KTM 525 XC Owner'S Manual Download

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SERVICE SCHEDULE

S45A

S90A

S180A

J1A

Check the transmission and shift mechanism.

•

Check the oil pressure regulator valve.

•

Check the oil pumps and lubrication system.

•

Check the timing assembly.

•

Change all engine bearings.

•

S45A:

Every 45 operating hours - corresponds to about 315 liters of fuel (83.2 US gal)

S90A:

Every 90 operating hours - corresponds to about 630 liters of fuel (166.5 US gal) / every 45 operating hours after sporting use - cor-

responds to about 315 liters of fuel (83.2 US gal)

S180A:

Every 180 operating hours - corresponds to about 1260 liters of fuel (333 US gal)

J1A:

Annually

Summary of Contents for 525 XC

Page 1: ...OWNER S MANUAL 2012 525 XC ATV Art no 3211727en ...

Page 2: ......

Page 3: ...l specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options ...

Page 4: ...According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...itch with rip cord 24 Opening filler cap 24 Closing filler cap 25 Fuel tap 26 Choke 27 Hot start button 27 Shift lever 28 Foot brake lever 29 PREPARING FOR USE 30 Checks and maintenance measures when preparing for use 30 Running in the engine 31 RIDING INSTRUCTIONS 32 Checks and maintenance measures when preparing for use 32 Starting 33 Starting off 35 Shifting 35 Shifting to reverse gear 36 Disen...

Page 6: ...cover 78 Removing the rear fender 79 Installing the rear fender 80 Removing the seat 82 Mounting the seat 82 Removing the air filter x 83 Installing the air filter x 85 Cleaning the air filter and air filter box x 86 Checking the toe x 87 Adjusting the toe x 89 Checking adjusting the camber x 91 Fork offset 93 Adjusting the fork offset x 94 Toe width of rear axle 94 Adjusting the toe width of rear...

Page 7: ... range of the headlight 143 COOLING SYSTEM 144 Cooling system 144 Radiator fan 144 Checking the antifreeze and coolant level 145 Checking the coolant level 146 Draining coolant x 147 Filling coolant bleeding cooling system x 149 TUNING THE ENGINE 152 Checking the play in the throttle cable 152 Adjusting play in throttle cable 152 Checking the play in the cable using the reverse gear release lever ...

Page 8: ...TENING TORQUES 180 TECHNICAL DATA CARBURETOR 183 TECHNICAL DATA CHASSIS 184 Lighting equipment 186 Tires 186 Capacity fuel 187 TECHNICAL DATA FRONT SHOCK ABSORBER 188 TECHNICAL DATA REAR SHOCK ABSORBER 189 TECHNICAL DATA TIGHTENING TORQUES FOR CHASSIS 190 SUBSTANCES 192 AUXILIARY SUBSTANCES 196 STANDARDS 199 INDEX 200 ...

Page 9: ... understanding In the interest of your own safety have these jobs performed at an authorized KTM workshop There your vehicle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained below Specific name Identifies a pro...

Page 10: ...ual are properly carried out Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above average wear of components such as the drive train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the...

Page 11: ...ot included with the vehicle but can be ordered under the number in parentheses E g valve spring mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals seal rings O rings pins lock washers must be replaced by new parts Where thread lockers are used on screw connections e g Loctite follow the instructions for use from the manufacturer Parts that are to be reus...

Page 12: ...6 Use straps or other suitable devices to secure the vehicle against accidents or falling over Pull the hand brake lever push the locking pawl 2 down and release the hand brake lever Figure 100006 10 p 20 Environment Off road riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest However it is a potential problem for the environment and can lead to confl...

Page 13: ...e measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this owner s manual carefully and completely before making your first trip It contains a lot of...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of the vehicle from the left front example 101522 10 ...

Page 15: ...Fuse box 3 Compression adjustment for front shock absorber 4 Front left shock absorber 5 Rebound adjustment for front shock absorber 6 Reverse gear release lever p 19 7 Clutch lever p 19 8 Filler cap 9 Emergency OFF switch with rip cord p 24 10 Shift lever p 28 ...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of the vehicle from the right rear example 101523 10 ...

Page 17: ... 2 ENG STOP switch p 22 2 Electric starter button p 22 3 Main silencer 4 Seat release 5 Rear shock absorber 6 Rebound adjustment for rear shock absorber 7 Rear brake 8 Throttle lever p 21 9 Compression adjustment for rear shock absorber 10 Foot brake lever p 29 ...

Page 18: ...sis number 101524 10 The chassis number 1 is stamped on the right side of the frame in the vicinity of the upper A arm 4 2 Type label 101525 10 The type label 1 is located on the frame tube on the right in front of the radiator ...

Page 19: ...y number 1 is indicated on the KEYCODECARD Info You need the key number to order a replacement key Keep the KEYCODECARD in a safe place 4 4 Engine number 100001 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket ...

Page 20: ...tting number front shock absorber 601024 10 The setting number 1 is stamped into the top of the shock absorber 4 6 Setting number rear shock absorber 601083 10 The setting number 1 is stamped into the top of the shock absorber ...

Page 21: ... button is pressed Clutch lever pulled In this position the force lock between the engine and the gear is broken and the starting circuit is closed The electric starter turns over when the electric starter button is pressed The clutch is hydraulically operated and self adjusting 5 2 Reverse gear release lever 101527 10 The reverse gear release lever 1 is fitted on the left side of the handlebar Re...

Page 22: ...er is combined with the parking brake which blocks the front wheels to prevent the vehicle from rolling away To activate the parking brake pull the hand brake lever push the locking pawl 2 down and release the hand brake lever Possible states Hand brake lever in basic position Front wheels are not locked Hand brake lever pulled and locked in position Front wheels are locked ...

Page 23: ...1 The light switch 1 is fitted on the left side of the handlebar Possible states High beam on Light switch is turned upwards In this position the high beam and the tail light are switched on Low beam on Light switch at the middle setting In this position the low beam and tail lights are switched on Lights off Light switch has been turned down In this position all lights are switched off ...

Page 24: ...g engine stops and the engine cannot be started ENG STOP switch on The switch must be in this position to operate the vehicle the ignition circuit is closed 5 7 Electric starter button 700377 01 Electric starter button 1 is fitted on the left side of the handlebar Possible states Electric starter button in basic position Electric starter button is pressed In this position the electric starter is a...

