KTM 525 XC Owner's Manual
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KTM 525 XC Owner's Manual

2012
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OWNER'S MANUAL
2012
525 XC ATV
Art. no. 3211727en

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Summary of Contents for KTM 525 XC

  • Page 1 OWNER'S MANUAL 2012 525 XC ATV Art. no. 3211727en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous DEAR KTM CUSTOMER pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle.
  • Page 4 DEAR KTM CUSTOMER ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Foot brake lever..............29 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 PREPARING FOR USE ............30 IMPORTANT INFORMATION ........... 8 Checks and maintenance measures when preparing for VIEW OF VEHICLE..............12 use ................. 30 View of the vehicle from the left front (example) ....12 Running in the engine............
  • Page 6 TABLE OF CONTENTS Rear shock absorber - adjusting the compression damping ... 52 Cleaning the air filter and air filter box ......86 Rear shock absorber - adjusting the rebound damping..54 Checking the toe ............87 Rear shock absorber - adjusting the spring preload ..
  • Page 7 TABLE OF CONTENTS Checking the front brake linings........116 Checking the coolant level..........146 Removing front brake linings ........117 Draining coolant ............147 Mounting front brake linings ........118 Filling coolant / bleeding cooling system ...... 149 TUNING THE ENGINE ............152 Changing the front brake linings .........
  • Page 8 TABLE OF CONTENTS TECHNICAL DATA - ENGINE ..........178 Capacity - engine oil ............179 Capacity - coolant............179 TECHNICAL DATA - ENGINE TIGHTENING TORQUES... 180 TECHNICAL DATA - CARBURETOR........183 TECHNICAL DATA - CHASSIS ..........184 Lighting equipment ............186 Tires ................

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed at an authorized KTM workshop! There, your vehicle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 10: Important Information

    IMPORTANT INFORMATION Use definition KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid regulations and categories of the top international motorsport organizations. Warning Danger of accidents Incorrect assessment of riding situations.
  • Page 11 Spare parts, accessories For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 12 IMPORTANT INFORMATION Transport Note Danger of damage Danger of damage from accidental rolling of vehicle. – Park the vehicle on a surface that is as level as possible and activate the parking brake. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. –...
  • Page 13 IMPORTANT INFORMATION Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured. Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 101522-10...
  • Page 15 VIEW OF VEHICLE Hand brake lever, parking brake ( p. 20) Fuse box Compression adjustment for front shock absorber Front left shock absorber Rebound adjustment for front shock absorber Reverse gear release lever ( p. 19) Clutch lever ( p. 19) Filler cap Emergency OFF switch with rip cord ( p.

  • Page 16: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 101523-10...
  • Page 17 VIEW OF VEHICLE Ignition lock ( p. 23) Light switch ( p. 21) ENG. STOP switch ( p. 22) Electric starter button ( p. 22) Main silencer Seat release Rear shock absorber Rebound adjustment for rear shock absorber Rear brake Throttle lever ( p.

  • Page 18: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper A-arm. 101524-10 Type label The type label is located on the frame tube on the right in front of the radiator. 101525-10...

  • Page 19: Key Number

    SERIAL NUMBERS Key number The key number is indicated on the KEYCODECARD. Info You need the key number to order a replacement key. Keep the KEYCODECARD in a safe place. 100089-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. 100001-10...

  • Page 20: Setting Number, Front Shock Absorber

    SERIAL NUMBERS Setting number, front shock absorber The setting number is stamped into the top of the shock absorber. 601024-10 Setting number, rear shock absorber The setting number is stamped into the top of the shock absorber. 601083-10...

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. Possible states Clutch lever in neutral position – In this position, the engine is force-locked with the • gear and the starting circuit is interrupted. The electric starter does not turn over when the electric starter button is pressed.

  • Page 22: Hand Brake Lever, Parking Brake

    CONTROLS Hand brake lever, parking brake The hand brake lever is located on the right side of the handlebar and operates the front brakes. The hand brake lever is combined with the parking brake, which blocks the front wheels to prevent the vehicle from rolling away.

  • Page 23: Throttle Lever

    CONTROLS Throttle lever The throttle lever is fitted on the right side of the handlebar. The throttle lever is used to control the engine speed. 100007-10 Light switch The light switch is fitted on the left side of the handlebar. Possible states High beam on –...

  • Page 24: Eng. Stop Switch

    CONTROLS ENG. STOP switch The ENG. STOP switch is fitted on the left side of the handlebar. Possible states ENG. STOP switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started. ENG.

  • Page 25: Ignition Lock

    CONTROLS Ignition lock The ignition lock is located on the instrument support. Possible states Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a standing engine will not start. Ignition on – In this position, the ignition circuit is closed and the engine can be started.

  • Page 26: Emergency Off Switch With Rip Cord

    CONTROLS Emergency OFF switch with rip cord 5.10 The emergency OFF switch is mounted on the left in front of the fuel tank. A rip cord is attached to clip . It can be attached to the clothing of the rider by means of carabiner The emergency OFF switch shuts the engine off if the rider falls off the vehicle.

