KTM 450 SX 2004 Скачать руководство пользователя страница 51

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ENGLISH

Type

250 EXC

450 SX

450 MXC

450 EXC

525 SX

525 MXC

525 EXC

Design

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

Displacement

250 cc

449 cc

448 cc

510 cc

Bore/Stroke

75 / 56.5 mm 95 / 63.4 mm

89 / 72 mm

95 / 72 mm

Ratio

12 : 1

11 : 1

Fuel

unleaded fuel with at least RON 95 (USA = Premium RON 91)

Valve timing

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

Camshaft

5532

590/5521

55/21

590/5521

Valve diameter Intake

28 mm

35 mm (Titan)

35 mm

Valve diameter Exhaust

24 mm

30 mm (Titan)

30 mm

Valve clearence cold Intake

0.12 mm (0.0047 in)

Valve clearence cold Exhaust

0.12 mm (0.0047 in)

Crank shaft bearing

2 cylinder roller bearing

Connecting rod bearing

needle bearing

Top end bearing

bronze bushing

Piston alluminium alloy -

cast

forged

cast

forged

Piston rings

1 compression ring, 1 oil scraper ring

Engine lubrication

pressure circulation lubrication with two rotor pumps

Engine oil

full synthetic oil (Motorex Power Synt 4T 10W/50)

Quantity of engine oil

1.25 liters

Primary ratio

straight geared spur wheels 33:76 Z

Clutch

multi disc clutch in oil bath

Transmission claw shifted

6-speed

4-speed

6-speed

4-speed

6-speed

Gear ratio
1

Gear

14:38

16:32

14:34

16:32

14:34

Gear

16:36

18:30

17:31

18:30

17:31

Gear

19:34

20:28

19:28

20:28

19:28

Gear

21:32

22:26

Gear

23:30

24:24

24:23

24:24

24:23

Gear

22:25

21:18

26:21

21:18

26:21

Ignition system

contactless DC-CDI ignition with digital advanced system by KOKUSAN

Generator

12V 150W

12V 40W

12V 150W

12V 40W

12V 150W

Spark plug

NGK DCPR 8 E

Spark plug gap

0.6 mm (0.02367 in)

Cooling system

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

Cooling liquid

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

Starting equipment

kick-electric starter

kickstarter

kick - electric starter

kickstarter

kick - electric starter

TECHNICAL DATA – ENGINE 250/450/525 SX, MXC, EXC RACING 2004

Содержание 450 SX 2004

Страница 1: ...OWNER S MANUAL MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES ART NR 3 210 77 250 EXC RACING 450 SX MXC EXC RACING 525 SX MXC EXC RACING BEDIENUNGSANLEITUNG2004...

Страница 2: ...moval or rendering inoperative 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...

Страница 3: ...formed If maintenance work should become necessary during a competition it should be performed by a trained mechanic KTM strongly recommends that all service work to your KTM should be performed by a...

Страница 4: ...age or consequential damage caused by manipulations or conversions to the motorcycle The use of the motorcycle under extreme conditions e g on extremely muddy and wet terrain can lead to higher than a...

Страница 5: ...ging the spring preloading of the shock absorber 28 Pivot bearing 28 Check chain tension 29 Correct chain tension 29 Chain maintenance 30 Chain wear 30 General information about KTM disc brakes 31 Adj...

Страница 6: ...ch lever see maintenance work on chassis and engine Hand decompression lever The hand decompression lever 2 is needed only if the carburetor overflows after a fall To pump the engine free pull the han...

Страница 7: ...to switch off the engine Leave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch 4 Flasher switch The flasher switch is...

Страница 8: ...front wheel turns the display will automatically change to the SPEED ODO mode SPEED H hours display mode When you stop driving and no impulses are sent from the wheel sensor the display mode will auto...

Страница 9: ...UTTON 3 SECONDS to reset the MAX figure to 0 SPEED LAP display mode LAP displays the stopped lap time in hours minutes and seconds BUTTON Starts and stops the stop watch The lap time is not reset to 0...

Страница 10: ...the first impulse received from the wheel sensor when the front wheel starts to turn and stops 3 seconds after the last impulse is received when the front wheel has stopped The TRP1 AVS1 and STP1 fig...

Страница 11: ...he SPEED STP2 mode and press the button BUTTON starts and stops the stop watch BUTTON no function press the MODE BUTTON to change to the next mode press and hold the MODE BUTTON 3 SECONDS to reset STP...

Страница 12: ...resets TRP1 STP1 and AVS1 to 0 resets TRP2 to 0 next display mode sets STP2 to 0 Kilometers or miles The unit kilometers or miles can also be changed The ODO figure will be retained and converted acc...

Страница 13: ...l tap is closed No fuel can flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the...

Страница 14: ...own in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the right side of the engine Its upper part can be swivelled Foot b...

Страница 15: ...bsorber SX The shock absorber on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of...

Страница 16: ...ng of shock absorber SX MXC EXC By using the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damp...

Страница 17: ...t ride Familiarize yourself with the operating elements Set the clutch lever the handbrake lever and the footbrake pedal to the positions that are most convenient for you Get used to handling the moto...

Страница 18: ...Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving pe...

Страница 19: ...o 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 fully rev up the engine actuate...

Страница 20: ...ED OR DIRTY ROADS CAN ALSO DELAY THE BRAKING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS WHEN YOU BRAKE THE BRAKE DISCS B...

Страница 21: ...etting Check function of electric systems low high beam brake light indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Ch...

Страница 22: ...and adjust if necessary Clean air filter and filter box Check tires for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements...