Page 25: ...t start Ignition on In this position the ignition circuit is closed and the engine can be started 5 9 Indicator lamp overview 400288 10 Possible states Reverse gear indicator lamp 1 lights up red Reverse gear is engaged Ignition indicator lamp 2 lights up yellow Ignition is switched on High beam indicator lamp 3 lights up blue High beam is switched on Idling speed indicator lamp 4 lights up green ...

Page 26: ...ble Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact bet...

Page 27: ...ewage system 100012 10 Press release button 1 turn filler cap counterclockwise and lift it free 5 12 Closing filler cap 100012 11 Replace the filler cap and turn clockwise until the release button 1 locks in place Check the fuel tank breather 2 to ensure it is properly seated If the fuel tank breather is at an angle or loose Correctly mount the fuel tank breather ...

Page 28: ...ose the supply of fuel to the car buretor Possible states Fuel supply off OFF No fuel can flow from the tank to the carburetor Fuel supply on ON Fuel can flow from the tank to the carburetor The fuel tank emp ties down to the reserve Reserve fuel supply on RES Fuel can flow from the tank to the carburetor The fuel tank empties completely ...

Page 29: ...p Choke function deactivated The choke lever is pushed in to the stop 5 15 Hot start button 100015 10 The hot start button red 1 is fitted on the left side of the carburetor Activating the hot start function frees an opening in the carburetor through which the engine can draw extra air This gives a leaner fuel air mixture which is needed for a hot start Info If the engine is cold the hot start fun...

Page 30: ...1 is mounted on the left side of the engine 100017 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears Reverse gear can only be engaged with the vehicle at a standstill and the lever pulled ...

Page 31: ...CONTROLS 29 5 17 Foot brake lever 100016 10 The foot brake lever 1 is located in front of the right footrest and operates the rear wheel brake ...

Page 32: ...uid level p 123 Check the front brake linings p 116 Check the rear brake linings p 126 Check that the brake system is functioning properly Check the coolant level p 146 Check the chain dirt accumulation p 97 Check the chain rear sprocket engine sprocket and chain guide p 101 Check the chain tension p 98 Check the tire condition p 133 Check the tire air pressure p 134 Check the air filter Check the...

Page 33: ...the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully opening the throttle ...

Page 34: ...luid level p 123 Check the front brake linings p 116 Check the rear brake linings p 126 Check that the brake system is functioning properly Check the coolant level p 146 Check the chain dirt accumulation p 97 Check the chain rear sprocket engine sprocket and chain guide p 101 Check the chain tension p 98 Check the tire condition p 133 Check the tire air pressure p 134 Check the air filter Check th...

Page 35: ... fuel in the float chamber The flammable elements of the fuel evaporate after a long time of standing If the float chamber is filled with fresh fuel the engine starts immediately Press the starter for a maximum of 5 seconds Wait for a least 5 seconds before trying again Condition Vehicle has not been operated 1 week Empty the carburetor float chamber x p 157 Turn the handle 1 of the fuel tap to ON...

Page 36: ...ted the electric starter turns over the engine but the engine does not start because there is no ignition spark Shift gear to neutral The green idling speed indicator lamp N light up Condition The engine is cold Pull choke lever out as far as possible Condition Engine hot Pull the hot start button red all the way out Pull the clutch lever Press the electric starter button Info When the clutch leve...

Page 37: ...ear wheels can lock Do not change into a low gear at high engine speed The engine races and the rear wheels can lock 100017 10 When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle Info The position of the 5 forward gears can be seen in th...

Page 38: ...vehicle and run the engine at idling speed Activate the clutch and engage 1st gear Apply light pressure to the shift lever and activate the reverse gear release lever Press the shift lever all the way down with your foot to engage reverse gear Release the reverse gear release lever Look toward the rear and slowly release the clutch lever while depressing the accelerator carefully Info The engine s...

Page 39: ... engine run at idling speed Press the shift lever up until 1st gear engages Info The reverse gear release lever no longer needs to be activated Slowly release the clutch lever while carefully depressing the accelerator or shifting into neutral 7 7 Braking Warning Danger of accidents If you brake too hard the wheels can lock When the front wheels lock the vehicle can no longer be steered Adapt your...

Page 40: ... 8 Riding Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop If the vehicle goes out of control and you fall off the vehicle the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing This short circuits the ignition circuit and the engine switches off During normal operation you sit erect on ...

Page 41: ...er of accidents Excessive speed and turning at sharp angles can cause the vehicle to roll over Decrease your speed before entering into bends Handling of the ATV is strongly influenced by shifts in the position of your body weight Always shift your body weight toward the inside of the bend and forward The faster you ride and the tighter the bend the more you need to shift your body weight Always e...

Page 42: ... slope with a slippery surface The vehicle can easily go out of control and roll over Note Material damage Damage to vehicle after fall or rollover Perform a vehicle check as is done every time before you start to ride Always ride straight up or down a slope and never at a slant Engage a gear with which you can ride all the way down the slope without shifting Shift your body weight to the rear and...

Page 43: ... vehicle can easily go out of control and roll over Always ride straight up or down a slope and never at a slant Engage a gear with which you can ride all the way up the slope without shifting Shift ing on the slope can cause the vehicle to roll over Shift your body weight to the front and ride cautiously Keep your vehicle speed and engine speed as constant as possible Always be prepared to jump s...

Page 44: ...d immediately dis mount on the uphill side 7 13 Turning on slopes Warning Danger of accidents Danger of accidents from turning the vehicle on a slope Never ride down a slope backward The vehicle can roll over easily Always position yourself next to the vehicle in a location where you cannot be caught by a wheel When turning on a slope always stand on the uphill side of the vehicle to avoid injury ...

Page 45: ...y until you reach a location where you can turn it Control its speed using the clutch To turn the vehicle steer it to the side When doing so you should always stand on the uphill side and apply pressure to the footrest on the uphill side When the vehicle is standing perpendicular to the slope or slightly downhill apply the parking brake Sit on the vehicle pull the clutch lever start the engine car...

Page 46: ...through the air filter and cause engine damage Only ride through water if it reaches no higher than the upper edge of the footrest Before riding through water determine the depth and current of the water Ride slowly and negotiate around obstacles After riding through water dry the brakes by lightly activating both brakes until normal braking power is available again If the vehicle became submerged...

Page 47: ...ngine is switched off using the emergency OFF switch the power consumers are not switched off All power consumers that are switched on headlights tail lights etc continue consuming electricity This uses battery power and causes the battery to discharge 7 16 Stopping parking Warning Danger of burns Some vehicle components become very hot when the vehicle is operated Do not touch hot components such...

