KTM 2008 525 XC ATV Manuals

Manuals and User Guides for KTM 2008 525 XC ATV. We have 2 KTM 2008 525 XC ATV manuals available for free PDF download: Repair Manual, Owner's Manual

KTM 2008 525 XC ATV Repair Manual

KTM 2008 525 XC ATV Repair Manual (223 pages)

Brand: KTM | Category: Offroad Vehicle | Size: 73.57 MB

Table of Contents

Table of Contents
4
Means of Representation
7
Important Notes
8
- Overview of Warning Labels
  10
View of Vehicle
12
- Vehicle View, Front Left
  12
- View of Vehicle, Rear Right
  13
Location of Serial Numbers
14
- Chassis Number
  14
- Type Label
  14
- Key Number
  14
- Engine Number
  14
- Setting Number, Front Shock Absorber
  14
- Setting Number, Rear Shock Absorber
  15
Vehicle
16
- Jacking up the Vehicle
  16
- Removing the Vehicle from the Work Stand
  16
02/Handlebar, Controls
17
03/Frame
20
- Removing the Engine Guard
  20
- Installing the Engine Guard
  20
04/Shock Absorber, Swingarm
21
05/Exhaust
50
- Removing the Main Silencer
  50
- Installing the Main Silencer
  50
- Removing the Manifold
  50
- Installing the Manifold
  51
06/Air Filter
52
07/Fuel Tank, Seat, Trim
54
- Removing the Seat
  54
- Mounting the Seat
  54
- Removing the Radiator Spoiler
  54
- Installing the Radiator Spoiler
  55
- Removing the Fuel Tank
  55
- Installing the Fuel Tank
  56
- Fuel Tap
  57
08/Mask, Fender
58
- Removing the Front Cover
  58
- Installing the Front Cover
  58
- Removing the Front Trim
  58
- Installing the Front Trim
  59
- Removing the Rear Fender
  59
- Installing the Rear Fender
  60
09/Front Wheel
61
- Checking Tire Air Pressure
  61
- Tire Condition Checking
  61
- Removing Wheel/Wheels
  61
- Mounting Wheel/Wheels
  62
- Checking Brake Discs
  62
10/Rear Wheel
63
- Checking Chain Dirt
  63
- Cleaning the Chain
  63
- Checking Chain Wear
  63
- Checking Rear Sprocket / Engine Sprocket for Wear
  63
- Checking the Chain Tension
  64
- Adjusting Chain Tension
  64
- Adjusting the Toe Width of Rear Axle
  65
- Removing the Rear Axle
  66
- Installing the Rear Axle
  67
- Changing the Rear Axle Bearing
  69
11/Wiring Harness, Battery
71
13/Brake System
76
30/Engine
84
- Removing the Engine
  84
- Installing the Engine
  86
30/Disassembling the Engine
89
- Preparations
  89
- Draining the Engine Oil
  89
- Removing the Oil Filter
  89
- Removing the Starter Motor
  89
- Removing the Shift Lever
  90
- Removing the Clutch Cover
  90
- Removing the Clutch Discs
  90
- Removing the Outer Clutch Hub
  91
- Removing the Starter Idler Gear/Torque Limiter
  92
- Removing the Shift Shaft
  92
- Removing the Shift Drum Locating
  92
- Removing the Locking Lever
  92
- Removing the Oil Pump Gear
  92
- Removing the Primary Gear with the Free-Wheel-Gear
  93
- Removing the Spark Plug
  93
- Removing the Generator Cover
  93
- Installing the Crankshaft Locking Bolt
  93
- Removing the Ignition Pulse Generator
  94
- Removing the Rotor
  94
- Removing the Oil Pumps
  95
- Removing the Oil Line
  95
- Removing the Timing Chain Tensioner
  96
- Removing the Water Pump Cover
  96
- Removing the Cylinder Head Top Section
  96
- Removing the Camshaft
  96
- Removing the Cylinder Head
  97
- Removing the Cylinder
  97
- Removing the Piston
  98
- Removing the Timing Chain
  98
- Removing the Timing Chain Sprocket
  98
- Removing the Locking Shaft Lever