Страница 23: ...centricity of the valve disk Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for damage...

Страница 24: ...tricity of the valve disk Check the valve guides for wear Check the radial clearance of the rocker arm rollers Check the elongation of the timing chain Check the chain tensioner tooting for damage vis...

Страница 25: ...GINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE...

Страница 26: ...rotection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lift the dust protection bellows out of the outer tubes and slide them down...

Страница 27: ...gain to establish dimension B The static sag is the difference between dimensions A and B EXAMPLE Motorcycle jacked up dimension A 600 mm Motorcycle on ground unloaded dimension B 565 mm Static sag 35...

Страница 28: ...parts catalog The fork springs may not be pretensioned by more than 20 mm The preload adjuster used in the SX models can easily be retrofitted for the telescopic forks of the MXC EXC models NOTE WP p...

Страница 29: ...purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One...

Страница 30: ...HE MOTORCYCLE Correct chain tension Loosen collar nut 1 loosen lock nuts 2 and turn right and left adjusting screws 3 equally far Tighten lock nuts To ensure the correct alignment of the rear wheel th...

Страница 31: ...K CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary Chain wear To check the chain wear observe the fol...

Страница 32: ...ess in a location B outside the contact face Check wear in several locations WARNING BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0 4 MM 0 016 IN CONSTI TUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACE...

Страница 33: ...oir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 e...

Страница 34: ...ve the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CA...

Страница 35: ...BRAKING SYSTEM ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and...

Страница 36: ...the reverse order Before tightening the collar nut to 80 Nm push the rear wheel forwards so that the chain tensioners lie on the tension screws WARNING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT H...

Страница 37: ...TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE...

Страница 38: ...ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STO...

Страница 39: ...TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the parking light lamp with hold...

Страница 40: ...Y AND CONSULT DOCTOR A mixture of 40 antifreeze liquid and 60 water is used as coolant However the antifreeze protection must be at least 25 C 13 F This mixture offers antifreeze protection but also g...

Страница 41: ...ntaining the packing into the silencer such that the slot engages the web A Use a blunt ended object to stuff the glassfiber yarn packing all the way into the silencer and mount the front cap C To cha...

Страница 42: ...the hand decompression release cable Start the engine and at idling speed slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever The backlash until sa...

Страница 43: ...ble from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS NEVER REFILL WITH MINERAL HYDRAULIC...

Страница 44: ...s been screwed 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 lar...

Страница 45: ...il from the oil sump of the transmission This engine oil flows through an oil line 5 into the cylinder head for camshaft lubrication 6 the oil quantity is controlled by the jet screw 7 An oil duct bra...

Страница 46: ...n 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 Dis mount the oil screen...

Страница 47: ...ide and fill the oil filter housings about halfway with engine oil Fill oil filter with oil place the long oil filter in the front and the short filter in the back of the filter box Grease the O rings...

Страница 48: ...the new fuels evaporate during longer periods of standing still 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 cham...

Страница 49: ...elay The battery isn t charged by the generator because REMEDY Dismount carburetor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well as carburetor Rep...

Страница 50: ...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 warm water that has been mixed with a normal bran...

Страница 51: ...n with two rotor pumps Engine oil full synthetic oil Motorex Power Synt 4T 10W 50 Quantity of engine oil 1 25 liters Primary ratio straight geared spur wheels 33 76 Z Clutch multi disc clutch in oil b...

Страница 52: ...mm 858 2 15 mm 858 2 15 mm 858 2 15 mm Hot start device 2 2 mm 250 EXC RACING Six Days 250 EXC RACING 11 kW 450 EXC RACING 12 kW 450 SX RACING BASIC CARBURATOR SETTING Type Keihin FCR MX 39 Keihin FCR...

Страница 53: ...0 Nm Hexagon collar screw locking lever M5 Loctite 243 6 Nm Hexagon collar screw shift roller M5 Loctite 243 6 Nm Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 8 Nm He...

Страница 54: ...Nm M10 50 Nm TIGHTENING TORQUES CHASSIS TECHNICAL DATA CHASSIS 250 450 525 SX MXC EXC RACING 2004 450 525 SX RACING 250 450 525 EXC RACING 450 525 MXC EXC USA Frame Central tube chrome moly steel fra...

Страница 55: ...mpression of shock absorber SX 14 Digital speedometer indicator lamps 7 Dismounting and mounting the front wheel 34 Dismounting and mounting the rear wheel 35 Draining the float chamber of the carbure...

Страница 56: ...front flasher handle bar switch left front flasher rear brake switch regulator rectifier U rear light brakelight start button generator G 3 ye bl ye bl cooling fan black 10 br ye re br ye re ye re re...

Страница 57: ...oil headlight handle bar switch regulator rectifier U rear light brakelight start bottom generator G 3 ye bl light switch cooling fan black 10 wh br ye re ye re br C_AB 9 ye br br bl wh ye bl br bu wh...

Страница 58: ...blue green black generator ignition coil throttle position sensor pick up stop button yellow black black brown red blue white I D C red white wiring diagramm SX 450 525 2004 19 05 2003 ANHANG APPENDIC...

Страница 59: ...sdigitaltacho Tachimetro digitale multifunzione Pick up Impulsgeber Pick up Position light Standlicht Luce di posizione Rear brake switch hinterer Bremslichtschalter Interruttore luce post di stop Rea...

Страница 60: ...dinateur de bord Veloc metro digital multifuncional Pick up Capteur d allumage Generador de impulsos Position light feu de position luz de posicion Rear brake switch Contacteur de frein arri re Interr...

Страница 61: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 6 2003 FOTO MITTERBAUER...

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