Page 48: ...d the clip from the emergency OFF switch Pull the hand brake lever push the locking pawl 2 down and release the hand brake lever Figure 100006 10 p 20 The front wheels are locked Turn the handle 1 of the fuel tap to OFF Figure 100013 10 p 26 No more fuel flows from the tank to the carburetor If the vehicle must be parked on an incline additionally secure the rear wheels against rolling see illustr...

Page 49: ...llowed contact a doc tor immediately Change clothing that has come into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system 400287 10 Switch off the engine Open the filler cap p 24 Fill the fuel tank with fuel up to measurement A Guideline Measurement of A 35 mm 1 38 i...

Page 50: ...nd leakage Check the rear brake fluid level p 123 Check the free travel of the foot brake lever p 121 Check the frame and swingarm x Check the swingarm bearing x Check the heim joints on the upper and lower shock absorbers x Check the tire condition p 133 Check the tire air pressure p 134 Check the wheel bearing for play x Check the wheel hubs x Check for rim run out x Check the front wheel suspen...

Page 51: ...mage and routing without sharp bends x Check the cables for damage routing without sharp bends and correct adjustment Clean the air filter and air filter box x p 86 Change glass fiber yarn filling of main silencer x Check the screws and nuts for tightness x Check the headlight setting p 142 Check the idle x Check that the radiator fan is functioning properly x Final inspection check the vehicle fo...

Page 52: ...g x Check adjust the carburetor components x Change the oil in the front shock absorber x Service the front shock absorber x Change the oil in the rear shock absorber x Service the rear shock absorber x Change the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Check the valves valve springs and valve spring seats x Check the camshaf...

Page 53: ...mbly x Change all engine bearings x S45A Every 45 operating hours corresponds to about 315 liters of fuel 83 2 US gal S90A Every 90 operating hours corresponds to about 630 liters of fuel 166 5 US gal every 45 operating hours after sporting use cor responds to about 315 liters of fuel 83 2 US gal S180A Every 180 operating hours corresponds to about 1260 liters of fuel 333 US gal J1A Annually ...

Page 54: ...oad but in the case of large weight differences the springs must be replaced Tip When changing the chassis settings always start with the standard setting Between test rides always change only one setting This will enable you to better assess the effect of the setting on vehicle han dling Do not make radical changes to the settings proceed in small steps instead Even small changes can have a large...

Page 55: ...er Remove the rear fender p 79 601040 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Tip Experience has shown that settings outside of this range are detrimental to vehi cle handling When changing the ch...

Page 56: ...djustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The rebound damping setting has an impact on the rebound of the shock absorber 601041 10 Turn adjusti...

Page 57: ... elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the descri...

Page 58: ...k absorber x p 72 After removing the shock absorber clean it thoroughly 601076 10 Loosen screw 1 Info Do not loosen lock nut B at the top of the shock absorber Turn adjusting ring 2 until the spring is no longer under tension Hook wrench T106S ...

Page 59: ...nd when it is installed Tighten the spring by turning the adjusting ring to the specified measurement Guideline Spring preload Comfort 0 mm 0 in Standard 3 mm 0 12 in Sport 3 mm 0 12 in Tighten screw 1 Guideline Screw shock absorber adjusting ring M6 5 Nm 3 7 lbf ft Info If you increase the spring preload you should also slightly increase the rebound damping Install the rear shock absorber x p 73 ...

Page 60: ...ents ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The compression damping setting has an impact on the compression of the shock absorber 601035 10 Turn adjus...

Page 61: ...ettings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pres...

Page 62: ...standard setting Info Turn clockwise to increase damping turn counterclockwise to reduce damping The left and right shock absorbers should have the same settings 9 7 Front shock absorber adjusting the cross over Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can caus...

Page 63: ...e short soft spring Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower The suspension travel and the progressive part of the long hard spring is not fully utilized Less cross over makes the spring action at the front harder and the front of the vehicle lies higher Adjust the spring preload for the front shock absorbers p 62 Raise the vehicle with...

Page 64: ...nt shock absorber adjusting the spring preload Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments r...

Page 65: ...ging the spring preload make a note of the present setting e g by measuring the length of the spring Raise the vehicle with the lifting gear p 69 Clean the shock absorber thoroughly 601037 10 Release retaining ring 1 Hook wrench 83019001000 Turn adjusting ring 2 until the spring pack is no longer under tension Measure the overall spring pack when not under tension ...

Page 66: ...th between the spring pack when it is unloaded and when it is installed The spring pack should never be installed loosely without preload The comfort setting is the lowest permissible spring preload If you increase the spring preload you should also slightly increase the rebound damping The left and right shock absorbers should have the same settings Tighten the retaining ring and adjusting ring R...

Page 67: ...y turning the handlebar support 1 and the handlebar support 2 The holes on the handlebar support are placed at a distance of A from the center Distance A between holes 3 5 mm 0 138 in The holes on the handlebar bridge are placed at a distance of B from the center Distance B between holes 7 5 mm 0 295 in ...

Page 68: ...e handlebar position x 101530 01 Pull the instrument support off the handlebar and swing it to the side Info Protect the vehicle and its attachments from damage by covering them Do not kink the cables and lines Remove handlebar attachment A ...

Page 69: ...desired position Mount and tighten screw 6 Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount and tighten screw 5 Guideline Screw steering column top M20x1 5 25 Nm 18 4 lbf ft Mount and tighten screws 7 Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount handlebar support 4 in the desired position using the screws Mount new self locking nuts 3 and tighten Guideline Nut handlebar sup...

Page 70: ...THE CHASSIS 68 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure the cables and wiring are positioned correctly Mount the handlebar attachment Position the instrument support on the handlebar ...

Page 71: ... on the frame underneath the engine The wheels must no longer touch the ground Secure the vehicle 10 2 Removing the vehicle from the lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Lower the vehicle Remove the lifting gear 10 3 Removing the front shock absorber x Info The operations are the same on the left and ri...

Page 72: ...MAINTENANCE WORK ON THE CHASSIS 70 101547 10 Secure the upper A arm on the frame using tension belt 1 101548 10 Remove screw 2 101554 10 Remove screw 3 Remove the shock absorber ...

