Instruction/ maintenance manual of the product EXC-F 400 XC-W KTM
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KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at KTM Group Partner 5/2006 FOTO: MITTERBAUER 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING OWNER’S MANUAL 2007 ART.
ENGLISH 1 INTRODUCTION » 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 IMPORTANT INFORMATION » INTENDED PURPOSE 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 3 IMPORTANT INFORMATION » W e expressly point out that work marked with an asterisk in the chapter „Maintenance work on the chas- sis and engine“ must be performed. If maintenance work should become necessary during a competition it should be performed by a trained mechanic.
TABLE OF CONTENTS » ENGLISH 4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 IMPOR T ANT INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . .2 SERIAL NUMBER LOCA TIONS . . . . . . . . . . . . . . . . . . . . .
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.
A B C OPERATION INSTRUMENTS » Hand brake lever The hand brake lever [3] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see "Maintenance").
OPERATION INSTRUMENTS » Headlamp switch (XC-W) 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 .
OPERATION INSTRUMENTS » ENGLISH 8 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).
OPERATION INSTRUMENTS » ENGLISH 9 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.
OPERATION INSTRUMENTS » ENGLISH 10 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.
OPERATION INSTRUMENTS » ENGLISH 11 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.
OPERATION INSTRUMENTS » ENGLISH 12 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.
OPERATION INSTRUMENTS » ENGLISH 13 1 2 XC EXC Filler cap (bayonet cap) To open the filler cap: T urn the filler cap 45 ° counter -clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. Filler cap (screw cap) To open the filler cap: T urn the filler cap counter -clockwise.
OPERATION INSTRUMENTS » ENGLISH 14 2,3,4 (5,6) 1 N 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 speed, is located between first and second gear .
1 2 2 3 3 5 6 4 OPERATION INSTRUMENTS » ENGLISH 15 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.
OPERATION INSTRUMENTS » ENGLISH 16 2 1 4 3 Compression damping of shock absorber (XC-W, EXC) The compression damping (during compression) can be adjusted for these shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw [1] with a screwdriver .
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE » ENGLISH 17 – W ear suitable clothing when driving a motorcycle. Clever KTM drivers always wear a helmet, boots, gloves and a jacket, regard- less of whether driving all day or just for a short trip.
1 DRIVING INSTRUCTIONS » ENGLISH 18 A B 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.
2 DRIVING INSTRUCTIONS » ENGLISH 19 – Always kick the kickstarter briskly all the way without opening the throt- tle. If you do not Kick hard enought, with an open throttle grip, the kick- back hazard will be higher . – Do not start the engine and allow it to idle in a closed area.
DRIVING INSTRUCTIONS » ENGLISH 20 35 mm NOTE: Dedicated to nothing but offroad racing, XC/EXC models make no compromises in their design. As such, they do not include any radi- ator fan, and the size of the radiator is dimensioned for optimum ergonomics.
PERIODIC MAINTENANCE » ENGLISH 21 250-F 2007 A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1st service after 3 hours or 20 l fuel every 20 hours or 140 l fuel or 1 race ENGINE Cha.
PERIODIC MAINTENANCE » ENGLISH 22 NOTE: If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced.
PERIODIC MAINTENANCE » ENGLISH 23 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 .
PERIODIC MAINTENANCE » ENGLISH 24 400/450/525 2007 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 C.
PERIODIC MAINTENANCE » ENGLISH 25 400/450/525 2007 IMPORTANT INSPECTIONS OR MAINTENANCE WORK THAT MUST BE PERFORMED BY THE SPECIALIZED KTM WORKSHOP FOR COMPETITIVE RACING / FOR HOBBY-USE (SEPARATE ORDER FOR SPECIALIZED KTM WORKSHOP) COMPETITIVE RACING A 100 liter fuel consumption is equivalent to approx.
ENGLISH 26.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 27 A 3 1 2 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 .
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 28 A B B C 65 SPRING RA TE 70 75 80 85 90 95 RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM 80/250 76/250 84/250 80/250 76/250 72/250 WP12187C06, WP12187C2.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 29 Checking the basic setup of the telescopic fork The precise riding sag of the telescopic fork cannot be determined for various reasons. Similar to the shock absorber , smaller deviations in your weight can be compensated by adjusting the spring preload.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 30 1 5 4 3 3 2 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 31 B A 2 1 3 2 5 4 3 4 5 2 Changing the fork offset (caster) (XC, EXC SIXDAYS) * The fork offset [A] in these 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 32 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 33 8-10 mm / 0.3-0.4 in A 2 3 1 4 B 2 B 3 4 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 34 15 KG 33 lbs max. 272 mm 1 2 3 16 17 18 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 35 A 1 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 36 5 mm min. 3 mm 1 3 2 4 min. 1 mm Adjusting the free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw [1] . In this way , the position of the point of pressure (i.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 37 3-5mm 1 1 2 2 1 2 4 3 6 5 A B 7 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] .
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 38 min. 1 mm 1 2 3 4 5 6 A B 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). At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.
