background image

ENGLISH

12

Only give as much gas as the engine can handle. Through
quick and high reving of throttle, the fuel usage increases.
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.

NOTE:
D

EDICATED TO NOTHING BUT OFFROAD RACING

, 400/520 SX/EXC

MODELS MAKE NO COMPROMISES IN THEIR DESIGN

. A

S SUCH

THEY DO

NOT INCLUDE ANY RADIATOR FAN

AND THE SIZE OF THE RADIATOR IS

DIMENSIONED FOR OPTIMUM ERGONOMICS

I

N NORMAL RACING

THE COOLING SYSTEM IS SUFFICIENT

I

F YOU USE YOUR MOTORBIKE IN OTHER CONDITIONS

PLEASE NOTE THAT

THE

E-

STARTER ALLOWS YOU TO START

EXC 

MODELS AGAIN AT ANY

TIME

. T

HEREFORE

TURN OFF THE ENGINE IF YOU INTEND TO RUN

YOUR MOTORCYCLE IN IDLE OR AT STANDSTILL FOR LONGER PERIODS
OF TIME

(

MORE THAN

MINUTES

). 

– A

VOID LETTING THE CLUTCH SLIP FREQUENTLY AND FOR EXTENDED

PERIODS

. T

HIS WOULD CAUSE THE ENGINE OIL TO HEAT UP

THEREBY

HEATING UP THE ENGINE AND THE COOLING SYSTEM

. R

ATHER

YOU

SHOULD DRIVE AT LOW SPEEDS

(4-

STROKE STYLE

LETTING THE

ENGINE PULL YOU

AND NOT AT HIGH SPEEDS NOT BY LETTING THE

CLUTCH SLIP

(2-

STROKE STYLE

).

WARNING

– O

BSERVE THE TRAFFIC REGULATIONS

DRIVE DEFENSIVELY AND TRYING

TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE

.

– A

DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

.

– D

RIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS

.

– W

HEN DRIVING OFF

-

ROAD

ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY

SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE

.

– R

EPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR

DAMAGED

IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR

LENS

THE OPERATOR WILL BE BLINDED

.

– A

FTER FALLING WITH THE MOTORCYCLE

CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

.

– A 

TWISTED HANDLEBAR MUST ALWAYS BE REPLACED

. D

O NOT ADJUST

THE HANDLEBAR

IT WILL LOSE STA

-

BILITY

.

!

CAUTION

!

– H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. W

E RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
A CHANCE TO WARM UP

. A

FTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

. T

HE ENGINE HAS REACHED ITS OPERA

-

TING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM

– N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

A LOWER GEAR

. T

HE ENGINE WILL OVER

-

REV

DAMAGING THE VALVES

.

I

N ADDITION

THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

.

– L

ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN

LEAD TO MOTOR DAMAGE

.

– I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING

CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT

.

– I

N THE EVENT THAT

WHILE RIDING ON YOUR MOTORCYCLE

YOU

NOTICE ANY UNUSUAL OPERATION

-

RELATED NOISE

STOP IMMEDIA

-

TELY

TURN THE ENGINE OFF

AND CONTACT AN AUTHORIZED

KTM

DEALER

.

– N

EVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN

-

TED

OTHERWISE

DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE

INCREASED WEAR

.

Braking

Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
When driving down hill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.

WARNING

– I

N CASE OF RAIN

AFTER WASHING THE MOTORCYCLE

AFTER RIDES

THROUGH WATER AND IN CASE OF RIDES ON WET OFF

-

ROAD TRACKS

,

HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT

. T

HE

BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN

.

– R

IDES ON SALT

-

STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRA

-

KING EFFECT

. T

HE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN

.

– D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS

.

– W

HEN YOU BRAKE

THE BRAKE DISCS

BRAKE PADS

BRAKE CALIPER

AND BRAKE FLUID HEAT UP

. T

HE HOTTER THESE PARTS GET

THE WEA

-

KER THE BREAKING EFFECT

. I

N EXTREME CASES

THE ENTIRE BRAKING

SYSTEM CAN FAIL

.

Stopping and parking

Apply the brakes fully and put the engine into neutral. To turn
off the engine, push the short-circuit button or the emergency-
OFF button with the engine at idling speed until the engine
stops. Turn the fuel tap to the OFF position, park on an area
where the ground is firm, and lock the motorcycle.

WARNING

– N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING

.

– M

OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE

RUNNING

. T

HE ENGINE

EXHAUST PIPE

MUFFLER

BRAKE ROTORS

AND

SHOCK ABSORBERS CAN BECOME VERY HOT

. D

O NOT TOUCH ANY OF

THESE PARTS AFTER OPERATING THE MOTORCYCLE

AND TAKE CARE TO

PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET
BURNED

.

!

CAUTION

!

– N

EVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE

ENGINE

. R

ATHER

USE THE SHORT

-

CIRCUIT BUTTON OR THE EMER

-

GENCY

-

OFF BUTTON

.

– C

LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE

.O

THERWISE THE

CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE

.

– N

EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE

HAZARDS

DUE

TO

DRY

GRASS

OR

OTHER

EASILY

FLAMMABLE

MATERIALS

.

NOTE REGARDING THE SIDE STAND:
Use your foot to kick side stand forward up to the stop and
lean the motorcycle sideways. Make sure that the ground is
solid and that your motorcycle is standing securely. Just in
case, you can shift into first gear.

!

CAUTION

!

T

HE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE

MOTORCYCLE

. T

HE SIDE STAND AND

/

OR THE FRAME CAN BE DAMAGED

AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR

-

CYCLE

THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND

.

Summary of Contents for 520 EXC RACING 2000

Page 1: ...OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2000 400 520 SX EXC RACING BEDIENUNGSANLEITUNG Art Nr 3 205 72 11 99...