Page 73: ...n the front shock absorber with the reservoir toward the rear Mount and tighten screw 1 Guideline Screw front shock absorber M10 45 Nm 33 2 lbf ft 101548 10 Position the shock absorber in the lower A arm Mount and tighten screw 2 Guideline Screw front shock absorber M10 45 Nm 33 2 lbf ft Remove the tension belt Remove the vehicle from the lifting gear p 69 ...

Page 74: ... removing the rear shock absorber secure the swingarm with a tension belt to prevent it from swinging down further Attach the swingarm to the subframe with a tension belt 1 to relieve the shock absorber Remove the bottom screw of the shock absorber Tip Press the screw out of the swingarm with a screw driver while moving the tension belt Remove the top screw 2 of the shock absorber and carefully re...

Page 75: ...n the top screw 1 Guideline Screw rear top shock absorber M12 60 Nm 44 3 lbf ft Position the shock absorber in the swingarm Mount and tighten the bottom screw Guideline Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Remove the tension belt Install the rear fender p 80 Remove the vehicle from the lifting gear p 69 10 7 Removing the front trim Remove the front cover p 78 ...

Page 76: ...NTENANCE WORK ON THE CHASSIS 74 601063 10 Remove screws 1 Raise the front trim and disconnect the plug in connectors from the head light and the emergency OFF switch with the rip cord Remove the front trim ...

Page 77: ...h with the rip cord and position the front trim Mount all screws Fully tighten screws 1 Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Fully tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the front cover p 78 10 9 Removing the radiator spoiler Info The operations are the same on the left and right Remove the seat p 82 ...

Page 78: ...S 76 101550 10 Remove the screws 1 on the fuel tank 101540 10 Remove the screws 2 on the radiator Detach the radiator spoiler and remove it 10 10 Installing the radiator spoiler Info The operations are the same on the left and right ...

Page 79: ... into holder 2 of the fuel tank and position it on the radiator 101541 10 Mount and tighten screws 3 on the radiator Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 4 on the fuel tank Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Mount the seat p 82 ...

Page 80: ...8 10 11 Removing the front cover 100053 10 Remove screw 1 Slide the front cover up and remove it 10 12 Installing the front cover 100055 10 Position the front cover in slots 1 on both sides of the front trim Mount and tighten the screw ...

Page 81: ...MAINTENANCE WORK ON THE CHASSIS 79 10 13 Removing the rear fender Remove the seat p 82 101542 10 Remove screws 1 ...

Page 82: ...der 3 at the rear and remove it 10 14 Installing the rear fender 200148 11 Raise the rear of the air filter box lid 1 At the same time use your other hand to press on the carburetor connection boot to kink it at that location Info This prevents the carburetor connection boot from disconnecting from the carbu retor Position front fender 2 Fix the air filter box lid in the fender Info If the air fil...

Page 83: ...MAINTENANCE WORK ON THE CHASSIS 81 101542 11 Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 82 ...

Page 84: ...1539 10 Pull the release hook 1 back Lift up the seat at the rear pull it back and then remove from above 10 16 Mounting the seat 100046 10 Hook slot 1 on the seat into collar sleeve A of the fuel tank lower the rear of the seat and slide tab 2 under fuel tank B ...

Page 85: ... Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Remove the seat...

Page 86: ...nd to press on the carburetor connection boot 2 to kink it at that location Info This prevents the carburetor connection boot from disconnecting from the carbu retor Unhook the air filter holder 3 and swing it to the side Remove the air filter 4 with the air filter support Remove the air filter from the air filter support ...

Page 87: ...se p 196 100086 10 Put in both parts together position them and fix them with the air filter support 1 Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Mount the air filter box lid Info If the air filter box lid is not correctly mounted dust and dirt can penetrate into the engine and cause damage Mount the seat p 82 ...

Page 88: ...not clean the air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 83 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 196 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 197 Clean the air filter box Che...

Page 89: ...dition p 133 Check the tire air pressure p 134 Check the chassis parts for damage play and wear 302865 10 Load the vehicle with the specified weight Guideline Average rider weight 75 85 kg 165 187 lb Move the handlebar into the straight ahead position and fix it Handlebar fixation for straight ahead position 83019015100 ...

Page 90: ...MAINTENANCE WORK ON THE CHASSIS 88 400333 10 Measure distances A and B If distances A and B are not equal Adjust the toe x p 89 Measure distances C and D Guideline Toe Front 0 mm 0 in ...

Page 91: ...oes not meet specifications Adjust the toe x p 89 10 21 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 133 Check the tire air pressure p 134 Check the chassis parts for damage play and wear Replace damaged or worn parts 302865 10 Load the vehicle with the specified weight Guideline Average rider weight 75 85 kg 165 187 lb Move the handlebar into the straigh...

Page 92: ...ASSIS 90 400333 11 Loosen nuts 2 and 3 Adjust the distances A and B to the same value by rotating the tie rods 1 Adjust the distances C and D to the specified value by evenly rotating the tie rods 1 Guideline Toe Front 0 mm 0 in ...

Page 93: ... the wheel center from rim flange to rim flange Tighten nuts 2 and 3 Guideline Lock nut tie rod outside M12x1 25 20 Nm 14 8 lbf ft Lock nut tie rod inside M12LHx1 25 20 Nm 14 8 lbf ft Info The tie rods 1 must still be freely movable 10 22 Checking adjusting the camber x Info The left and right camber should have the same settings The operations are the same on the left and right Raise the vehicle ...

Page 94: ...127 10 Insert tool 4 in the heim joint and clip onto the A arm Camber gauge 83019014000 Check the camber on both heim joints If marking 5 is not aligned with the top edge of the A arm Turn tool 4 with the heim joint in steps of 180 until the marking is in line with the top edge of the A arm Remove tool 4 ...

Page 95: ...rk offset The fork offset has an impact on the handling of the vehicle The fork offset can optionally be adjusted Fork offset is defined as the slanted position of the swivel axis in the direction of the longitudinal axis of the vehicle in relation to a verti cal line to the driving surface When both sleeves are installed in front of the A arms the fork offset increases This enhances driving stabi...

Page 96: ...th the lifting gear p 69 101529 11 Remove screws 1 with bushings 2 Place the A arm with bushings 2 in the desired position Mount and tighten screws 1 Guideline Screw A arm top M10x52 45 Nm 33 2 lbf ft Remove the vehicle from the lifting gear p 69 10 25 Toe width of rear axle 100101 10 The toe width A can be adjusted by installing the spacer in various ways Difference between narrow wide toe 76 mm ...

