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OWNER’S MANUAL 2006
250 SX-F
250 EXC RACING
400 EXC RACING
450 SX, XC, EXC RACING
525 SX, XC, EXC RACING
ART. NR. 3.211.73EN
ENGLISH
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IMPORTANT » 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. In your own interest, please pay particular attention to notices that are marked as follows: – IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB! – IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR- CYCLE’S TRAFFIC SAFETY! Please insert the serial numbers
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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. 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 d
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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 interna- tional 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 o
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ENGLISH TABLE OF CONTENTS » Page Page IMPORTANT LIMITED WARRANTY AND Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .29 LIMITED GUARANTEE INFORMATION . . . . . . . . . . . . . .3 Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .30 Cleaning the dust sleeves of the telescopic fork . . . . .30 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5 Checking and adjusting the steering head bearing . . .30 Chassis number . . . . . . . . . . . . . . . .
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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 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
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ENGLISH OPERATION INSTRUMENTS » Hot start lever (250 SX-F) 1 If you pull the red hot start lever [1] during the starting procedure backward, 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. Hand decompression lever (450/525 SX) The hand decompression lever [2] is needed only if the carburetor overflows 2 after a fall. To "pump the engine free", pull the hand decompression lever
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OPERATION INSTRUMENTS » Headlamp switch (EXC USA) In this model the headlamp is switched on with the pull switch [1]. 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 indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right 7 Starter button (EXC) Pushing the black s
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ENGLISH 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 sen- sor. 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
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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 blink- ing 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 automati- cally and the display will return to the SPEED/H mo
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ENGLISH 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 changes to the next lap time – button no function briefly press button changes
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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 no function – button no function briefly press button changes to the next display mode hold button 3 secs. changes to the next display mode SPEED / S1 display mode (stop watch 1) S1 sh
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ENGLISH 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. 0- 12 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 automati- cally and the
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OPERATION INSTRUMENTS » Filler cap (screw cap) To open the filler cap: Turn the filler cap counter-clockwise. 1 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. 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 wi
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ENGLISH 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. 2,3,4 (5,6) N 1 Kickstarter The kickstarter is mounted on the right side of the engine. Its upper part can be swivelled. 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 mai
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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]. 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 a
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ENGLISH OPERATION INSTRUMENTS » Compression damping of shock absorber (XC, EXC) The compression damping (during compression) can be adjusted for the XC 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, turn- 2 ing in a counterclockwise direction will decrease the damping. STANDARD ADJUSTMENT: – turn the adjusting screw clockwise to the stop. 1 –
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GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » Instructions for initial operation – Make sure the work for the „pre-delivery inspection“ was per- – WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. formed by your authorized KTM workshop. The DELIVERY CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES CERTIFICATE and SERVICE MANUAL will be handed over AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY when you pick up your vehicle. OR JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING –
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ENGLISH 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. B 2 FUEL A Check that there is sufficient fuel in the tank; when closing the filler cap, check that t
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DRIVING INSTRUCTIONS » – ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE. IF YOU DO NOT KICK HARD ENOUGHT, WITH AN OPEN THROT- TLE 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 CONSCIOUS- NESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING. 2 – ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE (NEUTRAL) BEFORE ACTUATING TH
