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Related Manuals for KTM 525 XC ATV 2008
Summary of Contents for KTM 525 XC ATV 2008
- Page 1 OWNER'S MANUAL 2008 450 XC ATV 525 XC ATV ART. NO. 3211251en...
- 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 pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below.
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Page 4: Table Of Contents
Important maintenance work to be carried out by an Recharging the battery ..........58 authorized KTM workshop. (as additional order)....29 changing main fuse ............59 Important checks and maintenance work to be carried Changing the fuses of individual power-consuming out by the rider. - Page 5 CONTENTS Removing the seat ............61 Mounting the seat ............61 Removing the radiator spoiler ......... 61 Installing the radiator spoiler .......... 62 Removing the front cover..........62 Installing the front cover ..........62 Removing the front trim ..........63 Installing the front trim ..........
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Page 6: 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 done in an authorized KTM workshop! There, your vehicle will be serviced opti- mally by specially trained experts using the specialist tools required. -
Page 7: Important Notes
You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss. - Page 8 If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the first time. A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you.
- Page 9 IMPORTANT NOTES...
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Page 10: Overview Of Warning Labels
IMPORTANT NOTES Overview of warning labels 100106-10... - Page 11 IMPORTANT NOTES Notes/warning notes Pay attention to the specified notes and warnings. Info Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured. Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death.
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Page 12: View Of Vehicle
VIEW OF VEHICLE Vehicle view, front left 600148-10 Hand brake lever Fuse box Headlight Front shock absorber Right-hand brake caliper Steering damper holder (steering damper is optional) Front left shock absorber Outside brake disk guard Shift lever Left footrest Heel protector Emergency OFF switch with rip cord Clutch lever... -
Page 13: View Of Vehicle, Rear Right
VIEW OF VEHICLE View of vehicle, rear right 600149-10 Light switch, electric starter button, ENG. STOP switch Filler cap Main silencer Rear shock absorber Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Compensating tank for coolant Manifold Top A-arm Front right fender... -
Page 14: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper control arm. 100002-10 Type label The type label is located on the frame tube on the right in front of the radiator. 100034-10 Key number The key number... -
Page 15: Setting Number, Rear Shock Absorber
LOCATION OF SERIAL NUMBERS Setting number, rear shock absorber The setting number is stamped into the top of the shock absorber. 100032-10... -
Page 16: Operating Elements
OPERATING ELEMENTS 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 17: Light Switch
OPERATING ELEMENTS Light switch The light switch is fitted on the left side of the handlebar. Possible states • High beam on HI Light switch is turned upwards. In this position, the high beam and the tail light are switched on. •... -
Page 18: Emergency Off Switch With Rip Cord
OPERATING ELEMENTS Emergency OFF switch with rip cord The emergency OFF switch is mounted on the left in front of the fuel tank. A rip cord is attached to the clip . It can be attached to the clothing of the rider by means of a carabiner . -
Page 19: Choke
OPERATING ELEMENTS Choke The choke knob 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 20: Tips On Putting Into Operation
When using your vehicle, remember that others may feel disturbed by excessive noise. Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. -
Page 21: Running In The Engine
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. Do not make any changes to the vehicle and use only KTM approved parts. Do not exceed the overall maximum permitted weight and the axle loads. -
Page 22: Riding Instructions
RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the vehicle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. Check the engine oil level. ( P. -
Page 23: Starting Up
RIDING INSTRUCTIONS Turn the key in the ignition switch to the position The yellow ignition indicator lamp ON lights up. 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, Bowden cable or carburetor. -
Page 24: Shifting To Reverse Gear
Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to wet or dirty brakes. -
Page 25: 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 26: Riding Downhill
RIDING INSTRUCTIONS Riding downhill 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. Never ride down a slope backward. -
Page 27: Riding Perpendicular To The Slope
RIDING INSTRUCTIONS Riding perpendicular to the slope 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. If the vehicle starts to tip over, steer it downhill and dismount immediately to the uphill side. -
Page 28: Switching Off The Engine
After riding through water, dry the brakes by lightly activating both brakes until nor- mal braking power is available again. If the vehicle becomes submerged, an authorized KTM workshop must perform a thorough check and comprehensive service.. Do not start the engine. -
Page 29: Refueling
RIDING INSTRUCTIONS Refueling Danger Fire hazard Fuel can easily catch fire. Never fill up 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. Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. -
Page 30: Greasing And Service Table
GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. S15A S30A Engine Change the engine oil and oil filter, clean the oil screens. P. 73) • • • Replace spark plug. • Check and adjust valve clearance. -
Page 31: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)
S15A: Every 15 service hours - corresponds to about 105 liters of fuel / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use... - Page 32 GREASING AND SERVICE TABLE NB1A Check the chain wear. ( P. 46) • Check rear sprocket / engine sprocket for wear. ( P. 45) • Clean the air filter. P. 66) • Checking the tire air pressure. ( P. 57) •...