Page 97: ...he feel of the new ride behavior Engage 1st gear 100102 10 Loosen nuts 4 of the wheel hubs on both sides Raise the vehicle with the lifting gear p 69 Remove the nuts 4 on both sides and take all parts off of the rear axle 0 0 3 3 0 0 1 1 0 0 2 2 100103 10 Setting a narrow toe width Mount the wheel hub 1 Mount the conical ring 2 with the cone facing outward Mount the spacer 3 with the cone facing i...

Page 98: ... with the cone facing inward Mount the conical ring 2 with the cone facing outward Mount the wheel hub 1 Mount the washer and the new self locking nut 100102 10 Remove the vehicle from the lifting gear p 69 Tighten nuts 4 on both sides Guideline Nut rear wheel hub M18x1 5 130 Nm 95 9 lbf ft Shift gear to neutral ...

Page 99: ... is very dirty Clean the chain p 97 10 28 Cleaning the chain Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance ...

Page 100: ... secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain may snap Conversely if the chain is too loose it may jump off the engine and rear sprockets causing the rear wheel to lock up or even leading to engine damage Check for correc...

Page 101: ...30 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain may snap Conversely if th...

Page 102: ...using the spe cial tool to rotate the rear wheel eccentric element forward or backward Guideline Chain tension 140 145 mm 5 51 5 71 in Info Rotating the rear wheel eccentric element forward increases chain tension Rotating the rear wheel eccentric element backward reduces chain tension The rear wheel eccentric element should always be positioned such that the grease nipple B is visible This ensure...

Page 103: ...ocket and chain guide 400227 01 Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 104: ...the upper chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the specified measurement Replace the chain x Info When you replace the chain you should also change the rear sprocket and engine sprocket New chains wear out faster on old wo...

Page 105: ...NANCE WORK ON THE CHASSIS 103 B00465 01 Check the chain sliding guard at the top for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard x ...

Page 106: ...or wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard x Check the chain sliding guard for tightness If the chain sliding guard is loose Tighten the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 107: ...If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece x Check the chain sliding piece for tightness If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft ...

Page 108: ...e x Info A frame that has been damaged due to a mechanical impact must always be changed Repair of the frame is not authorized by KTM 10 33 Checking the swingarm x 401386 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized...

Page 109: ...se nipple 1 until grease emerges from the left shaft seal ring A Long life grease p 194 Remove excess grease 10 35 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 198 ...

Page 110: ... grip 10 37 Adjusting basic position of clutch lever 101545 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw 1 Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw clockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is ...

Page 111: ...the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the coolant level does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 194 Position the cover with the membrane Mount and tighten screws 10 39 Removing the engine guard 600133 10 Remove scre...

Page 112: ...IS 110 10 40 Installing the engine guard 600133 10 Position the engine guard on the frame bearer Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 113: ... discs at several places on the disc to see if it conforms to measurement A Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 3 5 mm 0 138 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the brake disc Check the front and rear brake discs for damage cracking and deformation If the bra...

Page 114: ...vel on hand brake lever according to specifications 100088 10 Push the hand brake lever forward and check free travel A Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specifications Adjust the basic position of hand brake lever p 112 11 3 Adjusting basic position of hand brake lever 100052 10 Check the free travel of the hand brake lever p 112 Adjust the basic settin...

Page 115: ...ly any force Do not make any adjustments while riding 11 4 Checking front brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom of the viewer this indicates a leakage in the brake system or worn out brake lin ings Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents ...

Page 116: ... system or worn out brake lin ings Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with...

Page 117: ... etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container ...

Page 118: ...ge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 192 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 11 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help...

Page 119: ...king is visible Change the front brake linings x p 119 Mount the wheel wheels p 132 11 7 Removing front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Info The operations are the same on the left and right Remove the wheel wheels p 132 Pull the hand brake lever and rel...

Page 120: ...anger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals ...

Page 121: ...until the brake linings are in contact with the brake disc and there is a pressure point Mount the wheel wheels p 132 11 9 Changing the front brake linings x Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flus...

Page 122: ...nmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only c...

Page 123: ...e fluid level to level A Guideline Dimension A brake fluid level below top edge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 192 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 11 10 Checking free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the fo...

Page 124: ... in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 122 Reconnect spring 1 11 11 Adjusting basic position of foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust free travel on foot br...

Page 125: ...rake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 5 and tighten nut 4 Guideline Remaining nuts chassis M8 30 Nm 22 1 lbf ft Hold push rod 3 and tighten nut 2 Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft Reconnect spring 1 11 12 Checking rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom o...

Page 126: ...4 11 13 Topping up brake fluid of rear brake x Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom of the viewer this indicates a leakage in the brake system or worn out brake lin ings Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact ...

Page 127: ...s substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a...

Page 128: ...f accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 101534 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 130 Check the brake linings for damage and cracking If damage or cracki...

Page 129: ...ly Your authorized KTM workshop will be glad to help 101535 01 Press the brake caliper onto the brake disc by hand in order to push back the brake pis ton 101536 10 Loosen the screw 1 while holding the hexagonal head 2 of the bearing bolt Unscrew the screw by approx 10 turns and use the screw to press the bearing bolt out of the brake caliper Remove screw ...

Page 130: ...rake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably fr...

Page 131: ... brake lining 101537 11 Grease bearing bolt 2 and insert the brake caliper with the bearing bolt into the brake caliper support 3 Lubricant T625 p 197 101536 01 Swing the brake caliper downward Mount and tighten the screw Guideline Screw rear brake caliper M6 10 Nm 7 4 lbf ft Loctite 243 Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure p...

Page 132: ... due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based...

Page 133: ...back to its basic position and make sure that no brake fluid over flows from the brake fluid reservoir Install the rear brake linings x p 128 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 192 Mount the screw cap with the membrane and tighten Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 134: ...e with the lifting gear p 69 Remove the wheel nuts Remove the wheel Info Carefully remove the wheel making sure it does not become jammed with the threads of the screws 12 2 Mounting wheel wheels Note Material damage Damage and destruction of components from incorrect positioning and mounting Do not swap the wheels the tire valves must always be on the outside when the wheels are positioned and mo...

Page 135: ... hand brake lever Figure 100006 10 p 20 Tighten the wheel nuts crosswise Guideline Wheel nut M10x1 25 45 Nm 33 2 lbf ft 12 3 Checking the tire condition Info Only mount tires that have been approved and or recommended by KTM Other tires could have a negative effect on vehicle handling The type condition and air pressure of the tires all have an important impact on the handling characteristics of t...