  • Page 27: Closing Filler Cap

    CONTROLS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Press release button , turn filler cap counterclockwise and lift it free. 100012-10 Closing filler cap 5.12...

  • Page 28: Fuel Tap

    CONTROLS Fuel tap 5.13 The fuel tap is on the right of the fuel tank. With the tap handle on the fuel tap, you can open or close the supply of fuel to the car- buretor. Possible states Fuel supply off OFF – No fuel can flow from the tank to the carburetor. •...

  • Page 29: Choke

    CONTROLS Choke 5.14 The choke is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 30: Shift Lever

    CONTROLS Shift lever 5.16 The shift lever is mounted on the left side of the engine. 100018-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. Reverse gear can only be engaged with the vehicle at a standstill and the lever pulled. 100017-10...

  • Page 31: Foot Brake Lever

    CONTROLS Foot brake lever 5.17 The foot brake lever is located in front of the right footrest and operates the rear wheel brake. 100016-10...

  • Page 32: Preparing For Use

    PREPARING FOR USE Checks and maintenance measures when preparing for use Info Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the engine oil level. ( p.

  • Page 33: Running In The Engine

    PREPARING FOR USE Running in the engine – During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline Maximum engine speed During the first operating hour 7,000 rpm Maximum engine performance ≤ 75 % During the first 3 operating hours –...

  • Page 34: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the engine oil level. ( p.

  • Page 35: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
  • Page 36 RIDING INSTRUCTIONS Info Under no circumstances should you open the throttle when switching on the ignition! The vehicle is equipped with a safety system that switches off the engine in case of a malfunction in the throttle lever, cable, or carburetor.

  • Page 37: Starting Off

    RIDING INSTRUCTIONS Starting off Info Switch on the light before riding the vehicle. You will then be seen earlier by other motorists. – Pull the hand brake lever and release it again. Locking pawl moves into its basic position, parking brake is deactivated. –...

  • Page 38: Shifting To Reverse Gear

    RIDING INSTRUCTIONS Shifting to reverse gear Warning Danger of accidents Danger of accidents from blocked rear wheels if reverse gear is engaged while the vehicle is rolling. – To engage reverse gear, it is important to stop the vehicle first and have the engine at idle speed. Note Transmission damage Danger of transmission damage when engaging reverse gear while the vehicle is rolling.

  • Page 39: Braking

    Adapt your braking to the traffic situation and the road conditions. Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 40: Riding

    Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. If the vehicle goes out of control and you fall off the vehicle, the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing.

  • Page 41: Riding In Bends

    RIDING INSTRUCTIONS Guideline ≥ 2 min – Avoid slipping the clutch frequently and for prolonged periods. This heats the engine oil, the engine and the cooling system. – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch. Riding in bends Info When riding in bends, the outer wheels cover a greater distance than the inner wheels.

  • Page 42: Riding Downhill

    RIDING INSTRUCTIONS Riding downhill 7.10 Warning Danger of accidents Danger of accidents when riding on slopes. – Always check the terrain before riding onto a slope. – Never ride on a slope with an inclination of more than 25°. – Never ride on a slope that exceeds your driving skills. –...

  • Page 43: Riding Uphill

    RIDING INSTRUCTIONS Riding uphill 7.11 Warning Danger of accidents Danger of accidents when riding on slopes. – Always check the terrain before riding onto a slope. – Never ride on a slope with an inclination of more than 25°. – Never ride on a slope that exceeds your driving skills. –...

  • Page 44: Riding Perpendicular To The Slope

    RIDING INSTRUCTIONS Riding perpendicular to the slope 7.12 Warning Danger of accidents When riding perpendicular to a slope, the vehicle can tip easily and roll over. – Avoid riding perpendicular to the slope if possible. – Ride slowly and shift you weight toward the slope. –...
  • Page 45 RIDING INSTRUCTIONS – After coming to a stop on a slope with your vehicle, dismount from the vehicle and turn – Switch off the engine and activate the parking brake. Info A gear must be engaged. – Dismount from the vehicle on the uphill side. –...

  • Page 46: Riding Through Water

    After riding through water, dry the brakes by lightly activating both brakes until normal braking power is available again. – If the vehicle became submerged, an authorized KTM workshop must perform a thor- ough check and comprehensive service. Do not start the engine. Switching off the engine 7.15...

  • Page 47: Stopping, Parking

    RIDING INSTRUCTIONS – Turn the key in the ignition lock to the position Info All power consumers are switched off. Alternative 2 Switch off the engine using the ENG. STOP switch. – Press the ENG. STOP switch to the position Info All power consumers are switched off.