  98
- Removing the Gear Sensor
  99
- Taking off the Left Section of the Engine Case
  99
- Remove the Shift Rails and Forks
  100
- Removing the Shift Drum
  100
- Removing the Transmission Shaft
  101
- Removing the Balancer Shaft
  101
- Removing the Crankshaft
  101
30/Engine - Work on Individual Parts
102
- Work on the Right Section of the Engine Case
  102
- Removing the Oil Pressure Regulator Valve
  103
- Checking the Spring Length of the Oil Pressure Regulator Valve
  103
- Installing the Oil Pressure Regulator Valve
  103
- Work on the Left Section of the Engine Case
  104
- Changing the Crankshaft Seal Ring in the Clutch Cover
  104
- Disassembling the Autodecompressor
  105
- Assembling the Autodecompressor
  106
- Changing the Camshaft Bearing
  107
- Checking the Rocker Arms and Rocker Arm Shafts
  108
- Removing the Valves
  109
- Checking the Valves
  110
- Checking the Valve Springs
  110
- Checking the Lower Valve Spring Retainer
  110
- Checking the Cylinder Head
  111
- Installing the Valves
  111
- Checking the Timing Assembly
  112
- Preparing the Timing Chain Tensioner for Installation
  112
- Changing the Conrod Bearing
  112
- Checking the Crankshaft Run-Out on the Bearing Pin
  113
- Measuring the Axial Clearance of the Crankshaft
  114
- Correcting the Axial Clearance of the Crankshaft
  114
- Cylinder - Nikasil Coating
  115
- Checking/Measuring the Cylinder
  115
- Checking/Measuring the Piston
  116
- Checking the Piston Ring End Gap
  116
- Checking the Piston/Cylinder Mounting Clearance
  117
- Checking the Oil Pumps for Wear
  117
- Checking the Shift Mechanism
  118
- Disassembling the Shift Shaft
  119
- Preassembling the Shift Shaft
  120
- Checking the Clutch
  120
- Disassembling the Main Shaft
  121
- Checking the Main Shaft
  122
- Assembling the Main Shaft
  123
- Disassembling the Countershaft
  124
- Checking the Countershaft
  125
- Assembling the Countershaft
  126
- Checking/Premounting the Reverse Gear Shaft
  127
- Checking Electric Starter Operation
  128
- Removing the Free-Wheel
  129
- Checking the Free-Wheel
  129
- Installing the Free-Wheel
  129
30/Assembling the Engine
130
- Installing the Crankshaft
  130
- Installing the Balancer Shaft
  130
- Installing the Transmission Shaft
  130
- Installing the Shift Forks
  131
- Installing the Shift Drum
  131
- Installing the Shift Rails
  131
- Installing the Left Engine Case
  131
- Installing the Timing Chain Sprocket
  133
- Installing the Timing Chain Rails
  133
- Installing the Piston
  133
- Installing the Cylinder
  134
- Installing the Cylinder Head
  134
- Installing the Camshaft
  135
- Installing the Cylinder Head Top Section
  136
- Installing the Timing Chain Tensioner
  137
- Installing the Rotor
  137
- Checking the Valve Clearance
  137
- Adjusting the Valve Clearance
  138
- Installing the Valve Cover
  138
- Installing the Water Pump Cover
  138
- Installing the Oil Line
  138
- Installing the Spark Plug
  138
- Installing the Primary Gear with the Free-Wheel-Gear
  139
- Installing the Oil Pumps
  139
- Installing the Ignition Pulse Generator
  140
- Installing the Generator Cover
  140
- Installing the Gear Sensor
  141
- Installing the Locking Shaft Lever
  141
- Installing the Locking Lever
  141
- Installing the Shift Drum Locating
  142
- Installing the Shift Shaft