Page 136: ... markings and is indi cated by the last four digits of the DOT marking The first two digits indicate the week of manufacture and the last two digits the year of manufacture KTM recommends that the tires be changed after 5 years at the latest regard less of the actual state of wear If the tire is older than five years Change the tire 12 4 Checking the tire air pressure Info Low tire air pressure le...

Page 137: ...e the dust cap Check the tire air pressure when the tires are cold Tire pressure gauge 83519001000 Tire air pressure off road 0 3 bar 4 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap ...

Page 138: ... sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Switch off all power consumers and switch off the engine Remove the rear fender p 79 200150 10 Disconnect the negative minus cable 1 of the battery Pull back the plus pole cover a...

Page 139: ... Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Warning Environmental hazard The battery contains elemen...

Page 140: ... life If the charging current charging voltage and charging time are exceeded electrolyte escapes via the safety valves This reduces the battery capacity If the vehicle is started repeatedly until the battery is depleted the battery must be charged immediately If the battery is left in a discharged state for an extended period it will drain completely and sulfate destroying the battery The battery...

Page 141: ...device you cannot overcharge the battery Info Never remove the lid 1 Charge the battery to a maximum of 10 of the capacity specified on the bat tery housing 2 Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the vehicle is not in use 3 months Install the rear fender p 80 1...

Page 142: ...ical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Insert the new fuse Fuse 58011109120 p 186 Tip Replacement fuse 4 should always be present in the starter relay to make sure it is available when needed Replace the protection covers 13 5 Changing the fuses of individual power consumers Remove the front cover p 78 Swi...

Page 143: ...m indicator lamp Fuse 3 10 A radiator fan Fuse 4 10 A for auxiliary devices permanent positive Fuse 5 10 A for auxiliary devices plus switched on with ignition lock Fuse res 10 A 15 A replacement fuses Info You can recognize a blown fuse by its broken filament A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never...

Page 144: ...adlight Make another mark a distance B under the first mark Guideline Distance B 5 cm 2 in Position the vehicle vertically a distance A away from the wall Now the rider wearing a full set of protective clothing sits on the vehicle in the normal sitting position feet on the footrests Guideline Distance A 5 m 16 ft Switch on the low beam Check the headlight setting The boundary between light and dar...

Page 145: ... the headlight range of the headlight by moving it up or down Guideline The boundary between light and dark must be exactly on the lower mark for an opera tional vehicle with a rider to prepare the mark see Checking the headlight setting Info A change in weight on the vehicle may require a correction of the headlight range Tighten screw 1 ...

Page 146: ... temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream The radiator fan provides extra cooling The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 14 2 Radiator fan 600117 10 The radiator fan 1 is located on the radiator under the fuel tank Working range within which radiator fan is switched on and off ...

Page 147: ...Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Remove the front ...

Page 148: ...ternative 1 Coolant p 192 Alternative 2 Coolant mixed ready to use p 192 Mount the compensating tank cover 2 Install the front trim p 75 14 4 Checking the coolant level Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot Allow th...

Page 149: ...ust be completely full Coolant level A must be between MIN and MAX If the coolant level does not meet specifications Open the compensating tank cover 1 and correct the coolant level Alternative 1 Coolant p 192 Alternative 2 Coolant mixed ready to use p 192 Mount the compensating tank cover 1 14 5 Draining coolant x Warning Danger of scalding The coolant gets very hot and is under high pressure whe...

Page 150: ...e immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Remove the front trim p 73 Place a suitable container under the vehicle 600118 10 Remove screw 1 600119 10 Remove screw 2 ...

Page 151: ...n the screws 1 and 2 with new seal rings Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 14 6 Filling coolant bleeding cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and wate...

Page 152: ...ront wheels are blocked 600120 10 Fill the coolant into the radiator 1 Coolant With compen sating tank 1 50 l 1 59 qt Coolant p 192 Coolant mixed ready to use p 192 Without com pensating tank 1 30 l 1 37 qt Coolant p 192 Coolant mixed ready to use p 192 600121 10 Open the screw 2 to bleed the cylinder head Tighten the screw 2 when coolant emerges from the opening Guideline Remaining screws chassis...

Page 153: ... the opening Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 600123 10 Completely fill the radiator and close the radiator cap 4 Place the vehicle on the ground 600125 10 Top up the compensating tank to level B Mount the cap 5 Install the front trim p 75 Make a short test ride Check the coolant level p 146 ...

Page 154: ... in the throttle cable p 152 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the ent...

Page 155: ... Move the handlebar to the straight ahead position Move the reverse gear release lever back and forth slightly to ascertain the play in the cable A Guideline Play in the cable on the reverse gear release lever 10 mm 0 39 in If the cable play on the reverse gear release lever does not agree with the specifica tions Adjust the cable play on the reverse gear release lever p 153 15 4 Adjusting the cab...

Page 156: ...hrottle opening That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly Info The carburetor and its components are subject to increased wear caused by engine vibration Wear can result in malfunctioning If the idle speed is set significantly higher the engine does not start When the elec tric starter button is activated the electric starter turns...

Page 157: ...tion deactivated The choke lever is pushed in to the stop p 27 Idle speed 1 500 1 600 rpm Info If the idle speed is set significantly higher the engine does not start When the electric starter button is activated the electric starter turns over the engine but the engine does not start because there is no ignition spark Turn the idle mixture control screw 1 slowly clockwise until the idle speed beg...

Page 158: ...rongly dimensioned idling jet If you can turn the idle adjusting screw to the end without any change of engine speed you have to fit a smaller idling jet The idle adjusting screw must not be opened more than two turns If more than two turns are necessary rich mixture use a larger idling jet After changing the idling jet start from the beginning with the adjusting steps Adjust the idle speed with t...

Page 159: ...l and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Warnin...

Page 160: ... connection 100105 10 Plug in connector 1 is located under the trim at the front on the frame tube Possible states Performance The plug in connector is connected to achieve better performance Soft The plug in connector is disconnected for better driveability 15 9 Changing the ignition curve Remove the front trim p 73 Changing the ignition curve from Performance to Soft Disconnect plug in connector...

Page 161: ...59 Changing the ignition curve from Soft to Performance Connect the plug in connector 1 Figure 100105 10 p 158 Performance The plug in connector is connected to achieve better performance p 158 Install the front trim p 75 ...

