KTM 625 SXC Owner's Manual
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KTM 625 SXC Owner's Manual

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OWNER'S MANUAL
2007
625 SXC
ART. NR. 3.211.195EN

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  • Page 1 OWNER’S MANUAL 2007 625 SXC ART. NR. 3.211.195EN...
  • 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: Guarantee Information

    » 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.

  • Page 4: Important Limited Warranty And Limited Guarantee Information

    If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer.

  • Page 5: Table Of Contents

    Changing the basic position of the handbrake lever (SMC) .29 General information about KTM disc brakes ..29 SERIAL NUMBER LOCATIONS ....5 Checking of brake fluid level - front brake .

  • Page 6: Serial Number Locations

    » SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket.

  • Page 7: Operation Instruments

    » OPERATION INSTRUMENTS Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjust- ing screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). Hand decompression lever The hand decompression lever [2] is only used in two special cases: a) When the engine stalled.

  • Page 8: 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 9 » OPERATION INSTRUMENTS Activating and deactivating display modes In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blink- ing function can be activated by pressing the + button and deactivated by pressing the –...
  • Page 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.
  • Page 11 » 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 12: Overview Of The Electronic Speedometer Functions

    » OPERATION INSTRUMENTS Setting the clock To 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.

  • Page 13: Ignition Lock

    » OPERATION INSTRUMENTS Ignition lock Switch positions of ignition lock [1]: = Ignition off, light off (engine can't be started) = Ignition on, light off (engine can be started) = Ignition on, light on (engine can be started) Combination switch The light switch has 2 switch positions.

  • Page 14: Fuel Tap

    » OPERATION INSTRUMENTS Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. When using the motorcycle, the rotating handle must be set to the ON position. Now fuel may flow to carburetor. In this position the tank emp- ties down to the fuel reserve of approx.

  • Page 15: Foot Brake Pedal

    » OPERATION INSTRUMENTS Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). Handlebar lock The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw.

  • Page 16: Compression Damping Of Fork

    » OPERATION INSTRUMENTS Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing cap [A]. By using the knob [1] (COM), the degree of damping of the compres- sion can be adjusted.

  • Page 17: General Tips And Warnings For Starting The Motorcycle

    – The 625 SXC is designed and built for one person only - no Never exceed the maximum permissible laden weight and the additional passenger allowed! axle weights.

  • Page 18: 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 19: Starting When The Engine Is Cold

    » DRIVING INSTRUCTIONS Starting when the engine is cold 1 Open the fuel tap [1] 2 Switch on ignition (turn ignition key [2] into position 3 Swing up the side stand or center stand 4 Put the gear in neutral 5 Operate the choke [5] 6 Do not accelerate;...

  • Page 20: Starting Off

    NOTE: brake discs can delay the braking effect. The brakes must be Dedicated to nothing but offroad racing, 625 SXC models make pulled until they are dry or clean. no compromises in their design. As such, they do not include any –...

  • Page 21: Fuel

    » DRIVING INSTRUCTIONS INFORMATION ABOUT THE SIDE STAND Use your foot to push the side stand forward as far as possible, and lean your motorcycle to the side. Make sure that your motorcycle is standing safely on solid ground. Just in case, you can also put in a gear. The side stand is dimensioned for the weight of the motorcycle only.

  • Page 22: Periodic Maintenance Schedule

    » PERIODIC MAINTENANCE SCHEDULE 1. Service every after 5000 km A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY! 1000 km or 10 hours once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace every 10,000 km Check and adjust valve clearance...
  • Page 23 » PERIODIC MAINTENANCE SCHEDULE IMPORTANT SERVICE WORK THAT MUST BE PERFORMED BY AN AUTHORIZED KTM WORKSHOPUNDER A SEPARATE ORDER every 2500 at least once every 2 years km or 25 a year or 20000 km hours Perform complete fork maintenance...

  • Page 24: Maintenance Work On Chassis And Engine

    – When transporting your KTM, ensure that it is held upright with restraining straps or other mechanical fastening devices and that the fuel tap is in the OFF position - if the motorcycle should fall down, be aware of any leaking fuel from the carburetor or fuel tank –...

