Instruction/ maintenance manual of the product 525 EXC Racing (2006) KTM
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250 SX-F 250 EXC RACING 400 EXC RACING 450 SX, XC, EXC RACING 525 SX, XC, EXC RACING OWNER’S MANUAL 2006 ART. NR. 3.211.73 EN ENGLISH.
ENGLISH 1 IMPORTANT » Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation.
ENGLISH 2 INTRODUCTION » W e would like to congratulate you on your purchase of a KTM motorcycle. 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 .
ENGLISH 3 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.
ENGLISH 4 TABLE OF CONTENTS » IMPOR T ANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMA TION . . . . . . . . . . . . . .3 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . .5 Chassis number . . . . . . . . . . . . . . . . . . . . . . . .
ENGLISH 5 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.
OPERATION INSTRUMENTS » ENGLISH 6 Hand decompression lever (450/525 SX) The hand decompression lever [2] is needed only if the carburetor overflows after a fall. T o "pump the engine free", pull the hand decompression lever during the starting procedure.
ENGLISH 7 OPERATION INSTRUMENTS » Headlamp switch (EXC USA) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar .
ENGLISH 8 OPERATION INSTRUMENTS » TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly dis- played in millimeters (2205 mm corresponds to a front wheel circumference of 21" with production tires).
ENGLISH 9 OPERATION INSTRUMENTS » SPEED / LAP (lap time) display mode Y ou can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds.
ENGLISH 10 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.
ENGLISH 11 OPERATION INSTRUMENTS » Kilometers or miles The unit (kilometers or miles) can also be changed. The ODO figure will be retained and converted accordingly . The TR1, A1, S1, TR2 and A2 figures will be cleared. T o select the unit, select the SPEED/H mode and hold the | button for 3 sec- onds to access the SETUP menu.
ENGLISH 12 OPERATION INSTRUMENTS » Setting the clock T o 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.
ENGLISH 13 OPERATION INSTRUMENTS » Filler cap (screw cap) To open the filler cap: T urn the filler cap counter -clockwise. 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.
ENGLISH 14 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 . Kickstarter The kickstarter is mounted on the right side of the engine.
ENGLISH 15 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] .
ENGLISH 16 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 .
ENGLISH 17 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » – WEAR SUIT ABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER KTM DRIVERS AL WA YS WEAR A HELMET , BOOTS, GLOVES AND A JACKET , REGARDLESS OF WHETHER DRIVING ALL DA Y OR JUST FOR A SHOR T TRIP .
ENGLISH 18 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.
ENGLISH 19 DRIVING INSTRUCTIONS » – AL WA YS KICK THE KICKST ARTER BRISKL Y ALL THE W AY 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 ST ART THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA.
ENGLISH 20 DRIVING INSTRUCTIONS » NOTE: Dedicated to nothing but offroad racing, 250/400/450/525 SX/XC/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.
ENGLISH 21 PERIODIC MAINTENANCE » 250 SX-F 2006 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20 l fuel every 10 hours or 70 l fuel ENGINE Change engi.
ENGLISH 22 PERIODIC MAINTENANCE » 250 SX-F 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use at least once a year Chec.
ENGLISH 23 PERIODIC MAINTENANCE » IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVER Y RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider .
ENGLISH 24 PERIODIC MAINTENANCE » 250/400/450/525 SX/XC/EXC 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Before each start After every cleaning For cross- country use At least.
ENGLISH 25 PERIODIC MAINTENANCE » 250/400/450/525 SX/XC/EXC 2006 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIVE RACING (ADDITIONAL ORDER FOR THE KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx.
ENGLISH 26 PERIODIC MAINTENANCE » NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
ENGLISH 27 MAINTENANCE WORK ON CHASSIS AND ENGINE » Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring [1] . For this purpose, you should dismount the shock absorber and clean it thoroughly .
ENGLISH 28 MAINTENANCE WORK ON CHASSIS AND ENGINE » Basic suspension setup for the weight of the driver T o 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.
ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 30 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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. T o do this, place the motorcycle on a stand with the front wheel lifted off the ground.
ENGLISH 31 MAINTENANCE WORK ON CHASSIS AND ENGINE » B A 2 1 3 2 5 4 3 4 5 2 Changing the fork offset (caster) (SX) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course.
ENGLISH 32 MAINTENANCE WORK ON CHASSIS AND ENGINE » 15 mm 3,5 mm 1 2 3 4 Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw . T ighten the collar screw on the lower triple clamp to 60 Nm.
ENGLISH 33 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx.
ENGLISH 34 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 35 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 36 MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw [1] .
ENGLISH 37 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 .
ENGLISH 38 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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). A T THEIR MOST WORN POINT BRAKE P AD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE F AILURE.
ENGLISH 39 MAINTENANCE WORK ON CHASSIS AND ENGINE » – IF YOU DON’T HAPPEN TO HA VE A TORQUE WRENCH A T HAND, MAKE SURE YOU HA VE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MA Y LEAD TO AN UNST ABLE DRIVING BEHA V- IOR OF YOUR MOTORCYCLE.
ENGLISH 40 MAINTENANCE WORK ON CHASSIS AND ENGINE » Tires, air pressure T ire 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.
ENGLISH 41 MAINTENANCE WORK ON CHASSIS AND ENGINE » VOL T Battery (XC, EXC) The battery is located under the seat and is maintenance-free. Maintenance-free means you will not need to check the acid level. Clean the battery terminals regularly and grease with acid-free grease if necessary .
ENGLISH 42 MAINTENANCE WORK ON CHASSIS AND ENGINE » Fuse (XC/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.