Page 162: ...Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil reaches the middle of the viewer A When the engine oil does not reach the middle of the viewer A Add engine oil p 167 600131 11 Condition The engine is cold Check the engine oil level The engine oil reaches the bottom of the viewer B When the engine oil does not reach the bottom ...

Page 163: ... scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the ...

Page 164: ...lace a suitable container under the engine Remove the oil drain plug 1 600135 10 Remove screw plug 2 and the small oil screen with both O rings 600136 10 Remove screw plug 3 and the large oil screen with both O rings Completely drain the engine oil ...

Page 165: ...nsert them until the O ring is seated in the housing 6 with the oil screen Mount screw plug 7 with the seal ring and tighten it Guideline Locking screw oil screen long M20x1 5 15 Nm 11 1 lbf ft 600140 10 Insert oil screen 8 with O rings 9 into screw plug bk and tighten Guideline Locking screw oil screen short M16x1 5 10 Nm 7 4 lbf ft Lubricated with engine oil ...

Page 166: ...Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Place ...

Page 167: ...und cable A from the engine Remove screws 1 and 2 Take off the oil filter covers with the O ring 600138 10 Pull the oil filters 3 and 4 out of the engine case Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area ...

Page 168: ...of the oil filter covers and mount them with the oil filter covers Mount and tighten screws 1 and 2 Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft Connect ground wire A to the engine and tighten the screw Guideline Screw starter engine M6 10 Nm 7 4 lbf ft 16 6 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 169: ... gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Guideline Switch off the engine when the radiator fan switches on Check the engine oil level p...

Page 170: ... up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 193 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 193 Info To ensure optimal engine oil performance it is advisable to not use different engine oils We recommend making an oil change in this case Mount and tighten filler cap 1 ...

Page 171: ...onmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the vehicle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the vehicle during cleaning Info Do not place the vehicle onto the rear frame bracket to clean it...

Page 172: ... Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning take a short ride until the engine reaches operating temperature Info The heat produced causes water at inaccessible locations in the engine and the brakes to evaporate Push back the protection caps from the handlebar controls to allow any water that may have entered ...

Page 173: ...CLEANING CARE 171 Treat all plastic parts and powder coated parts with a mild cleaning and care product Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces p 198 ...

Page 174: ...he vehicle for a longer period take the following actions Before storing the vehicle check all parts for function and wear If service repairs or replacements are necessary these should be done during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401387 01 Clean the vehicle p 169 Change the engine oil and oil filter cl...

Page 175: ...sing corrosion Avoid running the engine of a vehicle in storage for a short time only Because the engine will not warm up sufficiently the water vapor produced during com bustion will condense causing engine parts and the exhaust system to rust 18 2 Preparing the vehicle for use after storage 401388 01 Recharge the battery x p 137 Install the battery p 137 Fill up with fuel p 46 Perform checks and...

Page 176: ...trode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 0 6 mm 0 024 in Fault in ignition system Check the ignition system x Socket connector of CDI control device pulse generator or ignition coil oxidized Clean the plug in connector and treat it with con tact spray Water in carburetor or jets is blocked Check adjust the carburetor components x Idle sp...

Page 177: ...ot be cranked electric starter Operating error Follow the instructions on starting the engine p 33 Battery discharged Recharge the battery x p 137 Check the charging voltage x Check the quiescent current x Check the stator winding of the alternator x Blown fuse Change the main fuse p 139 Engine does not speed up Carburetor running over because float needle is dirty or worn Check adjust the carbure...

Page 178: ...e contact or oxidized connector Check the electrical system Clean the plug in connector and treat it with con tact spray Engine overheats Coolant level low Check the cooling system for leakage Check the coolant level p 146 Radiator fins excessively dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 147 Fill coolant bleed cooling system x p 149 Bent radiator hose Chang...

Page 179: ... vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 160 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screens x p 161 Piston or cylinder worn Piston cylinder determine the mounting clear ance x Parts of the electrical system are not functional Fault in the electrical system Change the fuses of individual ...

Page 180: ... 1 18 in Valve clearance cold intake 0 10 0 15 mm 0 0039 0 0059 in Valve clearance cold exhaust 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing 2 cylinder roller bearing Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 rotor pumps Primary transmissio...

Page 181: ...ng Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 20 1 Capacity engine oil Engine oil 1 7 l 1 8 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 193 External temperature 0 C 32 F Engine oil SAE 5W 40 p 193 20 2 Capacity coolant Coolant With compensating tank 1 50 l 1 59 qt Coolant p 192 Coolant mixed ready to use p 192 Without compensating tank 1...

Page 182: ... lbf ft Loctite 243 Screw timing chain securing guide M5 6 Nm 4 4 lbf ft Loctite 243 Screw on cylinder head top section M6x45 10 Nm 7 4 lbf ft Screw on cylinder head top section M6x50 10 Nm 7 4 lbf ft Screw on cylinder head top section M6x55 10 9 10 Nm 7 4 lbf ft Screw on cylinder head top section M6x75 10 Nm 7 4 lbf ft Screw bearing stud starter engine M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch...

Page 183: ...sioner M6 10 Nm 7 4 lbf ft Screw valve cover M6 10 Nm 7 4 lbf ft Screw vent hose bracket M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Nut adjusting screw valve clearance M6x0 75 11 Nm 8 1 lbf ft Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Banjo bolt oil line M8 10 Nm 7 4 lbf ft Jet screw oil line M8 10 Nm 7 4 lbf ft Plug crankshaft location M8 10 Nm 7 4 l...

Page 184: ...m 14 8 lbf ft Plug oil pressure regulator valve M12x1 5 20 Nm 14 8 lbf ft Locking screw oil screen short M16x1 5 10 Nm 7 4 lbf ft Lubricated with engine oil Nut inner clutch hub M18x1 5 120 Nm 88 5 lbf ft Loctite 243 Locking screw oil screen long M20x1 5 15 Nm 11 1 lbf ft Nut primary gear M20LHx1 5 150 Nm 110 6 lbf ft Loctite 243 Screw in fitting cooling system in cylin der head top M20x1 5 Loctit...

Page 185: ...buretor identification number 3925H Needle position 3rd position from top Idle mixture adjusting screw Open 1 0 turn Pump membrane stop 2 15 mm 0 0846 in Main jet 170 Jet needle OBEKR Idling jet 42 Main air jet 200 Idle air jet 100 Cold start jet 85 Throttle slide 15 ...

