FCR-MX 39 Keihin FCR-MX 41 Carburator-setting number 3700A 3700A 3900A 4122A Main jet 160 160 178 185 Jet needle OBETP OBEKT OBDVR OBDTP Idling jet 42 42 42 40 Main air jet 200 200 200 200 Idling air jet 100 100 100 100 Needle position 3. rd from top 3. rd from top 3[...]

ENGLISH 54   – + 0°C 32°F 15W 40 15W 50 10W 40 10W 50 API: SG, SH TEMPERA TURE TIGHTENING TORQUES 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 10 Nm Hexagon plug, oil screen long M20x1,5 15 Nm Collar screw for oil filter cover M5 6 Nm Plug p[...]

ENGLISH 55 WP 5018 PDS WP 5018 PDS DCC MCC 1218X760 1218X761 Compression adjuster 15 LS (low speed) 17 2 HS (high speed) Rebound adjuster 26 26 Spring 76-95/260 71-90/260 Spring preload 6 mm (0.24 in) 8 mm (0.32 in) STANDARD ADJUSTMENT-SHOCK ABSORBER WP4860MXMA WP4860MXMA 1418X727 1418X737 Compression adjuster 18 21 Rebound adjuster 19 20 Spring 4.[...]

ENGLISH 56 Page Adjusting the free travel at the hand brake lever .................32 Adjusting the mixture control screw ....................................45 Adjusting the spring preload on the fork (SX)......................25 Adjusting the throttle cables ...............................................43 Basic suspension setup for the weight o[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 1 250/450/525 MXC / EXC 01/02/03[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 2 250/450/525 EXC Racing 2003[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 3[...]

ANHANG – APPENDICE APPENDIX – APÉNDICE 4[...]

KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet: www .ktm.at 321050[...]