  • Page 48: Refueling

    RIDING INSTRUCTIONS – Park the vehicle on a surface that is as level as possible and activate the parking brake. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. – Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run.
  • Page 49 RIDING INSTRUCTIONS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 50: Service Schedule

    SERVICE SCHEDULE Service schedule S15A S30A Check that the electrical equipment is functioning properly. • • • • • Check and charge the battery. • • • Change the engine oil and oil filter, clean the oil screens. p. 161) Check the front brake linings.
  • Page 51 • • Create a service entry in the KTM DEALER.NET and in the service record. S1N: Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal) S15A: Every 15 operating hours - corresponds to about 105 liters of fuel (27.7 US gal)

  • Page 52: Maintenance Work (As An Additional Order)

    SERVICE SCHEDULE Maintenance work (as an additional order) S45A S90A S180A • Change the front brake fluid. • Change the rear brake fluid. • Change the sealing sleeves of the foot brake cylinder. Change the hydraulic clutch fluid. • Lubricate the steering column bearing. •...
  • Page 53 SERVICE SCHEDULE S45A S90A S180A Check the transmission and shift mechanism. • • • • Check the oil pressure regulator valve. • • Check the oil pumps and lubrication system. • • Check the timing assembly. • • Change all engine bearings. S45A: Every 45 operating hours - corresponds to about 315 liters of fuel (83.2 US gal) S90A: Every 90 operating hours - corresponds to about 630 liters of fuel (166.5 US gal) / every 45 operating hours after sporting use - cor- responds to about 315 liters of fuel (83.2 US gal)

  • Page 54: Tuning The Chassis

    TUNING THE CHASSIS Basic information on changing the chassis settings The standard setting of the chassis is the result of many fine tuning tests. It is laid out for the weight of the average rider (with a full set of protective clothing) and for a sporty driving style.
  • Page 55 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The compression damping setting has an impact on the compression of the shock absorber.

  • Page 56: Rear Shock Absorber - Adjusting The Rebound Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The rebound damping setting has an impact on the rebound of the shock absorber.

  • Page 57: Rear Shock Absorber - Adjusting The Spring Preload

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.
  • Page 58 TUNING THE CHASSIS – Remove the rear shock absorber. p. 72) – After removing the shock absorber, clean it thoroughly. – Loosen screw Info Do not loosen lock nut at the top of the shock absorber. – Turn adjusting ring until the spring is no longer under tension.
  • Page 59 TUNING THE CHASSIS – Measure the overall spring length while the spring is not under tension. Info The spring preload is the difference in length between the spring when it is unloaded and when it is installed. – Tighten the spring by turning the adjusting ring to the specified measurement. Guideline Spring preload Comfort...

  • Page 60: Front Shock Absorber - Adjusting The Compression Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The compression damping setting has an impact on the compression of the shock absorber.

  • Page 61: Front Shock Absorber - Adjusting The Rebound Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The rebound damping setting has an impact on the rebound of the shock absorber.

  • Page 62: Front Shock Absorber - Adjusting The Cross Over

    TUNING THE CHASSIS – Turn adjusting screw clockwise up to the last perceptible click. – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks 601036-10 Experience has shown that settings outside of this range are detrimental to vehi- cle handling.
  • Page 63 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The cross over setting is used to adjust the suspension travel of the short (soft) spring.

  • Page 64: Front Shock Absorber - Adjusting The Spring Preload

    After making adjustments, ride slowly at first to get the feel of the new ride behavior. Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
  • Page 65 TUNING THE CHASSIS Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling. Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. –...
  • Page 66 TUNING THE CHASSIS – Tighten the spring pack by turning adjusting ring to measurement Guideline Spring preload 0 0 A Comfort 4 mm (0.16 in) Standard 5 mm (0.2 in) Sport 8 mm (0.31 in) Info Spring preload is the difference in length between the spring pack when it is unloaded and when it is installed.

  • Page 67: Handlebar Position

    TUNING THE CHASSIS Handlebar position The handlebar position can be adjusted 4-fold by turning the handlebar support and the handlebar support The holes on the handlebar support are placed at a distance of from the center. Distance between holes 3.5 mm (0.138 in) The holes on the handlebar bridge are placed at a distance of from the center.

  • Page 68: Adjusting The Handlebar Position

    TUNING THE CHASSIS Adjusting the handlebar position 9.10 – Pull the instrument support off the handlebar and swing it to the side. Info Protect the vehicle and its attachments from damage by covering them. Do not kink the cables and lines. –...
  • Page 69 TUNING THE CHASSIS – Remove the four screws . Remove handlebar clamps , swing the handlebar forward and set it down. – Remove nuts and remove handlebar support with the screws. – Remove screws – Remove screws . Remove handlebar bridge –...
  • Page 70 TUNING THE CHASSIS Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure the cables and wiring are positioned correctly. – Mount the handlebar attachment. – Position the instrument support on the handlebar.

