KTM 400 EXC Owner's Manual
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KTM 400 EXC Owner's Manual

Ktm owner's manual motorcycle 250 sx-f, 250 exc, 400 exc, 450 sx, xc, exc, 525 sx, xc
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OWNER'S MANUAL
250 EXC RACING
400 EXC RACING
450 SX, XC, EXC RACING
525 SX, XC, EXC RACING
ART. NR. 3.211.73 EN
2006
250 SX-F

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  • Page 1 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. 3.211.73 EN...
  • Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
  • Page 3 Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.

  • Page 4: Important Limited Warranty And Limited Guarantee Information

    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.

  • Page 5: Table Of Contents

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......17 Instructions for initial operation ....17 Running in the Racing models .

  • Page 6: Serial Number Locations

    SERIAL NUMBER LOCATIONS OPERATION INSTRUMENTS » 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.

  • Page 7: Hot Start Lever (250 Sx-F)

    » OPERATION INSTRUMENTS Hot start lever (250 SX-F) 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.

  • Page 8: Flasher Switch

    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. 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.

  • Page 9: Electronic Speedometer

    H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motor- cycles, making the service hour counter a very practical function.
  • Page 10 SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press button Changes to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures...
  • Page 11 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.
  • Page 12 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.

  • Page 13: Setting The Clock

    OPERATION INSTRUMENTS display briefly press + button SPEED / H SPEED / CLK starts/stops LAP without SPEED / LAP clearing LAP figure LAP / LAP SPEED / MAX SPEED / ODO SPEED / TR1 SPEED / TR2 increases the TR2 figure SPEED / A1 SPEED / A2 SPEED / S1...

  • Page 14: Fuel Tap

    OPERATION INSTRUMENTS » Filler cap (screw cap) To open the filler cap: Turn 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. Fuel tap OFF In this position the fuel tap is closed.

  • Page 15: Shift Lever

    » 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) Kickstarter The kickstarter is mounted on the right side of the engine.

  • Page 16: Compression Damping Of Fork

    Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compres- sion rates.

  • Page 17: Compression Damping Of Shock Absorber (Xc, Exc)

    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.

  • Page 18: General Tips And Warnings For Starting The Motorcycle

    – Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle. – Motorcycles are sensitive to alterations in the distribution of weight.

  • Page 19: Driving Instructions

    If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as com- plete failure of the braking system can be avoided.

  • Page 20: Starting When The Engine Is Warm

    ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE. NOTE: If you have trouble starting the motorcycle, this could be due to old fuel in the float chamber. The easily inflammable components of the new fuels evaporate during longer periods of standstill.When the...

  • Page 21: Braking

    E-starter allows you to start XC/EXC Racing models again at any time. Therefore, turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time (more than 2 minutes).

  • Page 22: Periodic Maintenance

    IF MOTORCYCLE IS USED FOR COMPETITION 10 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY 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. »...
  • Page 23 Check tightness of screws, nuts and hose clamps regularly 250 SX-F 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. 15 operating hours...
  • Page 24 IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY 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. »...
  • Page 25 PERIODIC MAINTENANCE 250/400/450/525 SX/XC/EXC 2006 IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly Clean and lubricate chain, check tension and adjust if necessary...
  • Page 26 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. 15 operating hours Check the clutch disks for wear...
  • Page 27 PERIODIC MAINTENANCE 250/400/450/525 SX/XC/EXC 2006 RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR HOBBY USE (ADDITIONAL ORDER FOR THE KTM WORKSHOP) A 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear...

  • Page 28: Maintenance Work On Chassis And Engine

    CARBURETOR OR FUEL TANK – ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.

  • Page 29: Basic Suspension Setup For The Weight Of The Driver

    EXAMPLE: Motorcycle jacked up (dimension A) .....600 mm Motorcycle on ground, unloaded (dimension B) ... .– 565 mm Static sag .

  • Page 30: Checking The Basic Setup Of The Telescopic Fork

    The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. According to our experience, the damping rate of the compression stage can remain unchanged.

  • Page 31: Breather Plug Front Fork

    [1] a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on the road, it will suffice to have this job performed in the course of the periodical maintenance service.

  • Page 32: Changing The Fork Offset (Caster) (Sx)

    MAINTENANCE WORK ON CHASSIS AND ENGINE 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.

  • Page 33: Checking And Adjusting The Steering Head Bearing

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw. Tighten the collar screw on the lower triple clamp to 60 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 stages.

  • Page 34: Check Chain Tension

    Tighten collar nut [1] to 80 Nm. – 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 BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 35: Chain Maintenance

    NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS, OTHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL. WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION.

  • Page 36: General Information About Ktm Disc Brakes

    CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDI- ATELY AS SOON AS THEY REACH THE WEAR LIMIT. – HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces- sary to top up the brake fluid.

  • Page 37: Adjusting The Free Travel At The Hand Brake Lever

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4].

  • Page 38: Replacing The Front Brake Pads

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].

  • Page 39: Checking The Rear Brake Pads

    ESTABLISHED. Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen the 2 clamping screws [4] on the left side of the fork fists.

  • Page 40: Dismounting And Mounting The Rear Wheel

    » – 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 BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 41: Tires, Air Pressure

    – Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER rear TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.

  • Page 42: Battery (Xc/Exc)

    Always use special charging devices to charge maintenance-free batteries, e.g. the KTM charging device (item no. 58429074000). You can also use this charging device to test the off-load voltage and startability of the battery and generator. It is impossible to overcharge the battery with this device.

