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IMPORTANT LIMITED WARRANTY AND LIMITED GUARAN-
TEE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . .6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand decompression lever . . . . . . . . . . . . . . . . . . . . .6
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . . . .6
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . .6
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Starter button (EXC) . . . . . . . . . . . . . . . . . . . . . . . . .7
Emergency OFF switch (EXC Australia) . . . . . . . . . . . .7
Digital speedometer, indicator lamps . . . . . . . . . . . . . .7
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . .8
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . .12
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Hot start device (450/525 SX) . . . . . . . . . . . . . . . . .13
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Compression damping of fork . . . . . . . . . . . . . . . . . .15
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . .15
Damping action during compression of shock absorber (SX)
.15
Compression damping of shock absorber (MXC, EXC) .16
Rebound damping of shock absorber (SX, MXC, EXC) .16
GENERAL TIPS AND WARNINGS FOR STARTING THE
MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Instructions for initial operation . . . . . . . . . . . . . . . .17
Running in the Racing models . . . . . . . . . . . . . . . . .17
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .18
Check the following before each start . . . . . . . . . . . .18
Starting when the engine is cold . . . . . . . . . . . . . . . .19
Starting when the engine is warm . . . . . . . . . . . . . . .19
What to do when the engine is “flooded” . . . . . . . . . .19
Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . .20
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . .21
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . .24
Changing the spring preloading of the shock absorber .25
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Basic suspension setup for the weight of the driver . . .26
Checking the shock absorber and spring . . . . . . . . . .26
Determining the static sag of the shock absorber . . . .26
Determining the riding sag of the shock absorber . . . .26
Checking the basic setup of the telescopic fork . . . . .27
Changing the spring preload on the telescopic fork
(SX models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Changing the spring preload on the telescopic fork
(MXC/EXC models) . . . . . . . . . . . . . . . . . . . . . . . . .27
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . .27
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Breather plug front fork . . . . . . . . . . . . . . . . . . . . . .28
Cleaning the dust sleeves of the telescopic fork . . . . .28
Checking and adjusting the steering head bearing . . .28
Changing the fork offset (caster) (SX) . . . . . . . . . . . .29
Checking and adjusting the steering head bearing . . .30
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . .31
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . .31
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . .32
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
General information about KTM disc brakes . . . . . . . .33
Adjusting the free travel at the hand brake lever . . . . .34
Checking the brake fluid level - front brake . . . . . . . .34
Refilling the front brake fluid reservoir . . . . . . . . . . .34
Checking the front brake pads . . . . . . . . . . . . . . . . .34
Replacing the front brake pads . . . . . . . . . . . . . . . . .35
Changing the basic position of the foot brake pedal . .35
Checking the rear brake fluid level . . . . . . . . . . . . . .35
Refilling the rear brake fluid reservoir . . . . . . . . . . . .35
Checking the rear brake pads . . . . . . . . . . . . . . . . . .36
Replacing the rear brake pads . . . . . . . . . . . . . . . . .36
Dismounting and mounting the front wheel . . . . . . . .36
Dismounting and mounting the rear wheel . . . . . . . . .37
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . .37
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . .38
Check/set distance of the magnetic sensor . . . . . . . . .38
Replacing the battery of the digital speedometer . . . .38
Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . .39
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . .39
Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Replacing headlight lamp/parking light lamp . . . . . . .40
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Checking the coolant level . . . . . . . . . . . . . . . . . . . .41
Bleeding the cooling system . . . . . . . . . . . . . . . . . . .41
Replacing the glassfiber yarn packing of the silencer .42
Cleaning the spark arrester (MXC/EXC USA) . . . . . . . .42
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . .43
Checking the adjustment of the hand decompression
release cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Adjusting the throttle cables . . . . . . . . . . . . . . . . . . .43
Changing the original position of the clutch lever . . . .44
Checking the oil level of the hydraulic clutch . . . . . .44
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . .44
CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41)
.45
Adjusting the mixture control screw . . . . . . . . . . . . .45
Checking the float level (float height) . . . . . . . . . . . .45
Draining the float chamber of the carburetor . . . . . . .46
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Checking the engine oil level . . . . . . . . . . . . . . . . . .46
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . .47
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .49
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CONSERVATION FOR WINTER OPERATION . . . . . . . . . .51
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . .51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
TECHNICAL DATA - ENGINE . . . . . . . . . . . . . . . . . . . .52
TECHNICAL DATA - CHASSIS . . . . . . . . . . . . . . . . . . . .55
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .appendix