ENGLISH 43 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 44 MAINTENANCE WORK ON CHASSIS AND ENGINE » Replacing the glassfiber yarn packing of the silencer * Aluminum silencers are filled with glassfiber yarn to muffle noise. Have the filling checked regularly by an authorized KTM workshop (see Lubrication and Service Chart).
ENGLISH 45 MAINTENANCE WORK ON CHASSIS AND ENGINE » Cleaning the air filter * The air filter must be cleaned prior to each race or whenever dust has accu- mulated. T o clean, lift the filter box cover [1] (see illustration) and pull off towards the front.
ENGLISH 46 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 47 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 .
ENGLISH 48 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 49 MAINTENANCE WORK ON CHASSIS AND ENGINE » Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four -stroke motorcycles - the JASO T903 MA standard.
ENGLISH 50 MAINTENANCE WORK ON CHASSIS AND ENGINE » 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.
ENGLISH 51 TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine doesn’t crank (E-starter). Operating errror Blown fuse Discharged battery . Low outside temperature T urn on the emergency-OFF switch (Australia only) Dismount the left paneling and the filter box cover and replace the fuse in the starter relay .
ENGLISH 52 TROUBLESHOOTING » TROUBLE CAUSE REMEDY Engine does not rev high Carburetor fuel level too high because float needle valve is dirty or worn out Loose carburetor jets Electronic ignition tim.
ENGLISH 53 CLEANING » Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet.
ENGLISH 54 TECHNICAL DATA – ENGINE » ENGINE 250 SX-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.51 ccm Bore/Stroke 76 / 55 mm Ratio 12.
ENGLISH 55 TECHNICAL DATA – ENGINE » BASIC CARBURATOR SETTING 250 SX-F T ype Keihin FCR-MX 3925D Main jet 168 Jet needle OBETP Idling jet 40 Main air jet 200 Idling air jet 100 Needle position 5 th from top Starting jet 85 Mixture control screw open 1.
ENGLISH 56 TECHNICAL DATA – ENGINE » ENGINE 250 EXC 400 EXC 450 SX 450 XC 450 EXC 525 SX 525 XC 525 EXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 250 cc 398 cc 449 cc 449 cc 448 cc 510 cc Bore/Stroke 75 / 56.
ENGLISH 57 TECHNICAL DATA – ENGINE » BASIC CARBURATOR SETTING 250 EXC RACING EU 400 EXC RACING EU 400 EXC-G RACING USA 450 EXC RACING EU T ype Keihin FCR-MX 3700B Keihin FCR-MX 3900D Keihin FCR-MX .
ENGLISH 58 TECHNICAL DATA – ENGINE » TIGHTENING TORQUES – ENGINE 250/400/450/525 SX/XC/EXC 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 Oil + 10 Nm Hexagon plug, oil screen long M20x1.
ENGLISH 59 TECHNICAL DATA – CHASSIS » CHASSIS 250 SX-F, 450/525 SX 250/400/450/525 XC/EXC 450/525 XC, EXC USA Frame Central tube chrome-moly-steel frame Fork WP 4860 MA/P A WP 4860 MA (450/525 XC U.
ENGLISH 60 TECHNICAL DATA – CHASSIS » TIGHTENING TORQUES – CHASSIS Collar screw , front wheel spindle M24x1,5 40 Nm Brake caliper , front M8 Loctite 243 + 25 Nm Brake caliper , FTE radial front M.
ENGLISH 61 HEAD WORD INDEX » Page Page Activating and deactivating display modes . . . . . . . . .9 Adjusting the free travel at the hand brake lever . . . . .36 Adjusting the mixture control screw . . . . . . . . . . . . .47 Adjusting the throttle cables .
ENGLISH 62.
ANHANG – APPENDICE APPENDIX – APÉNDICE 1 SCHALTPLAN » WIRING DIAGRAM 6 0 / 5 0 0 2 F - X S 0 5 2 5 0 0 2 . 2 0 . 0 2 p u k c i p G 3 r o t a r e n e g n o t t u b p o t s C D I l i o c n o i t i n g i 0 0 0 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 2 SCHALTPLAN » WIRING DIAGRAM 6 0 - 5 0 0 2 5 2 5 - 0 5 4 X S 5 0 0 2 . 2 0 . 0 2 p u k c i p G 3 r o t a r e n e g n o t t u b p o t s C D I l i o c n o i t i n g i 0 0 0 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAM 6 0 0 2 g n i c a R C X E m m a r g a i d g n i r i w s s e n r a h n i a m 0 5 1 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 4 SCHALTPLAN » WIRING DIAGRAM 6 0 - 5 0 0 2 A S U g n i c a R C X E m m a r g a i d g n i r i w s s e n r a h n i a m 0 0 1 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 5 SCHALTPLAN » WIRING DIAGRAM ENGLISH DEUTSCH IT ALIANO Battery Batterie Batteria Cooling fan Lüftermotor Motorino ventola Driving light lamp Fernlichtkon.
ANHANG – APPENDICE APPENDIX – APÉNDICE 6 SCHALTPLAN » WIRING DIAGRAM ENGLISH FRANCAIS ESP ANOL Battery Batterie Batería Cooling fan V entilateur Motor del ventilador Driving light lamp temoin f.
KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 5/2005 FOTO: MITTERBAUER.
An important point after buying a device KTM 525 EXC Racing (2006) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought KTM 525 EXC Racing (2006) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data KTM 525 EXC Racing (2006) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM 525 EXC Racing (2006) you will learn all the available features of the product, as well as information on its operation. The information that you get KTM 525 EXC Racing (2006) will certainly help you make a decision on the purchase.
If you already are a holder of KTM 525 EXC Racing (2006), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime KTM 525 EXC Racing (2006).
However, one of the most important roles played by the user manual is to help in solving problems with KTM 525 EXC Racing (2006). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM 525 EXC Racing (2006) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