  • Page 71: Maintenance Work On The Chassis

    MAINTENANCE WORK ON THE CHASSIS Raising the vehicle with the lifting gear 10.1 Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. – Raise the vehicle on the frame underneath the engine.
  • Page 72 MAINTENANCE WORK ON THE CHASSIS – Secure the upper A-arm on the frame using tension belt 101547-10 – Remove screw 101548-10 – Remove screw . Remove the shock absorber. 101554-10...

  • Page 73: Installing The Front Shock Absorber

    MAINTENANCE WORK ON THE CHASSIS Installing the front shock absorber 10.4 Info The operations are the same on the left and right sides. – Position the front shock absorber with the reservoir toward the rear. Mount and tighten screw Guideline Screw, front shock absorber 45 Nm (33.2 lbf ft)

  • Page 74: Removing The Rear Shock Absorber

    MAINTENANCE WORK ON THE CHASSIS Removing the rear shock absorber 10.5 – Raise the vehicle with the lifting gear. ( p. 69) – Remove the rear fender. ( p. 79) Note Danger of damage The chain sliding piece and frame can be damaged from incorrect handling.

  • Page 75: Installing The Rear Shock Absorber

    MAINTENANCE WORK ON THE CHASSIS Installing the rear shock absorber 10.6 – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw Guideline Screw, rear top shock absorber 60 Nm (44.3 lbf ft) –...
  • Page 76 MAINTENANCE WORK ON THE CHASSIS – Remove screws – Raise the front trim and disconnect the plug-in connectors from the head light and the emergency OFF switch with the rip cord. – Remove the front trim. 601063-10...

  • Page 77: Installing The Front Trim

    MAINTENANCE WORK ON THE CHASSIS Installing the front trim 10.8 – Connect the plug-in connectors of the head light and the emergency OFF switch with the rip cord and position the front trim. – Mount all screws. – Fully tighten screws Guideline Screw on fuel tank 6 Nm (4.4 lbf ft)

  • Page 78: Installing The Radiator Spoiler

    MAINTENANCE WORK ON THE CHASSIS – Remove the screws on the fuel tank. 101550-10 – Remove the screws on the radiator. – Detach the radiator spoiler and remove it. 101540-10 Installing the radiator spoiler 10.10 Info The operations are the same on the left and right.
  • Page 79 MAINTENANCE WORK ON THE CHASSIS – Hook catch of the radiator spoiler into holder of the fuel tank and position it on the radiator. 100058-10 – Mount and tighten screws on the radiator. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –...

  • Page 80: Removing The Front Cover

    MAINTENANCE WORK ON THE CHASSIS Removing the front cover 10.11 – Remove screw – Slide the front cover up and remove it. 100053-10 Installing the front cover 10.12 – Position the front cover in slots on both sides of the front trim. –...

  • Page 81: Removing The Rear Fender

    MAINTENANCE WORK ON THE CHASSIS Removing the rear fender 10.13 – Remove the seat ( p. 82) – Remove screws 101542-10...

  • Page 82: Installing The Rear Fender

    MAINTENANCE WORK ON THE CHASSIS – Raise the rear of the air filter box lid . At the same time, use your other hand to press on the carburetor connection boot to kink it at that location. Info This prevents the carburetor connection boot from disconnecting from the carbu- retor.
  • Page 83 MAINTENANCE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( p. 82) 101542-11...

  • Page 84: Removing The Seat

    MAINTENANCE WORK ON THE CHASSIS Removing the seat 10.15 – Pull the release hook back. Lift up the seat at the rear, pull it back and then remove from above. 101539-10 Mounting the seat 10.16 – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the seat and slide tab under fuel tank...

  • Page 85: Removing The Air Filter

    MAINTENANCE WORK ON THE CHASSIS – Push down the rear of the seat until release hook engages. – Make sure that the seat is correctly locked in. 101539-11 Removing the air filter 10.17 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –...
  • Page 86 MAINTENANCE WORK ON THE CHASSIS – Raise the rear of the air filter box lid . At the same time, use your other hand to press on the carburetor connection boot to kink it at that location. Info This prevents the carburetor connection boot from disconnecting from the carbu- retor.

  • Page 87: Installing The Air Filter

    MAINTENANCE WORK ON THE CHASSIS Installing the air filter 10.18 – Mount the clean air filter onto the air filter support. – Grease the air filter in area Long-life grease ( p. 196) 301262-10 – Put in both parts together, position them and fix them with the air filter support Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

  • Page 88: Cleaning The Air Filter And Air Filter Box

    MAINTENANCE WORK ON THE CHASSIS Cleaning the air filter and air filter box 10.19 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam.

