Related Manuals for KTM MXC 2004
Summarization of Contents
Serial Number Locations
Chassis Number
Location of the vehicle's unique identification number stamped on the steering head tube.
Engine Number and Type
Location of the engine's identification numbers stamped on the engine case.
Operation Instruments
Clutch Lever
Controls the clutch engagement and disengagement, adjustable for rider comfort.
Hand Decompression Lever
Aids in starting the engine, especially after a fall, by releasing compression.
Hand Brake Lever
Operates the front wheel brake, adjustable for rider preference.
Short Circuit Button
Turns the engine off by short-circuiting the ignition circuit.
Combination Switch (EXC)
Controls lights, horn, and engine shut-off on EXC models.
Headlamp Switch (EXC USA)
Controls the headlamp operation, typically via a pull switch.
Flasher Switch
Controls the turn indicators, designed for easy removal.
Starter Button (EXC)
Activates the electric starter motor to start the engine.
Electronic Speedometer and Tripmaster
Indicator Lamps and Basic Display Modes
Overview of indicator lights and core speed/hour/ODO modes.
Tripmaster Switch Functions
Operation of the tripmaster switch and its various display modes.
Display Mode Settings
Setting the clock and managing display mode visibility.
Unit Settings (Kilometers or Miles)
How to change the unit of measurement for distance.
Controls and Fuel System
Emergency OFF Switch (EXC Australia)
Safety switch to immediately shut off the engine.
Filler Cap
Location and function of the fuel tank filler cap.
Fuel Tap
Controls fuel flow to the carburetor; includes OFF, ON, and RES positions.
Choke Operation
Enriches fuel mixture for cold starting by opening a bore in the carburetor.
Hot Start Device
Hot Start Operation
Aids in starting the engine when warm by creating a lean mixture.
Shift Lever
Gear Shifting
Explanation of gear positions and how to shift gears.
Kickstarter
Kickstarter Operation
Manual method for starting the engine.
Foot Brake Pedal
Foot Brake Pedal Adjustment
Location and basic position adjustment of the foot brake pedal.
Side Stand
Side Stand Usage
Proper method for deploying and using the side stand.
Suspension Adjustments
Fork Damping
Adjusting compression and rebound damping on front forks.
Shock Absorber Damping
Adjusting compression and rebound damping on rear shock.
Steering Lock Operation
Mechanism to secure the handlebar position when parked.
General Tips and Warnings for Starting
Instructions for Initial Operation
Guidance for the first use of the motorcycle and operating elements.
Running In Racing Models
Specific break-in procedure for racing models to ensure engine longevity.
Driving Instructions
Pre-Ride Checks
Essential checks of oil, fuel, chain, tires, brakes, cables, and electrical system.
Starting Procedure (Cold)
Steps for starting a cold engine, including choke usage.
Starting Procedure (Warm)
Steps for starting a warm engine without choke.
Handling a Flooded Engine
Steps to take if the engine fails to start due to excessive fuel.
Starting Off and Shifting Gears
How to move off and change gears while riding the motorcycle.
Braking and Parking
Braking Techniques
Proper methods for applying brakes, including considerations for different surfaces.
Stopping and Parking
Procedures for safely stopping the engine and parking the motorcycle.
Fuel Recommendations
Recommended fuel type and octane rating for the engine.
Periodic Maintenance Schedule
Engine Maintenance
Scheduled maintenance for the engine components at specific intervals.
Carburetor Maintenance
Scheduled maintenance for the carburetor system.
Brakes Maintenance
Scheduled maintenance for the braking system components.
Chassis Maintenance
Scheduled maintenance for the chassis and suspension components.
Wheels Maintenance
Scheduled maintenance for wheels, chain, and bearings.
Rider Maintenance Checks
Pre-Ride Checks
Essential checks to perform before each start.
After Cleaning Checks
Checks to perform after cleaning the motorcycle.
Cross-Country Use Checks
Specific checks for off-road riding conditions.
Engine Inspection (Enduro Competitions)
Inspection Schedule
Recommended inspection intervals for competition engines.
Engine Inspection (Hobby Enduro)
Inspection Schedule
Recommended inspection intervals for hobby enduro engines.
Maintenance Work on Chassis and Engine
Steering Head Bearing Adjustment
Checking and adjusting the steering head bearing for play.
Front Fork Maintenance
Breather Plug
Releasing excess pressure from the front fork.
Dust Sleeve Cleaning
Cleaning fork dust seals to prevent leaks.
Spring Preload Adjustment (SX)
Adjusting fork spring preload for the SX model.
