Ktm 450 SX User Manual Page 1

250 SX-F250 EXC RACING400 EXC RACING450 SX, XC, EXC RACING525 SX, XC, EXC RACINGOWNER’S MANUAL 2006ART. NR. 3.211.73ENENGLISH

ENGLISH9OPERATION INSTRUMENTS »SPEED / LAP (lap time) display mode You can use the manual stop watch to stop and store up to 10 lap times,which you ca

ENGLISH10OPERATION INSTRUMENTS »LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been storedan

ENGLISH11OPERATION INSTRUMENTS »Kilometers or miles The unit (kilometers or miles) can also be changed. The ODO figure will beretained and converted a

ENGLISH12OPERATION INSTRUMENTS »Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Pressand hold the | button

ENGLISH13OPERATION INSTRUMENTS »Filler cap (screw cap)To open the filler cap: Turn the filler cap counter-clockwise.To close the filler cap: Put the f

ENGLISH14OPERATION INSTRUMENTS »Shift leverThe shift lever is mounted on the left side of the engine. The position of thegears is shown in the illustr

ENGLISH15OPERATION INSTRUMENTS »Compression damping of forkHydraulic compression damping determines the reaction when the fork is com-pressed. The deg

ENGLISH16OPERATION INSTRUMENTS »Compression damping of shock absorber (XC, EXC)The compression damping (during compression) can be adjusted for the XC

ENGLISH17GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE »– WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE.CLEVER KTM DRIVERS ALWAYS WEAR A HE

ENGLISH18DRIVING INSTRUCTIONS »Check the following before each startWhen you start off, the motorcycle must be in perfect technical condition.For safe

ENGLISH1IMPORTANT »Please insert the serial numbers of your motorcycle in the boxes belowFrame numberEngine numberKey numberStamp of dealerAll informa

ENGLISH19DRIVING INSTRUCTIONS »– ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENINGTHE THROTTLE. IF YOU DO NOT KICK HARD ENOUGHT, WITH AN

ENGLISH20DRIVING INSTRUCTIONS »NOTE:Dedicated to nothing but offroad racing, 250/400/450/525SX/XC/EXC Racing models make no compromises in their desig

ENGLISH21PERIODIC MAINTENANCE »250 SX-F 2006A CLEAN MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!1st service after3 hoursor20 l fuelevery1

ENGLISH22PERIODIC MAINTENANCE »250 SX-F 2006IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDERBefore eachstartAfter everycleaningFor cros

ENGLISH23PERIODIC MAINTENANCE »IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE.Service intervalls should

ENGLISH24PERIODIC MAINTENANCE »250/400/450/525 SX/XC/EXC 2006IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDERBefore eachstartAfter ever

ENGLISH25PERIODIC MAINTENANCE »250/400/450/525 SX/XC/EXC 2006RECOMMENDED INSPECTIONS OR MAINTENANCE WORK BY THE AUTHORIZED KTM WORKSHOP FOR COMPETITIV

ENGLISH26PERIODIC MAINTENANCE »NOTE:If the inspection establishes that permissible tolerances are exceeded, the respective components must be replaced

ENGLISH27MAINTENANCE WORK ON CHASSIS AND ENGINE »Changing the spring preloading of the shock absorberThe spring preload can be changed by turning the

ENGLISH28MAINTENANCE WORK ON CHASSIS AND ENGINE »Basic suspension setup for the weight of the driverTo achieve maximum handling performance and to pre

ENGLISH2INTRODUCTION »We would like to congratulate you on your purchase of a KTM motorcycle.You are now the owner of a state-of-the-art sport motorcy

ENGLISH29MAINTENANCE WORK ON CHASSIS AND ENGINE »According to our experience, the damping rate of the compression stage canremain unchanged. The dampi

ENGLISH30MAINTENANCE WORK ON CHASSIS AND ENGINE »Breather plug front forkAfter every 5 hours of use for competitive racing, slacken the breather plugs

ENGLISH31MAINTENANCE WORK ON CHASSIS AND ENGINE »BA2132543452Changing the fork offset (caster) (SX) * The fork offset [A] in the SX models (center for

ENGLISH32MAINTENANCE WORK ON CHASSIS AND ENGINE »15 mm3,5 mm1234Mount the lower triple clamp, upper steering head bearing, protection ring,O-ring, upp

ENGLISH33MAINTENANCE WORK ON CHASSIS AND ENGINE »Check chain tensionJack the motorcycle up on its frame so that the rear wheel no longer touchesthe gr

ENGLISH34MAINTENANCE WORK ON CHASSIS AND ENGINE »Chain maintenanceFor a long chain life, good maintenance is very important. Chains without X-rings sh

ENGLISH35MAINTENANCE WORK ON CHASSIS AND ENGINE »General information about KTM disc brakesBRAKE CALIPERS:The brake calipers of this series use a „floa