  • Page 89: Checking The Toe

    MAINTENANCE WORK ON THE CHASSIS Checking the toe 10.20 – Park the vehicle on a horizontal surface. – Check the tire condition. ( p. 133) – Check the tire air pressure. ( p. 134) – Check the chassis parts for damage, play and wear. –...
  • Page 90 MAINTENANCE WORK ON THE CHASSIS 400333-10 – Measure distances » If distances are not equal: – Adjust the toe. p. 89) – Measure distances Guideline Front 0 mm (0 in)

  • Page 91: Adjusting The Toe

    MAINTENANCE WORK ON THE CHASSIS Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv- ing straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. »...
  • Page 92 MAINTENANCE WORK ON THE CHASSIS 400333-11 – Loosen nuts – Adjust the distances to the same value by rotating the tie rods – Adjust the distances to the specified value by evenly rotating the tie rods Guideline Front 0 mm (0 in)

  • Page 93: Checking/Adjusting The Camber

    MAINTENANCE WORK ON THE CHASSIS Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv- ing straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. –...
  • Page 94 MAINTENANCE WORK ON THE CHASSIS – Loosen nuts 101528-10 – Remove screws with bushings 101529-10 – Insert tool in the heim joint and clip onto the A-arm. Camber gauge (83019014000) – Check the camber on both heim joints. » If marking is not aligned with the top edge of the A-arm: –...

  • Page 95: Fork Offset

    MAINTENANCE WORK ON THE CHASSIS – Position the A-arm with bushings . Mount and tighten screws Guideline Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) 101529-10 – Align the heim joint at right angles to screws and tighten nut Guideline Nut, A-arm top M12x1.25...

  • Page 96: Adjusting The Fork Offset

    MAINTENANCE WORK ON THE CHASSIS Adjusting the fork offset 10.24 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Raise the vehicle with the lifting gear. ( p.

  • Page 97: Adjusting The Toe Width Of Rear Axle

    MAINTENANCE WORK ON THE CHASSIS Adjusting the toe width of rear axle 10.26 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –...
  • Page 98 MAINTENANCE WORK ON THE CHASSIS Setting a wide toe width: – Mount the spacer with the cone facing inward. 0 0 2 0 0 3 – Mount the conical ring with the cone facing outward. – Mount the wheel hub –...

  • Page 99: Checking Chain Dirt

    MAINTENANCE WORK ON THE CHASSIS Checking chain dirt 10.27 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 97) 400678-01 Cleaning the chain 10.28 Warning Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 100: Checking The Chain Tension

    MAINTENANCE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 196) Off-road chain spray ( p. 197) 400725-01 Checking the chain tension 10.29 Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 101: Adjusting Chain Tension

    MAINTENANCE WORK ON THE CHASSIS – Push the upper chain section at the end of the chain sliding component upwards to measure the chain tension Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 102 MAINTENANCE WORK ON THE CHASSIS – Loosen the screws by four turns. Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric ele- ment. Alternative 2 – Position the special tool at the rear wheel eccentric element. Hook wrench (83019011000) –...

  • Page 103: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    MAINTENANCE WORK ON THE CHASSIS Checking the chain, rear sprocket, engine sprocket, and chain guide 10.31 – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: –...
  • Page 104 MAINTENANCE WORK ON THE CHASSIS – Pull on the lower part of the chain with the specified weight Guideline Chain-wear measuring weight 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the upper chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 105 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding guard at the top for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Change the chain sliding guard. B00465-01...
  • Page 106 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding guard at the bottom for wear. » If the lower edge of the chain pins is in line with or below the chain sliding guard: – Change the chain sliding guard. –...
  • Page 107 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness. »...

  • Page 108: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401385-01 Checking the swingarm 10.33 –...

  • Page 109: Greasing The Rear Wheel Eccentric Element

    MAINTENANCE WORK ON THE CHASSIS Greasing the rear wheel eccentric element 10.34 – Use a grease gun to fill the rear wheel eccentric element via grease nipple until grease emerges from the left shaft seal ring Long-life grease ( p. 194) –...

  • Page 110: Additionally Securing The Rubber Grip

    MAINTENANCE WORK ON THE CHASSIS Additionally securing the rubber grip 10.36 – Check the rubber grip. ( p. 107) – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rubber grip.

  • Page 111: Checking Fluid Level Of Hydraulic Clutch

    MAINTENANCE WORK ON THE CHASSIS Checking fluid level of hydraulic clutch 10.38 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 112: Installing The Engine Guard

    MAINTENANCE WORK ON THE CHASSIS Installing the engine guard 10.40 – Position the engine guard on the frame bearer. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) 600133-10...

  • Page 113: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to...

  • Page 114: Checking The Free Travel Of The Hand Brake Lever

    BRAKES Checking the free travel of the hand brake lever 11.2 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

  • Page 115: Checking Front Brake Fluid Level

    Check the brake system and not continue riding. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 116: Topping Up The Front Brake Fluid

    If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately. Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 117 BRAKES Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 118: Checking The Front Brake Linings

    100036-10 Checking the front brake linings 11.6 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) – Remove the wheel/wheels. ( p. 132)

  • Page 119: Removing Front Brake Linings

    11.7 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Info The operations are the same on the left and right. – Remove the wheel/wheels. ( p.