  • Page 25: Removal Of Seat (Smc)

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Removal of seat (SMC) Actuate the lever [1] while lifting the back of the seat [2]. When you mount the seat, make sure the retaining brackets are fastened to the seat. Tool set (SMC) The tool set [3] is located under the seat.

  • Page 26: Breather Plug Front Fork

    » 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. To do this, place the motorcycle on a stand with the front wheel lifted off the ground.

  • Page 27: Changing The Spring Preloading Of The Shock Absorber

    The space should be at least 2.5 mm (0.1 in) wide. Have min. 2,5 mm the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. Not replacing the rubber ring in time can result in damage to the rear shock absorber.

  • Page 28: Correct Chain Tension

    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.

  • Page 29: Chain Wear

    – The chain does not have a chain joint for safety reasons. Always have the chain replaced in an authorized KTM workshop where the service techni- cans have the required riveting tool.

  • Page 30: Adjusting Of Free Travel At The Hand Brake Lever (Sxc)

    Other brake pads are available for competition sports. Brake shoes available in the accessory trade are often not authorized for oper- ation of your KTM motorcycle in road traffic. The brake shoe's design and fric- tion factor and therefore the braking power can deviate significantly from orig- inal KTM brake shoes.

  • Page 31: Checking Of Brake Fluid Level - Front Brake

    – As a matter of principle, have any repair of the brake system carried out by a licensed KTM mechanic. Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the han- dlebar and the reservoir is provided with an inspection glass.

  • Page 32: Checking The Front Brake Pads (Sxc)

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the front brake pads (SXC) min. The brake pads can be inspected from below. The linings nust be at least 1 mm (0,04 in) thick. 1 mm At their most worn point brake pad linings should not be thinner than 1 mm, otherwise they could lead to brake failure.

  • Page 33: Replacing The Front Brake Pads (Smc)

    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 author- ized KTM dealer immediately. Refilling the rear brake fluid reservoir * When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir.

  • Page 34: Changing The Basic Position Of The Brake Pedal

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller [1]. Using the push rod [2], the free play on the foot brake pedal must be set.

  • Page 35: Dismounting And Mounting The Front Wheel (Sxc)

    – 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.

  • Page 36: 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 behavior of your motorcycle.

  • Page 37: Tires, Air Pressure

    Tire pressure should be checked regularly on a “cold” tire. Proper pressure ensures optimum driving comfort and extends the life of your tires. TIRES - AIR PRESSURE SXC – Do not mount tires which have not been approved by KTM. Other tires front rear could have adverse effects on the way your motorcycle behaves.

  • Page 38: Battery (Sxc)

    Storage temperature: 0 - 35°C (30 - 95°F). Do not expose to direct sunlight. Charging the battery NOTE: A battery charger, item no. 58429074000 is available from your KTM dealer. You can also use the battery charger to test the battery's off load voltage, starta- bility and the generator capacity.

  • Page 39: Fuses

    Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. Under no circumstances is a stronger fuse allowed to be set in or a fuse allowed to be “repaired”.

  • Page 40: Exchanging The Brake Light And Tail Light Bulb (Sxc)

    To mount the lamp reverse the worksteps indicated above. NOTE: Since the bulb on the tail end is subjected to higher vibrations, heavy- duty bulbs are available from your KTM dealer. Exchanging the brake light and tail light bulb (SMC) Remove seat.

  • Page 41: Checking The Coolant Level

    CAREFUL – RISK OF SCALDING! Only continue driving if there is enough liquid in the system. Stop at an authorized KTM workshop as soon as possible to have the defect elimi- nated. If you continue to drive with an overheated engine, you will dam- age the engine.

  • Page 42: Cleaning The Air Filter (Sxc)

    – Do not clean foam filter with fuel or petroleum since these damage the foam. KTM recommends the products of the company Motorex for air fil- ter maintenance (Bio Dirt Remover and Liquid Bio Power). Mount the air filter on the filter holder, position in the filter box (make sure to center) and fix with the retaining clip.

  • Page 43: Exhaust System (Sxc)

    „burn out“. In addition to causing a higher noise-level, it will also affect the power characteristic. The insulating mate- rial suitable for your exhaust is available from your authorized KTM workshop. Experience has shown that the front glass fiber pack [1] must be replaced more often than the rear pack [2].