  142
- Installing the Starter Idler Gear/Torque Limiter
  142
- Removing the Crankshaft Locking Bolt
  142
- Installing the Outer Clutch Hub and Clutch Discs
  143
- Installing the Clutch Cover
  144
- Installing the Starter Motor
  145
- Installing the Oil Drain Plug
  145
- Installing the Oil Screen
  145
- Mounting the Oil Filter
  145
- Filling up with Engine Oil
  146
- Installing the Shift Lever
  146
- Installing the Clutch Push Rod
  146
- Removing the Engine from the Universal Mounting Rack
  146
31/Carburetor
147
- Choke
  147
- Hot Start Button
  147
- Removing the Carburetor
  147
- Disassembling the Carburetor
  148
- Checking/Adjusting the Carburetor Components
  151
- Checking/Adjusting the Accelerator Pump
  151
- Checking the Hot Start Slide
  152
- Checking the Choke Slide
  152
- Checking the Jet Needle
  152
- Checking the Throttle Slide
  153
- Checking the Needle Jet
  153
- Checking the Float Needle Valve
  153
- Checking the Throttle Valve Sensor TPS
  154
- Adjusting the Position of Throttle Valve Sensor TPS
  154
- Checking/Adjusting the Throttle Slide Opening
  155
- Checking/Adjusting the Float Level
  155
- Assembling the Carburetor
  155
- Installing the Carburetor
  158
- Carburetor - Adjusting Idle
  159
- Checking the Throttle Valve Sensor Position
  160
- Emptying the Carburetor Float Chamber
  161
32/Clutch
162
- Checking Fluid Level of Hydraulic Clutch
  162
33/Transmission
163
- Removing the Engine Sprocket
  163
- Installing the Engine Sprocket
  163
35/Water Pump, Cooling System
164
- Checking Antifreeze and Coolant Level
  164
- Checking the Coolant Level
  164
- Draining Coolant
  165
- Filling Coolant / Bleeding Cooling System
  166
38/Lubrication System
168
- Changing Engine Oil and Oil Filter, Cleaning Oil Screens
  168
- Draining Engine Oil, Cleaning Oil Screens
  168
- Removing the Oil Filter
  169
- Mounting Oil Filter
  170
- Filling up with Engine Oil
  170
- Checking Engine Oil Level
  171
- Topping up Engine Oil
  171
39/Ignition System
172
- Checking the Generator
  172
- Checking the Ignition Pulse Generator
  172
- Checking the Ignition Coil
  172
- Checking the Spark Plug Connector
  173
61/Atv Front Section
174
- Toe, Checking
  174
- Adjusting the Toe
  175
- Checking/Adjusting Camber
  176
- Adjusting the Fork Offset
  177
- Removing the Wheel Carrier
  177
- Installing the Wheel Carrier
  179
- Removing the A-Arms
  180
- Installing the A-Arms
  180
- A-Arm Top - Changing the Bearing
  181
- A-Arm Bottom - Changing the Bearing
  182
Technical Data - Engine
185
- Capacity - Engine Oil
  185
- Capacity - Coolant
  186
Technical Data - Tolerance, Wear Limits of Engine
187
Technical Data - Engine Tightening Torques
188
Technical Data - Carburetor
190
- 450/525 XC Atv
  190
Technical Data - Carburetor Tightening Torques
191
Technical Data - Chassis
192
- Lighting Equipment
  193
- Tires
  193
- Capacity - Fuel
  193
Technical Data - Front Shock Absorber
194
Technical Data - Rear Shock Absorber
195
Technical Data - Chassis Tightening Torques
196
Cleaning
197
- Cleaning the Vehicle
  197
Storage
198
- Putting the Vehicle into Operation after Storage
  198
Greasing and Service Table
199
Wiring Diagram
202
- 450/525 XC Atv
  202
Substances
205
Auxiliary Substances
207
Special Tools
209
Standards
218
Index
219