  • Page 120: Mounting Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.

  • Page 121: Changing The Front Brake Linings

    BRAKES – Insert the inside brake lining into the brake caliper and fix with bolt – Insert the external brake lining into the brake caliper and slide the bolts in all the way. 100072-10 – Mount the locking split pins –...
  • Page 122 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 123: Checking Free Travel Of Foot Brake Lever

    BRAKES – Remove the front brake linings. p. 117) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws – Remove cover with membrane – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir.

  • Page 124: Adjusting Basic Position Of Foot Brake Lever

    BRAKES – Disconnect spring – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) »...

  • Page 125: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake lin- ings. Check the brake system and not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 126: Topping Up Brake Fluid Of Rear Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Park the vehicle on a horizontal surface.
  • Page 127 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 128: Checking Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥ 1 mm (≥ 0.04 in) Minimum thickness »...

  • Page 129: Removing Rear Brake Linings

    Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- ton.

  • Page 130: Installing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 131 BRAKES – Check that sliding plates are seated correctly in the brake caliper support and insert the brake linings. Info Make sure that decoupling plate is mounted on the piston side of the brake lining. 101538-10 – Grease bearing bolt and insert the brake caliper with the bearing bolt into the brake caliper support Lubricant (T625) (...

  • Page 132: Changing Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 133 BRAKES – Remove the rear brake linings. p. 127) – Remove screw cap with membrane – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir. – Install the rear brake linings.

  • Page 134: Wheels, Tires

    WHEELS, TIRES Removing wheel/wheels 12.1 Info Proceed in the same way on the other wheels if necessary. – Pull the hand brake lever, push the locking pawl down and release the hand brake lever. (Figure 100006-10 p. 20) – Loosen the wheel nuts –...

  • Page 135: Checking The Tire Condition

    12.3 Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on vehicle handling. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the vehicle.

  • Page 136: Checking The Tire Air Pressure

    DOT marking. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regard- less of the actual state of wear.
  • Page 137 WHEELS, TIRES – Remove the dust cap. – Check the tire air pressure when the tires are cold. Tire pressure gauge (83519001000) Tire air pressure off road 0.3 bar (4 psi) » If the tire pressure does not meet specifications: –...

  • Page 138: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 139: Installing The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
  • Page 140 ELECTRICAL SYSTEM Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Even if there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery.

  • Page 141: Changing The Main Fuse

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the quiescent current, the start ability of the battery and the alternator. With this device, you cannot overcharge the battery.

  • Page 142: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – The main fuse is located in the starter relay in front of the battery. – Remove protection covers – Remove the faulty main fuse. Info You can recognize a blown fuse by its broken filament Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used.
  • Page 143 ELECTRICAL SYSTEM – Open the cover of the fuse box Info The designation of the fuses is located on the inside cover of fuse box – Remove the faulty fuse. Guideline Fuse 1 - 10 A - ignition, CDI controller, indicator lamps ON, N, R Fuse 2 - 15 A - high beam, low beam, parking light, tail light, brake light, high beam indicator lamp Fuse 3 - 10 A - radiator fan...

  • Page 144: Checking The Headlight Setting

    ELECTRICAL SYSTEM The replacement fuses should always be present in the fuse box to make sure they are available when needed. – Close the cover of the fuse box. – Install the front cover. ( p. 78) Checking the headlight setting 13.6 –...

  • Page 145: Adjusting The Headlight Range Of The Headlight

    ELECTRICAL SYSTEM Adjusting the headlight range of the headlight 13.7 – Check the headlight setting. ( p. 142) – Loosen screw – Adjust the headlight range of the headlight by moving it up or down. Guideline The boundary between light and dark must be exactly on the lower mark for an opera- tional vehicle with a rider (to prepare the mark, see: Checking the headlight setting).

  • Page 146: Cooling System

    COOLING SYSTEM Cooling system 14.1 The water pump in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 147: Checking The Antifreeze And Coolant Level

    COOLING SYSTEM Checking the antifreeze and coolant level 14.3 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 148: Checking The Coolant Level

    COOLING SYSTEM – Open the compensating tank cover – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the coolant antifreeze does not meet specifications: – Correct the coolant antifreeze. – Coolant level must be between MIN and MAX. »...

  • Page 149: Draining Coolant

    COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 150 COOLING SYSTEM Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 151: Filling Coolant / Bleeding Cooling System

    COOLING SYSTEM – Remove the radiator cap . Completely drain the coolant. 600123-11 – Open the plug of the compensation tank – Remove the screws and empty the compensating tank – Position the compensating tank . Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft)
  • Page 152 COOLING SYSTEM – Position the vehicle as shown and secure it against rolling away. The height difference must be achieved. Guideline Height difference 50 cm (19.7 in) – Pull the hand brake lever, push the locking pawl down and release the hand brake lever.
  • Page 153 COOLING SYSTEM – Open the screw to bleed the radiator. Tighten the screw when coolant emerges from the opening. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 600122-10 – Completely fill the radiator and close the radiator cap – Place the vehicle on the ground.