Suspension Setup and Adjustment
Basic Setup for Driver Weight
Adjusting suspension based on rider weight.
Shock Absorber Sag Measurement
Determining static and riding sag for setup.
Fork Adjustments and Replacement
Basic Fork Setup
Checking and adjusting the fundamental fork settings.
Spring Preload Adjustment
Adjusting spring preload on fork models.
Replacing Fork Springs
Procedure for replacing fork springs based on weight.
Chassis Adjustments
Handlebar Position Adjustment
Modifying handlebar position for rider comfort.
Shock Absorber Spring Preload
Adjusting spring preload on the rear shock absorber.
Pivot Bearing Maintenance
Care and cleaning of the pivot bearing.
Chain Maintenance
Checking and Correcting Chain Tension
Procedures for checking and adjusting chain tension.
Chain Care and Wear
Chain Maintenance Procedures
Cleaning and lubricating the chain for longevity.
Checking Chain Wear
Method for measuring chain wear and replacement intervals.
KTM Disc Brakes
Brake Calipers and Pads
Information on caliper design and pad types.
Brake Discs and Fluid Reservoirs
Disc wear limits and reservoir design.
Brake Fluid Recommendations
Recommended brake fluid types and care.
Front Brake System
Hand Brake Lever Free Travel
Adjusting lever play for optimal feel.
Front Brake Fluid and Pad Checks
Monitoring fluid level and pad wear.
Brake System Maintenance
Replacing Front Brake Pads
Steps for replacing worn front brake pads.
Foot Brake Pedal and Rear Brake Fluid
Pedal adjustment and rear fluid level checks.
Refilling Rear Brake Fluid
Procedure for topping up rear brake fluid.
Rear Brake and Wheel Service
Rear Brake Pad Inspection
Checking rear brake pad thickness for wear.
Front Wheel Service
Procedure for removing and mounting the front wheel.
Rear Wheel and Spoke Service
Rear Wheel Service
Procedure for removing and mounting the rear wheel.
Spoke Tension Check
Ensuring correct spoke tension for wheel stability.
Tires, Sensors, and Battery
Tire Pressure and Condition
Importance of correct tire pressure and condition.
Speedometer Sensor and Battery
Sensor adjustment and speedometer battery replacement.
Battery Service
Battery Information and Care
Details on the maintenance-free battery and its care.
Battery Charging Procedure
Steps and guidelines for charging the battery.
Electrical System Components
Fuse Replacement
Location and replacement of fuses in the electrical system.
Headlight and Parking Light Bulb Replacement
Procedure for changing lamps in the headlight assembly.
Cooling System
Coolant Level Check
How to check and maintain the coolant level.
Bleeding the Cooling System
Procedure for removing air from the cooling system.
Exhaust System Maintenance
Silencer Packing Replacement
Replacing glassfiber yarn in the silencer for noise reduction.
Spark Arrester Cleaning
Cleaning the spark arrester for emissions control.
Engine and Control Adjustments
Air Filter Cleaning
Cleaning the air filter for optimal engine performance.
Decompression and Throttle Cable Adjustment
Adjusting decompression and throttle cables.
Hydraulic Clutch System
Clutch Lever Position Adjustment
Adjusting the clutch lever for optimal reach.
Hydraulic Clutch Fluid Service
Checking oil level and bleeding the clutch system.
Carburetor Adjustments
Idling and Mixture Control
Setting engine idling speed and fuel-air mixture.
Float Level Check
Verifying the fuel level in the carburetor float chamber.
Engine Lubrication and Oil
Draining Carburetor Float Chamber
Removing fuel from the float chamber.
Engine Oil Level and Circuit
Checking oil level and understanding the oil circuit.
Engine Oil Change
Engine Oil Specifications
Recommended engine oil types and viscosity.
Engine Oil and Filter Change Procedure
Steps for changing engine oil and filters.
Oil Screen Cleaning
Procedures for cleaning engine oil screens.
Oil Filters Maintenance
Oil Filter Replacement
Procedure for changing engine oil filters.
Troubleshooting
Problem Diagnosis and Solutions
Common issues, causes, and remedies for the motorcycle.
Storage and Cleaning
General Cleaning Procedure
How to clean the motorcycle properly.
Winter Conservation and Storage
Protecting the motorcycle for winter and storage guidelines.
Post-Storage Use
Preparations for using the motorcycle after storage.
Technical Data - Chassis
Fork Standard Adjustments
Default settings for fork components.
Chassis Tightening Torques
Torque specifications for chassis fasteners.
Shock Absorber Standard Adjustments
Default settings for shock absorber components.
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