KTM 625 SXC 2003 Owner's Manual
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KTM 625 SXC 2003 Owner's Manual

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  • Page 2 (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT...
  • Page 3 If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer.

  • Page 4: Limited Guarantee Information

    IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION KTM sports motorcycles are designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading international motorcycle associations.

  • Page 5: Table Of Contents

    Re-initation after time of storage........49 Chain maintenance............26 Chain wear..............26 TECHNICAL SPECIFICATIONS - ENGINE ......50 General informations about KTM disc brakes....27 Adjusting of free travel at the hand brake lever ....28 TECHNICAL SPECIFICATIONS - CHASSIS......52 Checking brake fluid level - front brake ......28 Refilling the front brake fluid reservoir......28...

  • Page 6: Serial Number Locations

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

  • Page 7: Indicator Lamps

    The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.

  • Page 8: Tripmaster Switch

    SPEED/ODO display mode The SPEED/ODO mode shows the speed and the total kilometers traveled. When the front wheel stops turning, the display will automatically change to the SPEED/H mode. The information will disappear in the display when the front wheel stops turning for 1 minute.
  • Page 9 The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function.
  • Page 10 SPEED/STP1 (stop 1) display mode STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received.

  • Page 11: Overview Of Tripmaster Functions

    OVERVIEW OF TRIPMASTER FUNCTIONS – Display Press Press Press MODE Hold MODE for 3 sec no function no function SPEED / ODO no function next display mode no function resets MAX to 0 SPEED / MAX no function next display mode starts / stops LAP clears all LAP figures SPEED / LAP...

  • Page 12: Ignition Lock

    Ignition lock Switch positions of ignition lock Ignition off, light off (engine can't be started) Ignition on, light off (engine can be started) Ignition on, light on (engine can be started) Combination switch The light switch has 2 switch positions. = Low beam light = High beam light The red short circuit button...

  • Page 13: Fuel Tap

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

  • Page 14: Kickstarter

    Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). Handlebar lock The handlebar can be locked by means of the lock located on the control head.

  • Page 15: Compression Damping Of Fork

    Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing . By using the knob (COM), the degree of damping of the compression can be adjusted.

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

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation WARNING – Verify that your KTM dealer performed the PREPARATION – W EAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE LEVER OF VEHICLE jobs (see Customer Service Manual). DRIVERS ALWAYS WEAR A HELMET...

  • Page 18: Driving Instructions

    If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided.
  • Page 19 Starting when the engine is cold 1 Open the fuel tap 2 Switch on ignition (turn ignition key into position 3 Swing up the side stand or center stand 4 Put the gear in neutral 5 Operate the choke 6 Do not accelerate; operate starter button WARNING –...
  • Page 20 WARNING CAUTION – A – C VOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE THERWISE THE ON WET OR SLIPPERY GROUND THERWISE YOU MIGHT EASILY LOSE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE –...

  • Page 21: Periodic Maintenance-Schedule

    PERIODIC MAINTENANCE SCHEDULE 2003 625 SXC 1. Service after after / every after / every 1000 km 2500 km 5000 km A washed motorcycle can be checked more quickly which saves money! 10 hours 25 hours once a year Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace every 10,000 km...
  • Page 22 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each after every for cross once a year start cleaning country use Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals...

  • Page 23: Maintenance Work On Chassis And Engine

    WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER. AT KTM YOUR MOTORCYCLE WILL RECIEVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS.

  • Page 24: Check And Adjust Steering Head Bearing

    Check and adjust steering head bearing * Check steering head bearing for play periodically. To check this put motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. To adjust, loosen the five pinch bolts of the top triple clamp and turn steering stem bolt clockwise...

  • Page 25: How To Change The Handlebar Position

    3,5 mm Changing the spring preloading of the shock absorber KTM sets the shock absorber for a driver with a weight of approximately 75 kg (165 lb). If the weight of the driver is more or less than 75 kg (165 lb), you should change the spring preloading accordingly.

  • Page 26: Checking Rubber Ring On The Wp Rear Shock Absorber

    Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm (0,1 in) wide. Have min. 2,5 mm the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. CAUTION...

  • Page 27: Chain Maintenance

    Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Shell Advance Bio Chain).

  • Page 28: General Informations About Ktm Disc Brakes

    BRAKE FLUID: KTM fills the brake systems with Shell Advance Brake DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 29: Adjusting Of Free Travel At The Hand Brake Lever

    Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw . In this way, the position of the point of pressure (i.e., the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size.

  • Page 30: Replacing Front Brake Pads

    Replacing front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips and pull out bolt . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air.

  • Page 31: Changing The Basic Position Of The Brake Pedal

    Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller . Using the push rod , the free play on the foot brake pedal must be set.

  • Page 32: Dismounting And Mounting The Front Wheel

    Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws on the left fork leg. Then loosen the collar nuts before loosening the clamp screws on the right fork leg.