  • Page 154: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Check the throttle lever for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle lever back and forth slightly to ascertain the play in the throttle cable Guideline Play in throttle cable 3…...

  • Page 155: Checking The Play In The Cable Using The Reverse Gear Release Lever

    TUNING THE ENGINE – Move the handlebar to the straight-ahead position. – Loosen the nut and use the screw to adjust the play in the throttle cable Guideline Play in throttle cable 3… 5 mm (0.12… 0.2 in) – Tighten nut 301795-10 Checking the play in the cable using the reverse gear release lever 15.3...

  • Page 156: Carburetor - Idle

    TUNING THE ENGINE – Move the handlebar to the straight-ahead position. – Release nut and use screw to adjust cable play on the reverse gear release lever. Guideline Play in the cable on the reverse gear 10 mm (0.39 in) release lever –...

  • Page 157: Carburetor - Adjusting Idle

    TUNING THE ENGINE Carburetor - adjusting idle 15.6 – Screw in the idle adjusting screw until it stops and then to the prescribed basic set- ting. Guideline Idle mixture adjusting screw Open 1.0 turn Adjustment tool for mixture control screw (59029034000) –...
  • Page 158 TUNING THE ENGINE Info If there is a large increase in the engine speed, reduce the idle speed to a nor- mal level and repeat the above steps. The extremely sporty rider will set the mixture about 1/4 of a turn back from this ideal value (leaner, clockwise) since the engine has a higher operating tempera- ture in sporting use.

  • Page 159: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Emptying the carburetor float chamber 15.7 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 160: Ignition Curve Plug Connection

    TUNING THE ENGINE – Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the float chamber.
  • Page 161 TUNING THE ENGINE Changing the ignition curve from Soft to Performance. – Connect the plug-in connector . (Figure 100105-10 p. 158) Performance – The plug-in connector is connected to achieve better performance. ( p. 158) – Install the front trim. ( p.

  • Page 162: Maintenance Work On The Engine

    MAINTENANCE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level can be checked on a cold or hot engine. – Park the vehicle on a horizontal surface. Condition The engine is at operating temperature. –...

  • Page 163: Changing Engine Oil And Oil Filter, Cleaning Oil Screens

    MAINTENANCE WORK ON THE ENGINE Changing engine oil and oil filter, cleaning oil screens 16.2 – Drain engine oil, clean oil screens. p. 161) – Remove the oil filter. p. 164) – Install the oil filter. p. 166) – Fill up with engine oil. p.
  • Page 164 MAINTENANCE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the oil drain plug 600134-10 – Remove screw plug and the small oil screen with both O-rings. 600135-10 – Remove screw plug and the large oil screen with both O-rings. –...
  • Page 165 MAINTENANCE WORK ON THE ENGINE – Thoroughly clean the parts and sealing area. – Oil O-rings , mount them on oil screen and, using a long hexagon key, insert them until the O-ring is seated in the housing with the oil screen. –...

  • Page 166: Removing The Oil Filter

    MAINTENANCE WORK ON THE ENGINE – Mount oil drain plug with the seal ring and tighten it. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Install the engine guard. ( p. 110) 600134-11 Removing the oil filter 16.4 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven.
  • Page 167 MAINTENANCE WORK ON THE ENGINE – Disconnect the ground cable from the engine. – Remove screws . Take off the oil filter covers with the O-ring. 600137-10 – Pull the oil filters out of the engine case. Circlip pliers reverse (51012011000) –...

  • Page 168: Installing The Oil Filter

    MAINTENANCE WORK ON THE ENGINE Installing the oil filter 16.5 – Fill oil filters with engine oil and insert them in the oil filter housing. 600147-10 – Oil the O-rings of the oil filter covers and mount them with the oil filter covers. Mount and tighten screws Guideline Screw, oil filter cover...

  • Page 169: Adding Engine Oil

    MAINTENANCE WORK ON THE ENGINE – Remove the screw cap on the clutch cover and fill up with engine oil. Engine oil 1.7 l (1.8 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 193) External Engine oil (SAE temperature:...
  • Page 170 MAINTENANCE WORK ON THE ENGINE – Check the engine for leakage. – Remove the filler cap on the clutch cover and fill up with engine oil. Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p.