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Page 33: Maintenance On Chassis And Engine
MAINTENANCE ON CHASSIS AND ENGINE Jacking up the vehicle 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. Jack up the vehicle on the frame underneath the engine. The wheels must no longer touch the ground. -
Page 34: Adjusting Front Shock Absorber Rebound Damping
MAINTENANCE ON CHASSIS AND ENGINE Turn the adjusting wheel clockwise until it stops. Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Compression damping Standard 14 clicks Maximum deviation from standard 5… 5 clicks value 100027-10 Experience has shown that settings outside of this range are detrimental to vehicle handling. -
Page 35: Adjusting Front Shock Absorber Cross Over
Jack up the vehicle. ( P. 31) Clean the shock absorber thoroughly. Loosen the adjusting ring . Suitable tools are available from an authorized KTM workshop. Hook wrench, Öhlins (83019001000) 100084-10 The cross over setting is measured between the sliding bushing and the collar... -
Page 36: Adjusting Rear Shock Absorber Compression Damping
MAINTENANCE ON CHASSIS AND ENGINE Press the spring pack and the spring retainer down to make the securing clip accessible. Using pliers, position the securing clip in one of the upper grooves. Do not over- strain the securing clip. Release the spring pack and measure the length of the unloaded spring pack. 100083-10 Press together the spring pack, position the securing clip in the corresponding groove and release the spring pack. -
Page 37: Adjusting Rear Shock Absorber Rebound Damping
MAINTENANCE ON CHASSIS AND ENGINE Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Compression damping Standard 15 clicks Maximum deviation from standard 5… 5 clicks value Experience has shown that settings outside of this range are detrimental to vehicle handling. -
Page 38: Adjusting Rear Shock Absorber Spring Preload
After removing the shock absorber, clean it thoroughly. Loosen the lock nut . Hold adjusting ring while doing so. Suitable tools available from an authorized KTM workshop. Hook wrench (83019002000) Info Do not loosen the lock nut at the top of the shock absorber. -
Page 39: Removing The Rear Shock Absorber
MAINTENANCE ON CHASSIS AND ENGINE Removing the rear shock absorber Jack up the vehicle. ( P. 31) Remove the rear fender. ( P. 63) Note Danger of damage The chain sliding piece and frame can be damaged from incor- rect handling. When removing the rear shock absorber, secure the swingarm with a tension belt to prevent it from swinging down further. -
Page 40: Adjusting The Toe
MAINTENANCE ON CHASSIS AND ENGINE Load the vehicle with the specified weight. Specification Standard rider weight 70… 80 kg (154… 176 lb.) Turn the steering to the straight-ahead position and fix it. Steering fixing for straight-ahead position (83019015000) 500228-01 400333-10 Measure distances »... - Page 41 MAINTENANCE ON CHASSIS AND ENGINE Load the vehicle with the specified weight. Specification Standard rider weight 70… 80 kg (154… 176 lb.) Turn the steering to the straight-ahead position and fix it. Steering fixing for straight-ahead position (83019015000) 500228-01 400333-11 Loosen nuts Adjust the distances to the same value by rotating the tie rods...
