KTM 400 EXC RACING Owner's Manual

KTM 400 EXC RACING Owner's Manual

Ktm motorcycle owner's manual
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BEDIENUNGSANLEITUNG2005
250 EXC RACING
400 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. 3.211.39

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Summary of Contents for KTM 400 EXC RACING

  • Page 1 BEDIENUNGSANLEITUNG2005 250 EXC RACING 400 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. 3.211.39...
  • Page 2 KTM may stop manufactur- ing certain models without previous notice. KTM shall not be held liable for any deviations of availabil- ity and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
  • Page 3 Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and 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 interna- tional motorcycle associations.
  • Page 5: Table Of Contents

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE ......17 Instructions for initial operation ....17 Running in the Racing models .
  • 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: Operation Instruments

    » OPERATION INSTRUMENTS Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjust- ing screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically.
  • Page 8: Flasher Switch

    OPERATION INSTRUMENTS » Headlamp switch (EXC USA) In this model the headlamp is switched on with the pull switch [1]. Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system.
  • Page 9: Electronic Speedometer

    H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motor- cycles, making the service hour counter a very practical function.
  • Page 10 SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press button Changes to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures...
  • Page 11 OPERATION INSTRUMENTS » LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds.
  • Page 12 OPERATION INSTRUMENTS » SPEED / A2 display mode (average speed 2) A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.
  • Page 13: Setting The Clock

    OPERATION INSTRUMENTS display briefly press + button SPEED / H SPEED / CLK starts/stops LAP without SPEED / LAP clearing LAP figure LAP / LAP SPEED / MAX SPEED / ODO SPEED / TR1 SPEED / TR2 increases the TR2 figure SPEED / A1 SPEED / A2 SPEED / S1...
  • Page 14: Filler Cap

    OPERATION INSTRUMENTS » Filler cap To open the filler cap: Turn the filler cap counter-clockwise. To close the filler cap: Put the filler cap on and tighten it by turning it clockwise. Install the tank breather hose [1] without kinks. Fuel tap OFF In this position the fuel tap is closed.
  • Page 15: Shift Lever

    » OPERATION INSTRUMENTS Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. 2,3,4 (5,6) Kickstarter The kickstarter is mounted on the right side of the engine.
  • Page 16: Compression Damping Of Fork

    Control). Low and high speed refers to the movement of the shock absorber during com- pression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compres- sion rates.
  • Page 17: Compression Damping Of Shock Absorber (Mxc, Exc)

    OPERATION INSTRUMENTS » 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 [1] with a screwdriver.
  • Page 18: General Tips And Warnings For Starting The Motorcycle

    GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read these operating instructions carefully before your first ride. – Familiarize yourself with the operating elements.
  • Page 19: 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 com- plete failure of the braking system can be avoided.
  • Page 20: Starting When The Engine Is Cold

    – MAXIMAL PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. – DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV UP THE ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER AND CAN CAUSE ENGINE DAMAGE.
  • Page 21: Braking

    E-starter allows you to start MXC/EXC Racing models again at any time. Therefore, turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time (more than 2 minutes).
  • Page 22: Periodic Maintenance

    IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE. Service intervalls should never be exceeded by more than 2 hours or 15 liters of fuel. Maintenance work done by KTM authorised workshops is not a substitute for care and checks done by the rider. »...
  • Page 23 PERIODIC MAINTENANCE IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER 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 Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box...
  • Page 24 PERIODIC MAINTENANCE RECOMMENDED INSPECTION OF THE 250/400/450/525 SX AND EXC ENGINE USED FOR ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear...
  • Page 25 PERIODIC MAINTENANCE RECOMMENDED INSPECTION OF THE 250/400/450/525 EXC ENGINE USED FOR HOBBY - ENDURO COMPETITIONS BY YOUR KTM WORKSHOP (ADDITIONAL ORDER FOR THE KTM WORKSHOP) a 100 liter fuel consumption is equivalent to approx. 15 operating hours Check the clutch disks for wear...
  • Page 26: Maintenance Work On Chassis And Engine

    CARBURETOR OR FUEL TANK – ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT.
  • Page 27: Basic Suspension Setup For The Weight Of The Driver

    EXAMPLE: Motorcycle jacked up (dimension A) .....600 mm Motorcycle on ground, unloaded (dimension B) ... .– 565 mm Static sag .
  • Page 28: Checking The Basic Setup Of The Telescopic Fork

    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. According to our experience, the damping rate of the compression stage can remain unchanged.
  • Page 29: Breather Plug Front Fork

    [1] 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. When riding the motorcycle mainly on the road, it will suffice to have this job performed in the course of the periodical maintenance serv- ice.
  • Page 30: Changing The Fork Offset (Caster) (Sx)

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the fork offset (caster) (SX) * The fork offset [A] in the SX models (center fork legs - center steering head angle) can be set to either 18 or 20 mm. This allows you to optimize the han- dling to match the race course.
  • Page 31: Checking And Adjusting The Steering Head Bearing

    Nm (EXC, MXC). IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL. IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI- ODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED.
  • Page 32: Check Chain Tension

    Tighten collar nut [1] to 80 Nm. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.
  • Page 33: Chain Maintenance

    NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS, OTHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL. WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION.
  • Page 34: General Information About Ktm Disc Brakes

    CONSTITUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDI- ATELY AS SOON AS THEY REACH THE WEAR LIMIT. – HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not neces- sary to top up the brake fluid.
  • Page 35: Adjusting The Free Travel At The Hand Brake Lever

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the front brake fluid reservoir * Loosen screws [2] and remove lid [3] and membrane [4].
  • Page 36: Replacing The Front Brake Pads

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear brake fluid reservoir * Add brake fluid as soon as a bubble is visible in inspection glass [A].
  • Page 37: Checking The Rear Brake Pads

    ESTABLISHED. 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 the 2 clamping screws [4] on the left side of the fork fists.
  • Page 38: Dismounting And Mounting The Rear Wheel

    » – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.
  • Page 39: 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. – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER rear TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.
  • Page 40: Battery (Mxc/Exc)

    (AS SHOWN IN THE ILLUSTRATION), OTHERWISE ELECTROLYTE CAN ESCAPE. BATTERY STORAGE: When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not expose to direct sunlight.
  • Page 41: 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. UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE INSTALLED OR A FUSE ALLOWED TO BE “REPAIRED”.
  • Page 42: Cooling System

    – EXTREME CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVER- HEATING PROBLEMS. TO AVOID THIS, AN ELECTRIC BLOWER [4] IS OFFERED FOR MODELS WITH ELECTRIC STARTERS (ASK YOUR KTM DEALER) 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 43: 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. THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN- NING.
  • Page 44: Cleaning The Air Filter

    The SX models do not have a throttle cap. – DO NOT CLEAN FOAM FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE (BIO DIRT REMOVER AND LIQUID BIO POWER).
  • Page 45: Changing The Original Position Of The Clutch Lever

    If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Motorex Kupplungs-Fluid 75).Biodegradable hydraulic oil is available from your KTM dealer (50ml). KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CON- TROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID.
  • Page 46: Carburetor - Adjust Idling (Keihin-Fcrmx 37/39/41)

    MAINTENANCE WORK ON CHASSIS AND ENGINE » 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 [1] and the mixture control screw [2].
  • Page 47: Draining The Float Chamber Of The Carburetor

    Checking the engine oil level The engine oil level can be checked with the engine either warm or cold. Place the motorcycle in an upright position and on a horizontal surface (not on the side stand). If the engine is cold, the engine oil must be visible at the lower edge of the inspection glass [A].
  • Page 48: Engine Oil

    Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
  • Page 49: Changing Oil Filters

    Check the O-rings of the oil filter covers for damage and, if necessary, replace them. Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil. Fill oil filter with oil, place the long oil filter in the front and the short filter in the back of the filter box.
  • Page 50: 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 CAUSE Engine doesn’t crank (E-starter).
  • Page 51 Dismount seat and fuel tank and check connections, have capacitor and voltage regulator checked Dismount left side paneling and filter box cover, replace fuse Remove seat and fuel tank and check voltage regulator con- nections; voltage regulator and generator should be checked by a KTM dealer.
  • Page 52: Storage

    CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take pre- cautions against the aggressive road salt.
  • Page 53: Technical Data - Engine

    TECHNICAL DATA - ENGINE TYPE Design Displacement Bore/Stroke Ratio Fuel Valve timing Camshaft Valve diameter Intake Valve diameter Exhaust Valve clearence cold Intake Valve clearence cold Exhaust Crank shaft bearing Connecting rod bearing Top end bearing Piston alluminium alloy - Piston rings Engine lubrication Engine oil...
  • Page 54 Mixture control screw open 1,25 Slide Performance restrictor – Stop pump membrane 858 / 2,15 mm Hot start device – » 400 EXC RACING EU / AUS 12 kW OBDVR from top from top 1,25 Slide stop 858 / 2,15 mm –...
  • Page 55 Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).
  • Page 56: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS CHASSIS 450/525 SX Frame Central tube chrome-moly-steel frame Fork 4860 PA/MA 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 260 mm (10.2 in), brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø...
  • Page 57 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES - CHASSIS Collar screw, front wheel spindle Brake caliper, front Brake caliper, FTE radial front Brake disk Clamping screws, upper fork bridge EXC Clamping screws, lower fork bridge EXC Clamping screws, upper fork bridge SX Clamping screws, lower fork bridge SX Clamping screws, fork stubs Hexagon nut, swing arm bolt...
  • Page 58 Fuse (MXC/EXC) ......40 General information about KTM disc brakes ..33 General tips and warnings for starting the motorcycle .17...
  • Page 60: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAMM...
  • Page 61 » SCHALTPLAN WIRING DIAGRAMM...
  • Page 62 » SCHALTPLAN WIRING DIAGRAMM...
  • Page 63 » SCHALTPLAN WIRING DIAGRAMM ENGLISH Battery Cooling fan Driving light lamp Flasher control lamp Flasher relay Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
  • Page 64 » SCHALTPLAN WIRING DIAGRAMM ENGLISH Battery Cooling fan Driving light lamp Flasher relay Flasher control lamp Front brake switch Generator Handle bar switch for multi-func.-digital-speedometer Headlight High / low beam switch Horn Ignition coil Ignition switch Left front flasher Left rear flasher Multi-func.-digital-speedometer Pick up Position light...
  • Page 66 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

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