  • Page 43: Fuse (Xc/Exc)

    Replace a blown fuse only with an equivalent one. If a new fuse that has just been installed gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere. UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED OR A FUSE ALLOWED TO BE “REPAIRED”.

  • Page 44: Cooling System

    – EXTREME CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVER- HEATING PROBLEMS. TO AVOID THIS, AN ELECTRIC BLOWER [4] IS OFFERED FOR MODELS WITH ELECTRIC STARTERS (ASK YOUR KTM DEALER) Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see diagram).

  • Page 45: Replacing The Glassfiber Yarn Packing Of The Silencer

    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). The insulating material fibers escape through the holes in the perforated pipe with time, causing the silencer to „burn out“.

  • Page 46: Cleaning The Air Filter

    The SX models do not have a throttle cap. – DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID BIO POWER).

  • Page 47: Changing The Original Position Of The Clutch Lever

    Kupplungs-Fluid 75).Biodegradable hydraulic oil is available from your KTM dealer (50ml). KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK- SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.

  • Page 48: Carburetor - Adjust Idling (Keihin-Fcrmx 37/39/41)

    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. The idle speed is controlled by means of the adjusting wheel [1] and the mixture control screw [2].

  • Page 49: Draining The Float Chamber Of The Carburetor

    Checking the engine oil level The engine oil level can be checked with the engine either warm or cold. Place the motorcycle in an upright position and on a horizontal surface (not on the side stand). If the engine is cold, the engine oil must be visible at the lower edge of the inspection glass [A].

  • Page 50: Engine Oil

    Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 51: Changing The Oil Filters

    The 250 SX-F engine only has one oil filter insert [3]. Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil. Fill oil filter with oil, place the long oil filter in the front and the short filter in the back of the filter box.

  • Page 52: Troubleshooting

    We would like to point out that many operations cannot be performed by yourself. In case of uncertainty, please contact a KTM-dealer. TROUBLE CAUSE Engine doesn’t crank (E-starter).
  • Page 53 Check if fan operates properly. To do this, start the engine, then bypass the connections to the thermoswitch (bottom right radiator), contact a KTM dealer Dislocate i.e. replace non-buckling vetilation hose Check engine oil level and, if necessary, correct it Use thicker engine oil;...

  • Page 54: Storage

    CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre- cautions against the aggressive road salt.

  • Page 55: Technical Data - Engine

    Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
  • Page 56 TECHNICAL DATA – ENGINE TIGHTENING TORQUES – ENGINE 250 SX-F Hexagon collar screw, engine case, clutch cover, ignition cover, water pump cover M6 Oil drain plug Allen head plug, oil screen short Hexagon plug, oil screen long Collar screw for oil filter cover Plug pressure valve Screws, oil pump cover Hexagon collar screw, cylinder / cylinder head...
  • Page 57 Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
  • Page 58 Mixture control screw open 1,25 Slide Performance restrictor – Stop pump membrane 858 / 2,15 mm Hot start device – » 400 EXC RACING OBDVR from top from top 1,25 Slide stop 858 / 2,15 mm – 450 EXC RACING SIXDAYS...
  • Page 59 TECHNICAL DATA – ENGINE TIGHTENING TORQUES – ENGINE 250/400/450/525 SX/XC/EXC Hexagon collar screw, engine case, clutch cover, ignition cover Oil drain plug Allan head plug, oil screen short Hexagon plug, oil screen long Collar screw for oil filter cover Plug pressure valve Jet screw and hollow screw, oil line Screws, oil pump cover Hexagon collar screw, cylinder head top section...

  • Page 60: Technical Data - Chassis

    TECHNICAL DATA – CHASSIS CHASSIS 250 SX-F, 450/525 SX Frame Central tube chrome-moly-steel frame Fork WP 4860 MA/PA Wheel travel front/rear 300/335 mm Rear suspension WP Progressive Damping System shock absorber, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø...
  • Page 61 TECHNICAL DATA – CHASSIS TIGHTENING TORQUES – CHASSIS Collar screw, front wheel spindle Brake caliper, front Brake caliper, FTE radial front Brake disks Clamping screws, upper fork bridge EXC Clamping screws, lower fork bridge EXC Clamping screws, upper fork bridge SX Clamping screws, lower fork bridge SX Clamping screws, fork stubs Hexagon nut, swing arm bolt...

  • Page 62: Head Work Index

    Fuse (XC/EXC) ......42 General information about KTM disc brakes ..35 General tips and warnings for starting the motorcycle .

  • Page 64: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAM red-white red-black...
  • Page 65 » SCHALTPLAN WIRING DIAGRAM red-white red-black...
  • Page 66 » SCHALTPLAN WIRING DIAGRAM headlight bl-wh bu-wh ye-bl re-wh re-bl re-bl re-wh multi-func.-digital-speedometer driving light lamp flasher control lamp front brake switch ye-re ye-re ye-re wh-gn rear light/brakelight ye-bl ye-re ye-bl ye-re wh-re black wh-re ye-re...
  • Page 67 » SCHALTPLAN WIRING DIAGRAM bl-wh bu-wh ye-bl re-wh re-bl headlight re-bl re-wh rear light/brakelight multi-func.-digital-speedometer ye-bl ye-re wh-re black ye-re wh-re ye-re...
  • Page 68 » SCHALTPLAN WIRING DIAGRAM ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
  • Page 69 » SCHALTPLAN WIRING DIAGRAM ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
  • Page 70 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

450 sx525 sx250 exc250 sx-f 2006250 exc racing 2006400 exc racing 2006 ... Show all

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