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Page 42: Checking/Adjusting Camber
MAINTENANCE ON CHASSIS AND ENGINE Checking/adjusting camber Info The left and right camber should have the same settings. The operations are the same on the left and right. Jack up the vehicle. ( P. 31) Loosen nuts 600128-10 Remove screws with bushings Check parts for damage and wear. -
Page 43: Fork Offset
MAINTENANCE ON CHASSIS AND ENGINE Fork offset The fork offset has an impact on the handling of the vehicle. The fork offset can optionally be adjusted. Fork offset is defined as the slanted position of the swivel axis in the direction of the longitudinal axis of the vehicle in relation to a vertical line to the driving surface. -
Page 44: Handlebar Position
MAINTENANCE ON CHASSIS AND ENGINE Setting a narrow toe width: Mount the wheel hub 0 0 1 0 0 3 Mount the conical ring with the cone facing outward. Mount the spacing sleeve with the cone facing inward. Mount the washer and the new self-locking nut. 100103-10 Setting a wide toe width: Mount the spacing sleeve... -
Page 45: Adjusting Handlebar Position
MAINTENANCE ON CHASSIS AND ENGINE Adjusting handlebar position 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 bend the cables and lines. 100100-10 Remove the four screws . -
Page 46: Adjusting Play In Gas Bowden Cable
MAINTENANCE ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death. When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space. Start the engine and let it run idle. -
Page 47: Checking Chain Dirt
MAINTENANCE ON CHASSIS AND ENGINE Checking chain dirt Check the chain for coarse dirt accumulation. » If the chain is very dirty: Clean the chain. ( P. 45) Cleaning the chain Warning Environmental hazard Problem materials cause environmental damage. Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info The service life of the chain depends largely on its maintenance. -
Page 48: Checking Chain Wear
MAINTENANCE ON CHASSIS AND ENGINE Checking chain wear Park the vehicle on a horizontal surface and shift gears to neutral. Pull the lower chain section with the specified weight Specification Chain-wear measuring weight 10… 15 kg (22… 33 lb.) Measure the distance of 18 chain links in the upper chain section. -
Page 49: Greasing The Rear Wheel Eccentric Element
Warning Danger of accidents Reduced braking due to worn brake discs. Worn brake discs should be replaced immediately in an authorized KTM workshop. Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement... -
Page 50: Checking Free Play Of Hand Brake Lever
Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Move the brake fluid reservoir mounted on the handlebar to a horizontal position. -
Page 51: Topping Up The Front Brake Fluid
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 52: Removing Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 53: Changing The Front Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 54: Checking Free Play Of Foot Brake Lever
Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. -
Page 55: Topping Up Brake Fluid Of Front Brake
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. -
Page 56: Checking Rear Brake Linings
Warning Danger of accidents Improper brake maintenance and repair. Always have your brake system maintained and repaired in an authorized KTM workshop. Press the brake caliper by hand on to the brake disc in order to press back the brake piston. -
Page 57: Mounting Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license. -
Page 58: Removing Wheel/Wheels
MAINTENANCE ON CHASSIS AND ENGINE Info Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOT 5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container! Remove the rear brake linings. -
Page 59: Tire Condition Checking
Tire condition checking Info Fit only tires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the vehicle. -
Page 60: Installing The Battery
MAINTENANCE ON CHASSIS AND ENGINE Disconnect the negative (minus) cable of the battery. Pull back the plus pole cover and disconnect the positive (plus) cable of the bat- tery. Loosen the rubber band Remove the battery. 200150-10 Installing the battery Check parts for damage and wear. -
Page 61: Changing Main Fuse
Use only fuses with the prescribed amperage. Never by-pass or repair fuses. Insert a new fuse. Fuse (58011109120) Info If the new fuse burns out, contact an authorized KTM workshop. 100091-10 The spare fuse should always be present in the starter relay so that it is available if needed. -
Page 62: Ignition Curve Plug Connection
Fuse (58011109110) Fuse (58011109115) Info If the new fuse burns out, contact an authorized KTM workshop. The spare fuses should always be present in the fuse box so that thez are available if needed. Close the cover of the fuse box. -
Page 63: Changing Ignition Curve
MAINTENANCE ON CHASSIS AND ENGINE Changing ignition curve Remove the front trim. ( P. 63) Changing the ignition curve from Performance to Soft. Connect the plug-in connector . (Figure 100105-10 P. 60) Soft The plug-in connector is connected for better driveability. ( P. -