  • Page 44: Adjusting The Throttle Cable

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the throttle cable * The throttle grip should always provide for a backlash of 3-5 mm (0.12-0.20 3-5 mm in). Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right.

  • Page 45: Changing The Original Position Of The Clutch Lever

    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 workshop) to make sure your clutch operates smoothly. Never refill with brake fluid.

  • Page 46: Activating The Ignition Curve For Low-Octane Fuel

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Activating the ignition curve for low-octane fuel (SMC) If you are traveling to a country where fuel having at least 95 octane (ROZ) is not available, you can easily activate the corresponding ignition curve. A socket connector [1] is located on a brown-black cable near the digital box.

  • Page 47: Adjusting The Mixture Control Screw

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

  • Page 48: Oil Circuit

    Remove oil dipstick on the clutch cover, fill with 1.3 litre (0.34 US gallons) engine oil and attach plug again. – Use only original KTM fine screen filters. Using another filter brand can result in damage to the engine. – If the engine oil has been drained from the front pipe of the frame, you...

  • Page 49: Changing Oil Filter

    » MAINTENANCE WORK ON CHASSIS AND ENGINE To facilitate bleeding of the oil system, we have added a hose connection piece and a plastic hose to the set of tools. Take an empty oil can (1 liter) and drill a 7 mm (0.28 in) -diameter hole into the lid. Screw the hose connection piece into the lid from the outside, and secure it from the inside with the M8 hexa- gon nut.

  • Page 50: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 51 Float leaks Replace the float Air filter very dirty Clean or replace air filter, contact a KTM dealer Valve clearance to small Have valve clearance adjusted Loss of compression because hand decom- Check setting of the hand decompression cable...

  • Page 52: Cleaning

    » 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 trade washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet.

  • Page 53: Technical Specifications - Engine

    Only use fully synthetic engine oils that meet the JASO MA quality require- JASO T903 MA ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
  • Page 54 » TECHNICAL SPECIFICATIONS – ENGINE BASIC CARBURETOR SETTING 625 SXC/SMC Type Keihin FCR-MX 4138A Carburator-setting number 4138A Main jet Jet needle OBDVT (OBEKR) Idling jet 42 (45) Main air jet Idling air jet Needle position from top (4 from top)

  • Page 55: Technical Specifications - Chassis

    » TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 625 SMC Frame Central chrome-moly-steel frame Fork WP Suspension 4357 MXMA WP Suspension 4860 MXMA Wheel travel front/rear 295 / 300 mm (11.6 / 11.8 in) 265 / 300 mm Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing...
  • Page 56 » TECHNICAL SPECIFICATIONS - CHASSIS TIGHTENING TORQUES - CHASSIS Collar nut front axle SXC M16x1,5 40 Nm Collar nut front axle SMC M24x1,5 40 Nm Collar nut rear axle M20x1.5 80 Nm Shock absorber top M10 (10.9) 45 Nm Shock absorber bottom M10 (10.9) 45 Nm Collar screws brake disk rear...

  • Page 57: Head Word Index

    Bleeding of the hydraulic clutch ....44 General information about KTM disc brakes ..29 Braking ....... . .19 General tips and warnings for starting the motorcycle .16...

  • Page 58: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAMM...
  • Page 59 » SCHALTPLAN WIRING DIAGRAMM g i l c t i c t i c t i g i l c t i c t i l i k c t i c t i c t i...
  • Page 60 » SCHALTPLAN WIRING DIAGRAMM ENGLISH DEUTSCH ITALIANO headlight Scheinwerfer faro parking light Standlicht luce di posizione turn indic left fr Blinker li vo lampegg ant sn turn indic left fr Blinker re vo lampegg ant dx ignition controll ON Zündungskontrolle ON spiedicontrollo ON high beam indicator Fernlichtkontrolle...
  • Page 61 ENGLISH FRANCAIS ESPANIOL headlight phare faro parking light feu de position luz de posicion turn indic left fr clignoteur av gauche interm izquierdo delantero turn indic left fr clignoteur av droit intermitene derecho delantero ignition controll ON temion ON luces de aviso ON high beam indicator temoin feu route lampara aviso luces largas...
  • Page 62 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

This manual is also suitable for:

625 smc 2005625 sxc 2005

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