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KTM 2008 525 XC ATV Owner's Manual

KTM 2008 525 XC ATV Owner's Manual (103 pages)

Brand: KTM | Category: Offroad Vehicle | Size: 4.52 MB

Table of Contents

Table of Contents
4
Means of Representation
6
Important Notes
7
- Overview of Warning Labels
  10
View of Vehicle
12
- Vehicle View, Front Left
  12
- View of Vehicle, Rear Right
  13
Location of Serial Numbers
14
- Chassis Number
  14
- Type Label
  14
- Key Number
  14
- Engine Number
  14
- Setting Number, Front Shock Absorber
  14
- Setting Number, Rear Shock Absorber
  15
Operating Elements
16
- Clutch Lever
  16
- Reverse Gear Release Lever
  16
- Hand Brake Lever, Parking Brake
  16
- Throttle Lever
  16
- Light Switch
  17
- ENG. STOP Switch
  17
- Electric Starter Button
  17
- Ignition Switch
  17
- Indicator Lamp Overview
  17
- Emergency off Switch with Rip Cord
  18
- Opening Filler Cap
  18
- Closing Filler Cap
  18
- Fuel Tap
  18
- Choke
  19
- Hot Start Button
  19
- Shift Lever
  19
- Foot Brake Pedal
  19
Tips on Putting into Operation
20
- Advice on First Use
  20
- Running in the Engine
  21
Riding Instructions
22
- Checks before Putting into Operation
  22
- Starting
  22
- Starting up
  23
- Shifting
  23
- Shifting to Reverse Gear
  24
- Disengaging Reverse Gear
  24
- Braking
  24
- Riding
  25
- Riding in Bends
  25
- Riding Downhill
  26
- Riding Uphill
  26
- Riding Perpendicular to the Slope
  27
- Turning on Slopes
  27
- Riding through Water
  27
- Switching off the Engine
  28
- Stopping, Parking
  28
- Refueling
  29
Greasing and Service Table
30
Basic Information on Changing the Chassis Settings
33
Jacking up the Vehicle
33
Removing the Vehicle from the Work Stand
33
Maintenance on Chassis and Engine
33
Adjusting Front Shock Absorber Compression Damping
33
Adjusting Front Shock Absorber Rebound Damping
34
Adjusting Front Shock Absorber Cross over
35
Adjusting Front Shock Absorber Spring Preload
35
Adjusting Rear Shock Absorber Compression Damping
36
Adjusting Rear Shock Absorber Rebound Damping
37
Adjusting Rear Shock Absorber Spring Preload
38
Removing the Rear Shock Absorber
39
Installing the Rear Shock Absorber
39
Toe, Checking
39
Adjusting the Toe
40
Checking/Adjusting Camber
42
Fork Offset
43
Adjusting the Fork Offset
43
Toe Width of Rear Axle
43
Adjusting the Toe Width of Rear Axle
43
Handlebar Position
44
Adjusting Handlebar Position
45
Checking Play in Gas Bowden Cable
45
Adjusting Play in Gas Bowden Cable
46
Checking the Play in the Bowden Cable Using the Reverse Gear Release Lever
46
Adjusting the Play in the Bowden Cable Using the Reverse Gear Release Lever
46
Checking Chain Dirt
47
Cleaning the Chain
47
Checking the Chain Tension
47
Checking Rear Sprocket / Engine Sprocket for Wear
47
Checking Chain Wear
48
Adjusting Chain Tension
48
Greasing the Rear Wheel Eccentric Element
49
Checking Brake Discs
49
Checking Free Play of Hand Brake Lever
50
Adjusting Basic Position of Handbrake Lever
50
Checking Front Brake Fluid Level
50
Topping up the Front Brake Fluid
51
Checking the Front Brake Linings
51
Removing Front Brake Linings
52
Mounting Front Brake Linings
52
Changing the Front Brake Linings
53
Checking Free Play of Foot Brake Lever
54
Adjusting Basic Position of Footbrake Lever
54
Checking Rear Brake Fluid Level
54
Topping up Brake Fluid of Front Brake
55
Checking Rear Brake Linings
56
Removing Rear Brake Linings
56
Mounting Rear Brake Linings
57
Changing Rear Brake Linings
57
Removing Wheel/Wheels
58
Mounting Wheel/Wheels
58
Tire Condition Checking
59
Checking Tire Air Pressure
59
Removing the Battery
59
Installing the Battery
60
Recharging the Battery
60
Changing the Fuses of Individual Power-Consuming Components
61
Changing Main Fuse
61
Ignition Curve Plug Connection
62
Removing the Seat
63
Mounting the Seat
63
- Removing the Radiator Spoiler
  63
- Installing the Radiator Spoiler
  64
- Removing the Front Cover
  64
- Installing the Front Cover
  64
- Removing the Front Trim
  65
- Installing the Front Trim
  65
- Removing the Rear Fender
  65
- Installing the Rear Fender
  66
- Removing the Engine Guard
  67
- Installing the Engine Guard
  67
- Removing the Air Filter
  67
- Installing the Air Filter
  68
- Cleaning Air Filter
  68
- Adjusting Basic Position of Clutch Lever
  68
- Checking Fluid Level of Hydraulic Clutch
  68
- Cooling System
  69
- Radiator Fan
  69
- Checking Antifreeze and Coolant Level
  69
- Checking the Coolant Level
  70
- Draining Coolant
  70
- Filling Coolant / Bleeding Cooling System
  71
- Carburetor - Idle
  72
- Carburetor - Adjusting Idle
  73
- Emptying the Carburetor Float Chamber
  74
- Checking Engine Oil Level
  74
- Changing Engine Oil and Oil Filter, Cleaning Oil Screens
  75
- Draining Engine Oil, Cleaning Oil Screens
  75
- Removing the Oil Filter
  76
- Mounting Oil Filter
  77
- Filling up with Engine Oil
  77
- Topping up Engine Oil
  78
Changing Ignition Curve
63
Troubleshooting
79
Cleaning
81
- Cleaning the Vehicle
  81
Storage
82
- Putting the Vehicle into Operation after Storage
  82
Technical Data - Engine
83
- Capacity - Engine Oil
  83
- Capacity - Cooling Liquid
  84
Technical Data - Engine Tightening Torques
85
Technical Data - Carburetor
87
- 450/525 XC Atv
  87
Technical Data - Chassis
88
- Lighting Equipment
  89
- Tires
  89
- Capacity - Fuel
  89
Technical Data - Front Shock Absorber
90
Technical Data - Rear Shock Absorber
91
Technical Data - Chassis Tightening Torques
92
Wiring Diagram
94
- 450/525 XC Atv
  94
Substances
97
Auxiliary Substances
99
Standards
100
Index
101

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