  • Page 171: Cleaning, Care

    CLEANING, CARE Cleaning the vehicle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 172 CLEANING, CARE – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p. 197) Info Clean the vehicle using a soft sponge and warm water containing normal motor- cycle cleaner.
  • Page 173 CLEANING, CARE – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 198)

  • Page 174: Storage

    STORAGE Storage 18.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 175: Preparing The Vehicle For Use After Storage

    STORAGE – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. – Cover the vehicle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 176: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Operating error Follow the instructions on starting the engine. p. 33) – Vehicle was out of use for a long time Empty the carburetor float chamber. and there is old fuel in the float cham- p.
  • Page 177 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Emergency OFF switch with rip cord Check the wiring harness. (visual check) faulty – Check the electrical system. – Throttle lever activated Do not activate the throttle lever. –...
  • Page 178 TROUBLESHOOTING Faults Possible cause Action – Engine has no idle Ignition system defective Check the spark plug connector. – Check the ignition coil. – Check the ignition pulse generator. – Check the stator winding of the alternator. – Engine stalls or is backfiring into the Lack of fuel Turn the handle of the fuel tap to ON.
  • Page 179 TROUBLESHOOTING Faults Possible cause Action – Engine has a lack of power Air filter excessively dirty Clean the air filter and air filter box. p. 86) – Exhaust system leaky, deformed or too Check exhaust system for damage. little glass fiber yarn filling in main silencer –...

  • Page 180: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine with balancer, water-cooled Displacement 510 cm³ (31.12 cu in) Stroke 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio 11:1 Idle speed 1,500… 1,600 rpm Control 4 valves controlled via rocker arm and overhead camshaft, camshaft drive via simplex chain Valve diameter, intake 35 mm (1.38 in)

  • Page 181: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 5th gear 23:26 Reverse gear 14:19:34 Alternator 12 V, 200 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK DCPR 8 E Spark plug electrode gap 0.6 mm (0.024 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid...

  • Page 182: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in alternator cover 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 183 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, engine case M6x65 10 Nm (7.4 lbf ft) – Screw, engine case M6x75 10 Nm (7.4 lbf ft) ® Screw, exhaust flange 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 184 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Spark plug M12x1.25 17 Nm (12.5 lbf ft) ® Bleeder flange, engine case M12x1.5 Loctite 243™ – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –...

  • Page 185: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3925H Needle position 3rd position from top Idle mixture adjusting screw Open 1.0 turn Pump membrane stop 2.15 mm (0.0846 in) Main jet Jet needle OBEKR Idling jet Main air jet Idle air jet Cold start jet...

  • Page 186: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Double cradle of chromium molybdenum steel tubes, powder- coated Wheel suspension Front Single wheel suspension with double transverse control arm Rear Rigid axle Suspension travel Front 275 mm (10.83 in) Rear 272 mm (10.71 in) Fork offset Front 46 mm (1.81 in)
  • Page 187 TECHNICAL DATA - CHASSIS Maximum allowable axle load Front 144 kg (317 lb.) Rear 149 kg (328 lb.) Maximum permissible overall weight 293 kg (646 lb.) Vehicle length 1,810 mm (71.26 in) Vehicle width 1,148 mm (45.2 in) Vehicle height 1,125 mm (44.29 in) Brake system Front...

  • Page 188: Lighting Equipment

    Brake / tail light Tires 23.2 Front tire Rear tire AT 21 x 7 - 10 AT 20 x 11 - 9 DWT XCF RCR V1 DWT XCF RCR V1 Additional information is available in the Service section under: http://www.ktm.com...

  • Page 189: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Capacity - fuel 23.3 Total fuel tank capacity approx. 13.5 l (3.57 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 194) Fuel reserve approx. 3 l (3 qt.)

  • Page 190: Technical Data - Front Shock Absorber

    TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber part number 03.18.7J.13 Shock absorber WP Suspension 3612 BAVP MCC Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Cross over 19 mm (0.75 in) Spring preload...

  • Page 191: Technical Data - Rear Shock Absorber

    TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber part number 15.18.7J.13 Shock absorber WP Suspension 4618 BAVP MCC Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Spring preload Comfort 0 mm (0 in)

  • Page 192: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw on fuel tank 6 Nm (4.4 lbf ft) – Screw, clamping nut, rear axle 10 Nm (7.4 lbf ft) ®...
  • Page 193 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) – Screw, footrest 45 Nm (33.2 lbf ft) – Screw, front shock absorber 45 Nm (33.2 lbf ft) – Screw, steering column at bottom of 25 Nm (18.4 lbf ft) steering lever –...

  • Page 194: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 195 SAE ( p. 199) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
  • Page 196 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 197 SUBSTANCES Info Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

  • Page 198: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 199 AUXILIARY SUBSTANCES Lubricant (T625) Guideline – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Off-road chain spray Guideline – ® KTM recommends Motorex products.
  • Page 200 AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Clean & Polish Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE...

  • Page 201: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.

  • Page 202: Index

    INDEX Brake linings of front brake INDEX changing ........119 Accessories .
  • Page 203 INDEX changing ........161 Choke ........27 draining .
  • Page 204 INDEX removing ........78 Hot start button .
  • Page 205 INDEX Parking brake ........20 Rider training ........9 Play in throttle cable Riding adjusting .
  • Page 206 INDEX Starting ........33 Stopping .
  • Page 207 *3211727en* 3211727en 08/2011 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

2012 525 xc atv

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