  • Page 33: Tires, Air Pressure

    (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING –...

  • Page 34: Check/Set Distance Of The Magnetic Sensor

    Check/set distance of the magnetic sensor The distance between magnet and sensor must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing in or off the sensor KMH: WS = mm x 3.14 mm x 3.14 MPH: WS = (mm x 3.14) : 1.61...

  • Page 35: Battery

    Battery The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. Removing the battery: Remove screws and swing retaining bracket and voltage regulator out of...

  • Page 36: Fuses

    Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. CAUTION NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE “...

  • Page 37: Exchanging The Brake Light And Tail Light Bulb

    Exchanging the brake light and tail light bulb Remove the cap on the underside of the license plate retainer. Turn the lamp socket approximately 30° counterclockwise and pull it out of the tail light housing. Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket.

  • Page 38: Checking The Coolant Level

    Check whether the air filter is positioned correctly and mount the filter box cover. CAUTION – D O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE . KTM THE FOAM RECOMMENDS THE PRODUCTS MADE BY IR FOR AIR FILTER MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER –...

  • Page 39: Exhaust System

    To replace the rear glass fiber yarn pack, drill the rivets open and remove the rear cap NOTE: Always renew the O-rings Glass fiber yarn packs are available in your KTM store. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING AVOID BURNS...

  • Page 40: Adjusting The Throttle Cable

    Adjusting the throttle cable * The throttle grip should always provide for a backlash of 3-5 mm 3-5 mm (0,12-0,20 in). Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. KEIHIN FCR-MX41: To adjust the throttle cables, dismount the seat and the tank together with spoilers.

  • Page 41: Checking The Oil Level Of The Hydraulic Clutch

    SAE 10 hydraulic oil. Refill oil until oil is discharged from the bore the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer. Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with...

  • Page 42: Carburetor - Adjust Idling (Keihin Fcr-Mx41)

    CARBURETOR – Adjust idling (Keihin-FCRMX 41) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel and the mixture control screw...

  • Page 43: Carburetor - Adjust Idling (Mikuni Bst40)

    CARBURETOR – Adjust idling (Mikuni BST 40) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.

  • Page 44: Engine Oil

    Engine oil API: SG, SH Only use synthetic high-quality oils (Shell Advance Ultra 4) meeting or surpassing the quality requirements of API classes SG, or SH (for TEMPERATUR specifications see containers). – 0°C CAUTION 32°F NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE 10W 40 15W 40 10W 50...

  • Page 45: Changing The Engine Oil

    Changing the engine oil * The engine oil change is to be carried out when the engine is still warm. WARNING N ENGINE HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT ARE VERY HOT NOT BURN YOURSELF Place the motorbike on a horizontal surface. Remove the two plugs ( ), and drain oil into a container.

  • Page 46: Changing Oil Filter

    Changing oil filter * Replace the oil filter when changing the engine oil. Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible. Remove banjo bolt and the three screws.

  • Page 47: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 48 Carburetor leaking Check vacuum hose and venting hose of carburetor for correct position (no kinks) Air filter very dirty Clean or replace air filter, contact a KTM dealer Valve clearance to small Have valve clearance adjusted Loss of compression because hand...
  • Page 49 Recharge the battery according to the relevant instructions. The battery is discharged hasn’t been switched off The battery isn’t charged by the Remove seat and check voltage regulator connections; voltage generator because regulator and generator should be checked by a KTM dealer.

  • Page 50: Cleaning

    CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH...

  • Page 51: Technical Specifications - Engine

    TECHNICAL SPECIFICATIONS – ENGINE 625 SXC 2003 Engine 625 SXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,5 : 1 Fuel unleaded premium gasoline with a least RON 95...
  • Page 52 BASIC CARBURATOR SETTING 625 SXC Type Keihin FCR-MX 41 Carburator-setting number 4138A Main jet Jet needle OBDVT Idling jet Main air jet Idling air jet Needle position 5. rd from top Starting jet Mixture control screw open Slide Performance restrictor Slide stop Stop pump membrane 858 / 2,15 mm...

  • Page 53: Technical Specifications - Chassis

    TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2003 625 SXC Frame Central chrome-moly-steel frame Fork White Power 4357 MXMA Wheel travel front/rear 295 / 320 mm (11,8 / 12,8 in) Rear suspension Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing...
  • Page 54 TIGHTENING TORQUES - CHASSIS 625 SXC 2003 Collar nut front axle M16x1,5 40 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top M10 (10.9) 45 Nm Shock absorber bottom M10 (10.9) 45 Nm Collar screws brake disk front M6 (10.9)

  • Page 58: Head Word Index

    Chain wear .................26 Fuses ..................35 Changing and bleeding the microfilter ........44 General informations about KTM disc brakes ......27 Changing oil filter ...............45 General Tips and warnings for starting the motorcycle ..16 Changing the basic position of the brake pedal ....30 Hand brake lever ..............5...
  • Page 62 321053...

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