Page 186: ...l Front 275 mm 10 83 in Rear 272 mm 10 71 in Fork offset Front 46 mm 1 81 in Toe Front 0 mm 0 in Camber Front 0 Toe width Front 1 115 mm 43 9 in Rear 1 148 mm 45 2 in Wheelbase 1 280 10 mm 50 39 0 39 in Turning radius 5 625 mm 221 46 in Fording depth 330 mm 12 99 in Seat height unloaded 820 mm 32 28 in Ground clearance unloaded 290 mm 11 42 in Weight fuel tank empty 163 kg 359 lb fuel tank full 17...

Page 187: ...9 in Brake system Front Disc brakes brake calipers fixed 4 brake pistons per brake caliper Rear Disc brake brake caliper floating 1 brake piston Brake discs diameter Front 180 mm 7 09 in Rear 200 mm 7 87 in Brake discs wear limit Front 3 5 mm 0 138 in Rear 3 5 mm 0 138 in Tire air pressure off road 0 3 bar 4 psi Rim Front 5x10 DWT Al 6061 Rear 8x9 DWT Al 6061 Rear wheel gearing 14 38 Chain 5 8 x 1...

Page 188: ...1109110 10 A 23 1 Lighting equipment Headlight S2 socket BA20d 12 V 35 35 W Parking light W5W socket W2 1x9 5d 12 V 5 W Indicator lights W1 2W socket W2x4 6d 12 V 1 2 W Brake tail light LED 23 2 Tires Front tire Rear tire AT 21 x 7 10 DWT XCF RCR V1 AT 20 x 11 9 DWT XCF RCR V1 Additional information is available in the Service section under http www ktm com ...

Page 189: ...TECHNICAL DATA CHASSIS 187 23 3 Capacity fuel Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 194 Fuel reserve approx 3 l 3 qt ...

Page 190: ...ss over 19 mm 0 75 in Spring preload Comfort 4 mm 0 16 in Standard 5 mm 0 2 in Sport 8 mm 0 31 in Spring rate main spring Weight of rider 64 75 kg 141 165 lb 21 26 N mm 120 148 lb in Weight of rider 75 85 kg 165 187 lb 24 29 N mm 137 166 lb in Weight of rider 85 95 kg 187 209 lb 27 32 N mm 154 183 lb in Spring rate auxiliary spring 40 N mm 228 lb in Spring length main spring 275 mm 10 83 in Spring...

Page 191: ...rt 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Spring preload Comfort 0 mm 0 in Standard 3 mm 0 12 in Sport 3 mm 0 12 in Spring rate Rider weight 65 75 kg 143 165 lb 45 N mm 257 lb in Rider weight 75 85 kg 165 187 lb 48 N mm 274 lb in Rider weight 85 95 kg 187 209 lb 50 N mm 286 lb in Spring length 260 mm 10 24 in Fitted length 435 5 mm 17 146 in ...

Page 192: ...eering M8 25 Nm 18 4 lbf ft Screw front brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw front brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw rear brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw rear wheel eccentric element M8 20 Nm 14 8 lbf ft Screw steering bridge M8 20 Nm 14 8 lbf ft Sc...

Page 193: ...el hub M12 70 Nm 51 6 lbf ft Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Screw rear top shock absorber M12 60 Nm 44 3 lbf ft Lock nut tie rod inside M12LHx1 25 20 Nm 14 8 lbf ft Lock nut tie rod outside M12x1 25 20 Nm 14 8 lbf ft Nut A arm top M12x1 25 30 Nm 22 1 lbf ft Nut ball head A arm bottom M12x1 5 40 Nm 29 5 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel hub ...

Page 194: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 195: ...corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 5W 40 According to JASO T903 MA p 199 SAE p 199 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier M...

Page 196: ...ong life grease According to NLGI Guideline Use only grease that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Fett 2000 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to t...

Page 197: ...SUBSTANCES 195 Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 198: ... Remover Chain cleaner Guideline KTM recommends Motorex products Supplier Motorex Chain Clean Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 ...

Page 199: ...Medium Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power ...

Page 200: ... cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE ...

Page 201: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 202: ...13 Brake fluid level of rear brake checking 123 Brake fluid of front brake topping up 114 Brake fluid of rear brake topping up 124 Brake linings of front brake changing 119 checking 116 installing 118 removing 117 Brake linings of rear brake changing 130 checking 126 installing 128 removing 127 C Camber adjusting 91 checking 91 carburetor float chamber emptying 157 idle 154 idle adjusting 155 Chai...

Page 203: ...TOP switch 22 Engine running in 31 switching off 44 Engine guard installing 110 removing 109 Engine number 17 Engine oil adding 167 changing 161 draining 161 refilling 166 Engine oil level checking 160 Engine sprocket checking 101 Environment 10 F Fender rear installing 80 removing 79 Filler cap closing 25 opening 24 Filling up fuel 46 Foot brake lever 29 basic position adjusting 122 free travel c...

Page 204: ...onsumers changing 140 main fuse changing 139 H Hand brake lever 20 basic position adjusting 112 free travel checking 112 Handlebar position 65 adjusting 66 Headlight setting checking 142 headlight range adjusting 143 Hot start button 27 I Ignition curve changing 158 plug connection 158 Ignition lock 23 Indicator lamp overview 23 K Key number 17 L Light switch 21 M Main fuse changing 139 O Oil filt...

Page 205: ...g preload adjusting 55 Rear sprocket checking 101 Rear wheel eccentric element greasing 107 Reverse gear release lever 19 adjusting 153 checking 153 Rider training 9 Riding bends 39 brakes 37 downhill 40 engine switching off 44 general information 38 perpendicular to the slope 42 riding through water 44 starting off 35 stopping parking 45 turning on slopes 42 uphill 41 Rubber grip checking 107 sec...

Page 206: ...bsorber 188 rear shock absorber 189 Throttle lever 21 Tire air pressure checking 134 Tire condition checking 133 Toe adjusting 89 checking 87 rear toe width adjusting 95 Toe width of rear axle 94 Transport 10 Troubleshooting 174 177 Type label 16 U Use definition 8 V Vehicle cleaning 169 lifting gear raising with 69 lifting gear removing from 69 W Warranty 8 Wheel wheels installing 132 removing 13...

Page 207: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 08 2011 Photo Mitterbauer 3211727en 3211727en ...

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KTM 525 XC, Owner'S Manual

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