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ENGLISH

4

Chassis number

The chassis number is stamped on the right side of the steering head tube.
Write this number into 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. Please note this number down on
page 1.

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

Clutch lever 

The clutch lever 

1

is located on the left side of the handlebar. The adju-

sting screw 

A

is used to change the original position of the clutch lever (see

maintenance work on chassis and engine).

Hand decompression lever

The hand decompression lever 

2

is needed only if a fall on your motorcycle

causes overflowing in the carburetor. To "pump the engine free", pull the
hand decompression lever during the starting procedure.
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 decompression level
encounters).

!

CAUTION

!

N

EVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE

. R

ATHER

,

USE THE SHORT

-

CIRCUIT BUTTON OR THE EMERGENCY

-OFF 

BUTTON

.

– T

HE SETTING OF THE DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED

. A

LACK OF PLAY IN THE DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE

.

Hand brake lever

The hand brake lever 

3

is mounted on the handle bars on the right and

actuates the front wheel brake. The adjusting screw 

B

can be used to

change the basic position of the hand brake lever (see "Maintenance").

WARNING

I

F THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS

SPONGY

(

TOO MUCH GIVE

), 

THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE

BRAKE SYSTEM

. D

ON

T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE

BRAKE SYSTEM LOOKED OVER BY A

KTM 

DEALER

.

1

A

2

3

B

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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