Page 64: Installing The Radiator Spoiler
MAINTENANCE ON CHASSIS AND ENGINE Remove the screws on the radiator. Unhinge and remove the radiator spoiler and the fuel tank. 100057-10 Installing the radiator spoiler Info The operations are the same on the left and right. Check parts for damage and wear. Replace damaged or worn parts. Hook the catch of the radiator spoiler into the holder of the fuel tank and... -
Page 65: Removing The Front Trim
MAINTENANCE ON CHASSIS AND ENGINE Removing the front trim Remove the front cover. ( P. 62) 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. -
Page 66: Installing The Rear Fender
MAINTENANCE ON CHASSIS AND ENGINE Remove screws . Remove the collar sleeves. 200149-10 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. This prevents the carburetor connection boot from disconnecting from the carburetor. -
Page 67: Removing The Engine Guard
MAINTENANCE ON CHASSIS AND ENGINE Removing the engine guard Remove screws . Remove the engine guard. 600133-10 Installing the engine guard Check parts for damage and wear. Replace damaged or worn parts. Position the engine guard on the frame bearer. Mount and tighten screws Specification Remaining screws, chassis 10 Nm (7.4 lbf ft) -
Page 68: Installing The Air Filter
MAINTENANCE ON CHASSIS AND ENGINE Installing the air filter Check parts for damage and wear. Replace damaged or worn parts. Mount the clean air filter onto the air filter support. 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 69: Cooling System
MAINTENANCE ON CHASSIS AND ENGINE Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. Remove screws Remove cover with membrane Check the fluid level. Fluid level under top level of container. 4 mm (0.16 in) » If the level of the cooling liquid does not meet specifications: Correct the fluid level of the hydraulic clutch. -
Page 70: Checking The Coolant Level
MAINTENANCE ON CHASSIS AND ENGINE Open the compensating tank cover Check antifreeze of coolant. 25… 45 °C ( 13… 49 °F) » If the antifreeze of the cooling liquid does not meet specifications: Correct antifreeze of coolant. The coolant level must be between MIN and MAX. -
Page 71: Filling Coolant / Bleeding Cooling System
MAINTENANCE ON CHASSIS AND ENGINE Remove screw 600118-10 Remove screw 600119-10 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 Check parts for damage and wear. Replace damaged or worn parts. Position the compensating tank . -
Page 72: Carburetor - Idle
MAINTENANCE ON CHASSIS AND ENGINE Fill the coolant into the radiator Coolant With compen- 1.50 l (1.59 qt.) Coolant ( P. 95) sating tank Coolant (mixed ready to use) ( P. 95) Without com- 1.30 l (1.37 qt.) Coolant ( P. -
Page 73: Carburetor - Adjusting Idle
MAINTENANCE ON CHASSIS AND ENGINE The idle speed is adjusted with the adjustment screw The idle mixture is adjusted with the idle mixture adjustment screw Carburetor - adjusting idle Screw in the idle adjusting screw until it stops and then to the prescribed basic setting. -
Page 74: Emptying The Carburetor Float Chamber
MAINTENANCE ON CHASSIS AND ENGINE Emptying the carburetor float chamber Danger Fire hazard Fuel can easily catch fire. Never fill up 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. -
Page 75: Changing Engine Oil And Oil Filter, Cleaning Oil Screens
MAINTENANCE ON CHASSIS AND ENGINE Condition Engine is cold. Check the engine oil level. The engine oil reaches the bottom of the viewer » When the engine oil does not reach the bottom of the viewer Top up the engine oil. ( P. -
Page 76: Removing The Oil Filter
MAINTENANCE ON CHASSIS AND ENGINE Remove the plug screw and large oil screen with both O-rings. Completely drain the engine oil. 600136-10 Check parts for damage and wear. Replace damaged or worn parts. Thoroughly clean parts and sealing area. Oil the O-rings , mount them on the oil screen and using a long hexagon key insert them until the O-ring is seated in the housing... -
Page 77: Mounting Oil Filter
MAINTENANCE ON CHASSIS AND ENGINE Disconnect the ground cable from the engine. Remove screws . Take off the oil filter cover with the O-ring. 600137-10 Pull the oil filters out of the engine housing. Circlip pliers reverse (51012011000) Completely drain the engine oil. Thoroughly clean parts and sealing area. -
Page 78: Topping Up Engine Oil
MAINTENANCE ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon- sciousness and/or death. When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in a closed space. Start the engine and check that it is oil-tight. -
Page 79: Troubleshooting
Do not touch parts of the ignition system. Have work on the ignition system car- ried out in an authorized KTM workshop. Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine. - Page 80 P. 59) Check electrical system. Low external temperature Recharge the battery. Establish the reason for discharging or have it checked in a KTM workshop. Engine does not speed up. Carburetor running over because float Have carburetor checked. needle dirty or worn Loose carburetor jets Have carburetor checked.
