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250 EXC RACING, 450/525 SX, EXC, MXC RACING
BEDIENUNGSANLEITUNG
OWNERS’S MANUAL
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
2003
Art.Nr. 3.210.50 04/2002
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IMPORTANT WE STRONGLY SUGGEST THAT YOU 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. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: WARNING IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CY
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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. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate so
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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 international motorcycle associations. 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 pr
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ENGLISH TABLE OF CONTENTS Page Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5 Checking the brake fluid level - front brake . . . . . . . . . .32 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Refilling the front brake fluid reservoir . . . . . . . . . . . . . .32 Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5 Checking the front brake pads . . . . . . . . . . . . . . . . . . .32 Replacing the front brake pads .
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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. 5 OPERATION INSTRUMENTS Clutch lever 1 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
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ENGLISH Digital speedometer, indicator lamps 1 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. 2 Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move. The engine must be started in order for the speedometer to be supplied with electricity from the generator. An impulse must be received fr
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Tripmaster switch The switch has three buttons: MODE, + (plus) and – (minus). WARNING + MODE DO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT. Electronic speedometer functions provided by the Tripmaster switch The display modes on the electronic speedometer will change in the – following order. If not, please read the chapter "ACTIVATING AND DEACTIVATING THE DISPLAY MODE." SPEED/ODO dis
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ENGLISH 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 are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counte
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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 3 seconds after the last impulse is received. + BUTTON increases the TRP2 figure – BUTTON decreases the TRP2 figure press the MODE BUTTON to change to the next m
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ENGLISH OVERVIEW OF TRIPMASTER FUNCTIONS Display Press + Press – Press MODE Hold MODE for 3 sec X SPEED / ODO no function no function next display mode no function X X SPEED / MAX no function no function next display mode resets MAX to 0 X X SPEED / LAP starts / stops LAP stops LAP, stores LAP next display mode clears all LAP figures figure LAP remains figure, resets LAP to 0 X LAP / LAP next figure no function next display mode next display mode X X SPEED / CLK no function no function next
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Short circuit button (SX/MXC) The short circuit button 1 turns off the engine. When pressing this button, the ignition circuit is short-circuited. 1 Combination switch (EXC) The light switch has 2, respectively 3 switch positions. 2 3 A = Light off (this function is not available in all models) B = Low beam on C = High beam on You may use button 2 to actuate the horn. The red short circuit button 3 serves to switch off the engine. Leave the switch pressed until the engine stops. A B C 11 Headlam
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ENGLISH 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. 1 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 you attempt to start it with the kickstarter. Pushing the black starter button 2 will actuate the E-starter. 2 Filler cap To open the filler cap: Turn
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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 basic position. 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 s
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ENGLISH Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting 1 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 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 th
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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 counterclockwise direction will decrease the damping. STANDARD ADJUSTMENT: 2 – turn the adjusting screw clockwise to the stop. 1 – then turn the adjusting screw coun
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ENGLISH GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation WARNING – Verify that your KTM dealer performed the PREPARATION –WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER OF VEHICLE jobs (see Customer Service Manual). KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A – Read these operating instructions carefully before your first JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A ride. SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE
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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 B damage. 2 FUEL A Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank ve
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ENGLISH 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 –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 KICK- STARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH 1 GREAT FORCE. –AL
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NOTE: WARNING Dedicated to nothing but offroad racing, 250/450/525 MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE SX/MXC/EXC Racing models make no compromises in their RUNNING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND design. As such, they do not include any radiator fan, and the SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF size of the radiator is dimensioned for optimum ergonomics. THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO In normal racing
