KTM 520 EXC RACING 2000 Owner'S Handbook Manual Download

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ENGLISH

Type

400 SX RACING

400 EXC RACING

520 SX RACING

520 EXC RACING

Design

Liquid-cooled single cylinder 4-stroke engine with balancer shaft

Displacement

398 ccm

510 ccm

Bore/Stroke

89 / 64 mm

95 / 72 mm

Ratio

11 : 1

Fuel

unleaded premium gasoline with at least RON 95

Valve Timing

4 valves over rocker arm and 1 overhead camshaf, camshaft drive through single chain

Camshaft

Valve diameter

Intake: 35 mm Exhaust: 30 mm

Valve clearence cold

0,12 mm (feeler gage 0,10 light, feeler gage 0,15 should not inserted)

Crank shaft bearing

2 cylinder roller bearing

Connecting rod bearing

needle bearing

Top end bearing

bronze bushing

Piston

alluminium alloy cast

alluminium alloy forged

Piston rings

1 compression ring, 1 oil scraper ring

Engine lubrication

pressure circulation lubrication mit two rotorpumps

Engine oil

fullsynthetic oil (Shell Advance Ultra 4)

Quantity of engine oil

1,25 liters

Primary ratio

straight geared spur wheels 33:76 Z

Clutch

multi disc clutch in oil bath

Transmission

4-speed claw shafted

6-speed claw shafted

4-speed claw shafted

6-speed claw shafted

Gear ratio
1

Gear

14:34

Gear

18:30

17:31

18:30

17:31

Gear

20:28

19:28

20:28

19:28

Gear

22:26

Gear

–

24:23

–

24:23

Gear

–

26:21

–

26:21

Iginition system

contactless DC-CDI ignition with digital advanced system by KOKUSAN

Generator

12V 40W

12V 110W

Spark plug

NGK CR8 EK

Spark plug gap

0,6 mm

Cooling system

liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump

Cooling liquid

1 liter, 40% antifreeze, 60% water, at least -25° (-13° F)

Starting equipment

kickstarter

kick - electric starter

kickstarter

kick - electric starter

TECHNICAL DATA – ENGINE 400/520 SX, EXC RACING 2000

BASIC CARBURETOR SETTING

Type

MX-FCR39

Carb.-setting number

250899

130799

100699

Main jet

175

Jet needle

OBDTM

OBDVR (OBDTM)

OBDTM

Idling jet

Main air jet

200

Idling air jet

100

Needle clip position

2nd from top

3rd from top

2nd from top

Starting jet

Mixture control screw open

1,25

2,5

Throttle valve

Performance restrictor

–

slide stop 24,5 mm

–

Stop pump membrane

055

400/520 SX RACING

400 EXC RACING

400 EXC RACING (12kW)
520 EXC RACING (12,5kW)

520 EXC RACING

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...

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KTM 520 EXC RACING 2000, Owner'S Handbook Manual

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