Related Manuals for KTM 250 EXC RACING 2004
Summary of Contents for KTM 250 EXC RACING 2004
- Page 1 BEDIENUNGSANLEITUNG2004 250 EXC RACING 450 SX, MXC, EXC RACING 525 SX, MXC, EXC RACING OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART.NR: 3.210.77...
- 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 TECHNICAL SPECIFICATIONS...
- 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: Important Limited Warranty And 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
Chain wear ........30 General information about KTM disc brakes ..31 OPERATION INSTRUMENTS . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. -
Page 7: Short Circuit Button (Sx/Mxc)
Short circuit button (SX/MXC) The short circuit button turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. = Light off (this function is not available in all models) = Low beam on = High beam on You may use button... -
Page 8: Digital Speedometer, 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 9: Tripmaster Switch
Tripmaster switch The switch has three buttons: MODE, + (plus) and – (minus). MODE WARNING O NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC WHICH CAN EASILY LEAD TO AN ACCIDENT Electronic speedometer functions provided by the Tripmaster –... - Page 10 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 11: Setting The Clock
SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons. This is a very useful function for trips taken according to a roadbook. TRP2 is activated by the first impulse received from the wheel sensor and stops automatically 3 seconds after the last impulse is received. -
Page 12: Kilometers Or Miles
If you retrofit this Tripmaster on another motorcycle, the power can also be supplied by the 12 V vehicle electric system. You will need an additional cable harness, spare part no. 583.14.069.210, which you can order from your KTM dealer. OVERVIEW OF TRIPMASTER FUNCTIONS –... -
Page 13: Emergency Off Switch (Exc Australia)
Emergency OFF switch (EXC Australia) The red emergency-OFF switch is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrup- ted. The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. -
Page 14: Hot Start Device (450/525 Sx)
Hot start device (450/525 SX) If you pull the hot start device out as far as possible, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean“ fuel-air mixture of the type needed for hot starts. To deactivate the hot start device, push the hot start button back into its basic position. -
Page 15: Compression Damping Of Fork
Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap Turn the adjusting screws clockwise to increase damping, turn it counter- clockwise to reduce damping during compression. -
Page 16: Compression Damping Of Shock Absorber (Mxc, Exc)
Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping. -
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
Starting when the engine is cold 1 Open the fuel tap 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke 5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter. -
Page 20: Fuel
NOTE: WARNING Dedicated to nothing but offroad racing, 250/450/525 OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE SX/MXC/EXC Racing models make no compromises in their RUNNING HE ENGINE EXHAUST PIPE MUFFLER BRAKE ROTORS design. As such, they do not include any radiator fan, and the SHOCK ABSORBERS CAN BECOME VERY HOT O NOT TOUCH ANY OF size of the radiator is dimensioned for optimum ergonomics. -
Page 21: Periodic Maintenance Schedule 2004
PERIODIC MAINTENANCE SCHEDULE 2004 250/450/525 SX/MXC/EXC RACING 1. service after after/every 3 hours 15 hours A clean motorcycle can be checked more quickly which saves money! 20 l fuel 100 l fuel Change engine oil, short and long oil filters Clean oil screen and drain plug magnet Check oil lines for damage or bends Replace spark plug (after 30 hours) - Page 22 MPORTANT HECKS AND AINTENANCE TO BE ARRIED OUT BY THE IDER Before each After every For cross- start cleaning country use Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regularly Remove and clean fork dust bellows regularly...
- Page 23 250/450/525 SX ECOMMENDED INSPECTION OF THE ENGINE USED FOR ENDURO COMPETITIONS BY YOUR WORKSHOP ADDITIONAL ORDER FOR THE WORKSHOP a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check) Check the camshaft for wear (visual check)
- Page 24 250/450/525 EXC ECOMMENDED INSPECTION OF THE ENGINE USED FOR HOBBY ENDURO COMPETITIONS BY YOUR WORKSHOP ADDITIONAL ORDER FOR THE WORKSHOP a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear Check the length of the clutch springs Check the cylinder and piston for wear Check the groove on the piston pin retainer for wear (visual check) Check the camshaft for wear (visual check)
-
Page 25: Maintenance Work On Chassis And Engine
MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED, SKILLED STAFF. -
Page 26: Breather Plug Front Fork
Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. -
Page 27: Basic Suspension Setup For The Weight Of The Driver
At delivery, KTM's offroad motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing). If your weight exceeds or falls short of this range, you will need to adjust the basic setup for the suspension components accordingly. -
Page 28: Changing The Spring Preload On The Telescopic Fork
The standard spring is shown in bold print. The type number of the telescopic fork is embossed on the caps on the top of the telescopic fork. If you are uncertain which spring to use, contact your KTM workshop. 4,4 N/mm... -
Page 29: How To Change The Handlebar Position
How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar in the position that is the most convenient for you. The upper tri- ple clamp includes 2 bores arranged at a distance of 15 mm (0.6 in) from one another. -
Page 30: Check Chain Tension
Check chain tension Jack the motorcycle up on its frame so that the rear wheel no longer tou- ches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. 8 - 10 mm (0.31 - 0.39 in). -
Page 31: Chain Maintenance
Chain maintenance For a long chain life, good maintenance is very important. Chains without X-rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (e.g. Motorex Chainlube 622). X-ring chains on the other hand are very simple to clean. The best way is to use lots of water, but never use brushes or cleaning liquids. -
Page 32: General Information About Ktm Disc Brakes
KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with Motorex Brake Fluid DOT 5.1 brake fluid, one of the best brake 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 33: Adjusting The Free Travel At The Hand Brake Lever
Adjusting the 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 (e.g. the resis- tance 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 34: Replacing The Front Brake Pads
Replacing the 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 35: Checking The Rear Brake Pads
Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings 1 mm may not be less than 1 mm (0.04 in). WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE OR YOUR OWN SAFETY ’... -
Page 36: Dismounting And Mounting The Rear Wheel
(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. -
Page 37: Tires-Air Pressure
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. WARNING – D KTM. O O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY THER TIRES TIRES-AIR PRESSURE COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES –... -
Page 38: Battery (Mxc/Exc)
Battery (MXC/EXC) 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: First disconnect the negative and then the positive pole of the battery. -
Page 39: Fuse (Mxc/Exc)
Replace a blown fuse only with an equivalent one. If a new fuse that has just been installed gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere. CAUTION NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED OR A FUSE “... -
Page 40: Cooling System
RAFFIC MAY CAUSE OVERHEATING PROBLEMS O AVOID THIS AN ELECTRIC BLOWER IS OFFERED FOR MODELS WITH KTM D ELECTRIC STARTERS ASK YOUR EALER Checking the coolant level The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (see diagram). -
Page 41: Replacing The Glassfiber Yarn Packing Of The Silencer
Then, drill open the rivets and remove the end cap. NOTE! In every exhaust repair procedure, the O-rings must be replaced by new ones. Glass fiber yarn packings are available from your licensed KTM mechanic. WARNING... -
Page 42: Cleaning The Air Filter
The SX models do not have a throttle cap. CAUTION O NOT CLEAN THE AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE . KTM THE FOAM RECOMMENDS THE PRODUCTS MADE BY OTOREX FOR AIR FILTER... -
Page 43: Changing The Original Position Of The Clutch Lever
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 44: Carburetor - Adjust Idling (Keihin-Fcrmx 37/39/41)
CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) * 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 45: Draining The Float Chamber Of The Carburetor
Draining the float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes malfunctioning. Perform this task on a cold engine. -
Page 46: Engine Oil
Only use fully synthetic engine oils that meet the JASO MA quality require- JASO T903 MA ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). - Page 47 CHANGING THE OIL FILTERS Remove the screw and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws and dismount the two oil filter covers. Using circlip pliers, pull the oil-filter inserts out of the housing.
-
Page 48: Troubleshooting
We would like to point out that many operations cannot be performed by yourself. In case of uncertainty, please contact a KTM-dealer. TROUBLE... - Page 49 Dismount left side paneling and filter box cover, replace fuse E-starter do not work The battery is discharged The battery isn’t charged by the Remove seat and fuel tank and check voltage regulator generator because connections; voltage 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 brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH... -
Page 51: Technical Data - Engine
TECHNICAL DATA – ENGINE 250/450/525 SX, MXC, EXC RACING 2004 Type 250 EXC 450 SX 450 MXC 450 EXC 525 SX 525 MXC 525 EXC Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 250 cc 449 cc 448 cc 510 cc Bore/Stroke 75 / 56.5 mm 95 / 63.4 mm... - Page 52 BASIC CARBURATOR SETTING 250 EXC RACING 250 EXC RACING 450 EXC RACING 450 SX RACING Six Days 11 kW 12 kW Type Keihin FCR-MX 37 Keihin FCR-MX 37 Keihin FCR-MX 39 Keihin FCR-MX 41 Carburator-setting number 3700A 3700A 3900A 4122A Main jet Jet needle OBETP...
-
Page 53: Tightening Torques
Only use fully synthetic engine oils that meet the JASO MA quality require- JASO T903 MA ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for temperatures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F). -
Page 54: Technical Data - Chassis
TECHNICAL DATA – CHASSIS 250/450/525 SX, MXC, EXC RACING 2004 450/525 SX RACING 250/450/525 EXC RACING 450/525 MXC, EXC USA Frame Central tube chrome-moly-steel frame Fork WP Up Side Down 4860 MXMA Wheel travel front/rear 300/335 mm Rear suspension WP Progressive Damping System shock absorber, aluminium swing arm Front brake Disk brake with carbon-steel brake disc Ø... -
Page 55: Head Word Index
Bleeding of the hydraulic clutch ....42 General information about KTM disc brakes ..31 Bleeding the cooling system . - Page 59 ENGLISCH DEUTSCH ITALIENISCH Battery Batterie Batteria Cooling fan Lüftermotor Motorino ventola Driving light lamp Fernlichtkontrolle spia abbagliante Flasher control lamp Blinkerkontrolle spia lampeggiatori Flasher relay Blinkerrelais Relè indicatori Front brake switch vorderer Bremslichtschalter Interruttore luce ant. di stop Generator Generator Generatore Lenkerschalter für Kombiinstrument Handle bar switch for multi-func.-digital-speedometer...
- Page 60 ENGLISCH FRANZÖSISCH SPANISCH Battery Batterie Batería Cooling fan Ventilateur Motor del ventilador Driving light lamp temoin feu route lampara aviso luces largas Flasher relay Relais de clignotants Relé de la luz intermitente Flasher control lamp temoin de clignoteur lampara aviso intermitentes Front brake switch Contacteur de frein avant Interruptor de luz del freno delantero...
- Page 61 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...