MAINTENANCE WORK ON CHASSIS AND ENGINE » 3 ENGLISH 39 7 1 2 – If you don’t happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 40 1 2 3 1 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 41 VOL T 2 3 1 Battery 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 .
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 42 2 A 1 3 4 6 5 5 Fuse 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 43 when engine is cold 10 mm 3 4 5 6 1 1 2 400/450/525 250-F 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 44 XC EXC C 6 5 3 7 3 7 5 C 4 6 A B 2 1 EXC-F 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).
MAINTENANCE WORK ON CHASSIS AND ENGINE » Adjusting the throttle cables * The throttle grip should always provide for a backlash of 3-5mm. Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 46 1 2 4 3 6 5 7 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 47 1 2 3 4 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 .
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 48 3 4 5 6 7 8 9 10 11 12 13 15 14 28 20 22 21 23 24 25 26 29 30 27 A B 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.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 49 1 2 3 4 5 JASO T903 MA 5°C 41°F 0°C 32°F + – 10W/50 10W/50 5W/40 5W/40 250-F: 400/450/525: Engine oil Automobile engine oil used to be used for four -stroke motorcycles before there were separate motorcycle specifications.
MAINTENANCE WORK ON CHASSIS AND ENGINE » ENGLISH 50 2 2 2 3 3 4 5 3 Changing the oil filters Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws [2] and dismount the two oil filter covers. Using circlip pliers, pull the oil-filter inserts [3] out of the housing.
TROUBLESHOOTING » ENGLISH 51 If you had the specified maintenance work on your motorcycle carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the troubleshooting chart in order to find the cause of error .
TROUBLESHOOTING » ENGLISH 52 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.
TECHNICAL DATA – ENGINE » ENGLISH 54 JASO T903 MA 5°C 41°F + – 10W/50 5W/40 250-F: TEMPERA TUR ENGINE 250 XC-F 250 XCF-W, EXC-F Design Liquid-cooled single cylinder 4-stroke engine Displacement 249.
TECHNICAL DATA – ENGINE » ENGLISH 55 BASIC CARBURATOR SETTING 250 XC-F USA 250 XCF-W USA 250 EXC-F 250 EXC-F SIXDAYS T ype Keihin FCR-MX 3900G Keihin FCR-MX 3900G Keihin FCR-MX 3900G Keihin FCR-MX .
TECHNICAL DATA – ENGINE » ENGLISH 56 ENGINE 400 XC-W, EXC 450 XC 450 XC-W, EXC 525 XC 525 XC-W, EXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 cc 449 .
TECHNICAL DATA – ENGINE » 57 ENGLISH 57 BASIC CARBURATOR SETTING 400 XC-W USA 400 EXC RACING EU T ype Keihin FCR-MX 3900D Keihin FCR-MX 3900E Main jet 178 178 Jet needle OBDVR OBDVR Idling jet 42 42 Main air jet 200 200 Idling air jet 100 100 Needle position 1st from top 1st from top Starting jet 85 85 Mixture control screw open 1.
TECHNICAL DATA – ENGINE » ENGLISH 58 TIGHTENING TORQUES – ENGINE 400/450/525 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.
TECHNICAL DATA – CHASSIS » ENGLISH 59 CHASSIS 250/400/450/525 Frame Central tube chrome-moly-steel frame Fork WP Suspension – 4860 MXMA / MXMA + P A Wheel travel front/rear 300/335 mm Rear suspension WP Suspension – 5018 PDS MCC / DCC, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.
TECHNICAL DATA – CHASSIS » ENGLISH 60 STANDARD ADJUSTMENT – FORK 250 XCF-W 250 EXC-F 400/450/525 XC-W 400/450/525 EXC 525 XC DESERT RACING 250 XC-F 250 EXC-F SIXDAYS 450/525 XC 450/525 EXC SIXDAY.
HEAD WORD INDEX » ENGLISH 61 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 7 0 - 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 2 SCHALTPLAN » WIRING DIAGRAM 7 0 - 5 0 0 2 W - C X , C X 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 6 0 0 2 .
ANHANG – APPENDICE APPENDIX – APÉNDICE 3 SCHALTPLAN » WIRING DIAGRAM ENGLISH DEUTSCH IT ALIANO Battery Batterie Batteria Cooling fan Lüftermotor Motorino ventola Driving light lamp Fernlichtkon.
ANHANG – APPENDICE APPENDIX – APÉNDICE 4 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 5/2006 FOTO: MITTERBAUER 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING BEDIENUNGSANLEITUNG 2007 ART. NR. 3.211.
An important point after buying a device KTM EXC-F 400 XC-W (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 EXC-F 400 XC-W 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 EXC-F 400 XC-W - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, KTM EXC-F 400 XC-W you will learn all the available features of the product, as well as information on its operation. The information that you get KTM EXC-F 400 XC-W will certainly help you make a decision on the purchase.
If you already are a holder of KTM EXC-F 400 XC-W, 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 EXC-F 400 XC-W.
However, one of the most important roles played by the user manual is to help in solving problems with KTM EXC-F 400 XC-W. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device KTM EXC-F 400 XC-W 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