Page 2: ......

Page 3: ...by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or d...

Page 4: ...lists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this Owner s Handbook to carry out most of the maintenance steps yourself If on the oth...

Page 5: ...illing the front brake fluid reservoir 19 Page Checking the front brake pads 19 Replacing the front brake pads 19 Changing the basic position of the brake pedal 20 Checking rear brake fluid level 20 R...

Page 6: ...e The outer end of the lever must at all times provide for a backlash of approx 10mm 0 4 in Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompr...

Page 7: ...t stop function DST Total distance up to 99 999 km CLK Clock See maintenance work for change of battery and basic setting Odometer EXC USA The odometer is a mileage indicator and can be set to 0 by me...

Page 8: ...ton 5 actuates the E starter WARNING ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE...

Page 9: ...E UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Fuel...

Page 10: ...OPENING THE THROTTLE KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM AND AN OPENED THROTTLE GRIP INCREASE THE KICK BACK HAZARD Foot brake pedal The foot brake pedal is disposed in front of the right...

Page 11: ...educe damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the...

Page 12: ...nical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insuffici...

Page 13: ...uate the E starter What to do when the engine is flooded In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decompression lever full...

Page 14: ...ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER NEVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN...

Page 15: ...eck adjustment and function of telescopic fork Check telescopic fork for leaks Loosen breather screws at fork legs overpressure Change fork oil Perform a full maintenance job for the telescopic fork C...

Page 16: ...WORK ON CHASSIS AND ENGINE Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing ad...

Page 17: ...may start to leak Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them...

Page 18: ...icated with either grease or other lubri cants Grease and other lubricants cause the Teflon coat to dissolve whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a...

Page 19: ...ean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry you can use a special O ring chain spray i e Shell Advance Bio Chain WARNING NO LUBRICATI...

Page 20: ...a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are...

Page 21: ...DREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CON...

Page 22: ...DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking rear brake fluid level The reservoir for the rear disc brake is disposed on...

Page 23: ...EEN FITTED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST...

Page 24: ...ll out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully tak...

Page 25: ...ecome unba lanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a screwdriv...

Page 26: ...by pushing the right but ton you jump to the next figure 4 repeat nos 2 3 until correct time is indicated 5 push the button on the back approx 1 second to terminate the setting procedure 2 push the l...

Page 27: ...e indication TRP is active and push the but ton on the back approx 5 seconds WS appears 2 use the right button to select the position to be changed 3 push the left button until the right figure is sho...

Page 28: ...ING BAR 2 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the...

Page 29: ...TM dealer The fuse capacity is 10 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL...

Page 30: ...efore not be replaced by pure water CAUTION IF THE COOLANT HAS BEEN DRAINED IT WILL BE ABSOLUTELY NECESSARY TO BLEED THE COOLING SYSTEM DURING FILLING SEE BELOW FOR THE COOLING SYSTEM USE ONLY WITH HI...

Page 31: ...king of the silencer Aluminum silencers are filled with glass fiber yarn to muffle noise The effect of heat causes the glass fiber yarn to become loose This may lead to a loss of performance and reduc...

Page 32: ...cklash Tighten the counter nut and check whether the throttle grip can be actuated smoothly Mount tank and seat Checking the oil level of the hydraulic clutch To check the oil level in the master cyli...

Page 33: ...crewed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idli...

Page 34: ...ng oil filter 6 where the coarser particles contained in the engine oil are filtered away Then the engine oil arrives at the short oil filter 7 which also filters the fine particles Now the purified e...

Page 35: ...reen 2 is accommodated in the hex socket plug 3 at the engine bottom Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug...

Page 36: ...cle on its side and fill the oil filter housings about halfway with engine oil Insert the long oil filter at the front and the short oil filter at the back of the housing Grease the O rings 4 of the o...

Page 37: ...rate during longer periods of standstill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will imm...

Page 38: ...n the starter relay The battery isn t charged by the generator because REMEDY Dismount carburettor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well a...

Page 39: ...iting times at your mechanic at the beginning of the next biking season STORAGE Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use...

Page 40: ...hafted 4 speed claw shafted 6 speed claw shafted Gear ratio 1st Gear 14 34 14 34 14 34 14 34 2nd Gear 18 30 17 31 18 30 17 31 3rd Gear 20 28 19 28 20 28 19 28 4th Gear 22 26 22 26 22 26 22 26 5th Gear...

Page 41: ...ft lb Allan head screw shift roller locking piece M6 Loctite 243 8 Nm 6 ft lb Hexagon collar screw locking lever M5 Loctite 243 6 Nm 6 ft lb Hexagon collar screw securing guide chain guide chain tensi...

Page 42: ...ine brace M 8 33 Nm 24ft lb Screw adjusting ring spring preload shock abs M6 8 Nm 6ft lb Other screws on chassis M 6 10 Nm 7ft lb M 8 25 Nm 19ft lb M 10 45 Nm 33ft lb Other collar nuts on chassis M 6...

Page 43: ...onservation for winter operarion 37 Cooling system 28 Correct chain tension 17 Digital speedometer EXC 5 Digital speedometer indicator lamps EXC 5 Dismounting and mounting the front wheel 21 Dismounti...

Page 44: ...regulador de tension 5 generador 6 bobina de encendido 7 bujia 3 interruptor d luz 1 faro 9 conect multiple 3 12 connect multiple 4 12 connettore a 4 poli 12 multip cont plug 4 12 4 pol Stecker 11 rel...

Page 45: ...ANHANG APPENDICE APPENDIX AP NDICE 2...

Page 46: ...ANHANG APPENDICE APPENDIX AP NDICE 3...

Page 47: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria nternet www ktm at...

Reviews: