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4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .2
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .6
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Short circuit button (XC) . . . . . . . . . . . . . . . . . . . . . . . . .6
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6
Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . . . . . .7
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . . .7
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . .8
Activating and deactivating display modes . . . . . . . . . . . .9
Overview of the electronic speedometer functions . . . . . .12
Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Filler cap (bayonet cap) . . . . . . . . . . . . . . . . . . . . . . . . .13
Filler cap (screw cap) . . . . . . . . . . . . . . . . . . . . . . . . . .13
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
Compression damping of shock absorber
(XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Compression damping of shock absorber (XC-W, EXC) . . .16
Rebound damping of shock absorber . . . . . . . . . . . . . . .16
GENERAL TIPS AND WARNINGS FOR STARTING
THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Instructions for initial operation . . . . . . . . . . . . . . . . . . .17
Running in the XC/EXC models . . . . . . . . . . . . . . . . . . .17
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .18
Check the following before each start . . . . . . . . . . . . . . .18
Starting when the engine is cold . . . . . . . . . . . . . . . . . .18
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 . . . . . . .27
Changing the spring preloading of the shock absorber . . .27
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Basic suspension setup for the weight of the driver . . . . .28
Checking the shock absorber and spring . . . . . . . . . . . . .28
Determining the static sag of the shock absorber . . . . . . .28
Determining the riding sag of the shock absorber . . . . . . .28
Checking the basic setup of the telescopic fork . . . . . . . .29
Changing the spring preload on the telescopic fork
(XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Changing the spring preload on the telescopic fork
(XC-W/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . . . .29
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .30
Cleaning the dust sleeves of the telescopic fork . . . . . . . .30
Checking and adjusting the steering head bearing . . . . .30
Changing the fork offset (caster) (XC, EXC SIXDAYS) . . . .31
How to change the handlebar position . . . . . . . . . . . . . .32
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .33
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
General information about KTM disc brakes . . . . . . . . . .35
Adjusting the free travel at the hand brake lever . . . . . . .36
Checking the brake fluid level - front brake . . . . . . . . . . .36
Refilling the front brake fluid reservoir . . . . . . . . . . . . . .36
Checking the front brake pads . . . . . . . . . . . . . . . . . . . .36
Replacing the front brake pads . . . . . . . . . . . . . . . . . . .37
Changing the basic position of the foot brake pedal . . . . .37
Checking the rear brake fluid level . . . . . . . . . . . . . . . . .37
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . .37
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .38
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . .38
Dismounting and mounting the front wheel . . . . . . . . . . .38
Dismounting and mounting the rear wheel . . . . . . . . . . .39
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .39
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Check/set distance of the magnetic sensor . . . . . . . . . . .40
Replacing the battery of the digital speedometer . . . . . . .40
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Replacing headlight lamp/parking light lamp . . . . . . . . . .42
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . .43
Bleeding the cooling system (400/450/525) . . . . . . . . . .43
Bleeding the cooling system (250-F) . . . . . . . . . . . . . . .44
Replacing the glassfiber yarn packing of the silencer . . . .44
Cleaning the spark arrester (XC-W USA) . . . . . . . . . . . . .44
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .45
Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . .45
Changing the original position of the clutch lever . . . . . . .46
Checking the oil level of the hydraulic clutch
(400/450/525) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Checking the oil level of the hydraulic clutch (250-F) . . .46
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .46
Carburetor – Adjust idling (Keihin-FCRMX 37/39/41) . . . .47
Basic information on carburetor wear . . . . . . . . . . . . . . .47
Adjusting the mixture control screw . . . . . . . . . . . . . . . .47
Checking the float level (float height) . . . . . . . . . . . . . . .47
Draining the float chamber of the carburetor . . . . . . . . . .48
Oil circuit (400/450/525) . . . . . . . . . . . . . . . . . . . . . . .48
Oil circuit (250-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . .48
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .49
Changing the oil filters . . . . . . . . . . . . . . . . . . . . . . . . .50
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . .53
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . . . . . .53
TECHNICAL DATA – ENGINE . . . . . . . . . . . . . . . . . . . . . . .54
TECHNICAL DATA – CHASSIS . . . . . . . . . . . . . . . . . . . . . .59
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . .appendix
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