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Page 81: Cleaning
CLEANING Cleaning the vehicle 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 electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage. -
Page 82: Storage
STORAGE Storage 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately. -
Page 83: Technical Data - Engine
TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine with balancer, water-cooled Displacement (450 XC ATV) 448 cm³ (27.34 cu in) Displacement (525 XC ATV) 510 cm³ (31.12 cu in) Stroke 72 mm (2.83 in) Bore (450 XC ATV) 89 mm (3.5 in) Bore (525 XC ATV) 95 mm (3.74 in) Compression ratio... -
Page 84: Capacity - Cooling Liquid
TECHNICAL DATA - ENGINE Capacity - cooling liquid Coolant With compensating tank 1.50 l (1.59 qt.) Coolant ( P. 95) Coolant (mixed ready to use) ( P. 95) Without compensating tank 1.30 l (1.37 qt.) Coolant ( P. 95) Coolant (mixed ready to use) ( P. -
Page 85: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover Loctite 243™ ® Screw, timing chain securing guide 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, ignition pulse generator 6 Nm (4.4 lbf ft) Loctite... - Page 86 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Oil drain plug with magnet M12x1,5 20 Nm (14.8 lbf ft) Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) Locking screw, oil sieve, short M16x1,5 10 Nm (7.4 lbf ft) Engine oil (any) ®...
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Page 87: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR 450/525 XC ATV Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3925H Needle position (450 XC ATV) 2nd position from top Needle position (525 XC ATV) 3rd position from top Idle mixture adjusting screw Open 1.0 turn Pump membrane stop 2.15 mm (0.0846 in) Main jet... -
Page 88: 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 257 mm (10.12 in) Rear 265 mm (10.43 in) Fork offset Front 46 mm (1.81 in) -
Page 89: Lighting Equipment
20 x 11.00 - 9 MAXXIS Razr M 931 MAXXIS Razr M 932 For further information, see the Service section under: http://www.ktm.com Capacity - fuel Tank capacity 13.4 l (3.54 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. -
Page 90: Technical Data - Front Shock Absorber
TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber type 36PRC Setting number KT 7702 Compression damping Standard 14 clicks Maximum deviation from standard value 5… 5 clicks Rebound damping Standard 20 clicks Maximum deviation from standard value 5… 5 clicks Cross over 17±1.5 mm (0.67±0.059 in) Clip position, spring preload... -
Page 91: Technical Data - Rear Shock Absorber
TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber type 46PRCQ Setting number KT 7710 Compression damping Standard 15 clicks Maximum deviation from standard value 5… 5 clicks Rebound damping Standard 15 clicks Maximum deviation from standard value 5… 5 clicks Spring preload Standard 3 mm (0.12 in) -
Page 92: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 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, rear brake caliper 10 Nm (7.4 lbf ft) Loctite 243™... -
Page 94: Wiring Diagram
WIRING DIAGRAM 450/525 XC ATV pos. high C_BC/4 50,48 C_DG/4 C_AK/2 C_AH/2 54,55 C_AU/2 C_BI/2 C_AH/2 C_AK/2 C_AJ/3 C_BG/3 -S10 600146-10... - Page 95 WIRING DIAGRAM Components CDI controller ACC1 Socket connector for auxiliary devices (switching on with ignition) ACC2 Socket connector for auxiliary devices (permanent positive) Throttle valve sensor TPS Battery Generator Idling speed indicator lamp Reverse gear indicator lamp Ignition indicator lamp High beam indicator light Brake / tail light Headlight...
- Page 96 WIRING DIAGRAM yellow blue-red orange brown yellow-green black-yellow orange orange orange brown brown black brown brown brown brown brown brown black-green yellow-green yellow-green brown brown brown brown yellow white yellow white yellow yellow green blue blue white-green white-green white-blue brown white blue-red green...
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Page 97: Substances
Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 ®... - Page 98 SAE ( P. 98) (SAE 5W/40) Specification Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre- ® sponding properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex...
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Page 99: Auxiliary Substances
AUXILIARY SUBSTANCES Chain cleaner Specification ® KTM recommends Motorex products. Supplier ® Motorex Chain Clean 611 Offroad chain spray Specification ® KTM recommends Motorex products. Supplier ® Motorex Chain Lube 622 Air filter cleaner Specification ® KTM recommends Motorex products. -
Page 100: 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 specifi- cation. -
Page 101: Index
INDEX Coolant draining ....... . . 68 Air filter refilling ........69 cleaning . - Page 102 INDEX Reverse gear release lever ......14 adjusting ....... . . 44 Hand brake lever .
- Page 103 *3211251en* 3211251en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...