ENGLISH36MAINTENANCE WORK ON CHASSIS AND ENGINE »Adjusting the free travel at the hand brake leverFree travel at the hand brake lever may be readjuste

ENGLISH37MAINTENANCE WORK ON CHASSIS AND ENGINE »Replacing the front brake pads *Press the brake caliper toward the brake disk, to put the brake pisto

ENGLISH38MAINTENANCE WORK ON CHASSIS AND ENGINE »Checking the rear brake padsThe brake pads can be inspected from the rear. The thickness of the linin

ENGLISH3IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION»KTM sports motorcycles are designed and constructed to resist the usual wear and

ENGLISH39MAINTENANCE WORK ON CHASSIS AND ENGINE »– IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SUREYOU HAVE THE TIGHTENING TORQUE CORREC

ENGLISH40MAINTENANCE WORK ON CHASSIS AND ENGINE »Tires, air pressureTire type, tire condition, and air pressure level affect the way your motor-cycler

ENGLISH41MAINTENANCE WORK ON CHASSIS AND ENGINE »VOLTBattery (XC, EXC)The battery is located under the seat and is maintenance-free.Maintenance-free m

ENGLISH42MAINTENANCE WORK ON CHASSIS AND ENGINE »Fuse (XC/EXC)The fuse [1] is located in the starter relay of the E-starter [2] underneath theleft sid

ENGLISH43MAINTENANCE WORK ON CHASSIS AND ENGINE »Cooling systemCoolant is circulated by a water pump [1] located in the engine. When theengine is cold

ENGLISH44MAINTENANCE WORK ON CHASSIS AND ENGINE »Replacing the glassfiber yarn packing of the silencer *Aluminum silencers are filled with glassfiber

ENGLISH45MAINTENANCE WORK ON CHASSIS AND ENGINE »Cleaning the air filter *The air filter must be cleaned prior to each race or whenever dust has accu-

ENGLISH46MAINTENANCE WORK ON CHASSIS AND ENGINE »Changing the original position of the clutch leverThe adjusting screw [1] can be used for individual

ENGLISH47MAINTENANCE WORK ON CHASSIS AND ENGINE »CARBURETOR – Adjust idling (Keihin-FCRMX 37/39/41) *Idling adjustment of the carburetor strongly affe

ENGLISH48MAINTENANCE WORK ON CHASSIS AND ENGINE »Draining the float chamber of the carburetorFollowing every wet cleaning procedure, the float chamber

ENGLISH4TABLE OF CONTENTS »IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION . . . . . . . . . . . . . .3SERIAL NUMBER LOCATIONS . . . .

ENGLISH49MAINTENANCE WORK ON CHASSIS AND ENGINE »Engine oilAutomobile engine oil used to be used for four-stroke motorcycles before therewere separate

ENGLISH50MAINTENANCE WORK ON CHASSIS AND ENGINE »Changing the oil filtersRemove the screw [1] and swing the brake fluid container sideward. Place arec

ENGLISH51TROUBLESHOOTING »TROUBLE CAUSE REMEDYEngine doesn’t crank (E-starter). Operating errrorBlown fuseDischarged battery.Low outside temperatureTu

ENGLISH52TROUBLESHOOTING »TROUBLE CAUSE REMEDYEngine does not rev high Carburetor fuel level too high because floatneedle valve is dirty or worn outLo

ENGLISH53CLEANING »Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces.The best manner would be to use warm water

ENGLISH54TECHNICAL DATA – ENGINE »ENGINE 250 SX-FDesign Liquid-cooled single cylinder 4-stroke engineDisplacement 249.51 ccmBore/Stroke 76 / 55 mmRati

ENGLISH55TECHNICAL DATA – ENGINE »BASIC CARBURATOR SETTING250 SX-FTypeKeihin FCR-MX 3925DMain jet 168Jet needle OBETPIdling jet 40Main air jet 200Idli

ENGLISH56TECHNICAL DATA – ENGINE »ENGINE 250 EXC 400 EXC 450 SX 450 XC 450 EXC 525 SX 525 XC 525 EXCDesign Liquid-cooled single cylinder 4-stroke engi

ENGLISH57TECHNICAL DATA – ENGINE »BASIC CARBURATOR SETTING250 EXC RACINGEU400 EXC RACING EU400 EXC-G RACING USA450 EXC RACING EUTypeKeihin FCR-MX 3700

ENGLISH58TECHNICAL DATA – ENGINE »TIGHTENING TORQUES – ENGINE 250/400/450/525 SX/XC/EXCHexagon collar screw, engine case, clutch cover, ignition cover

ENGLISH5SERIAL NUMBER LOCATIONS »Chassis numberThe chassis number is stamped on the right side of the steering head tube.Enter this number in the fiel

ENGLISH59TECHNICAL DATA – CHASSIS »CHASSIS 250 SX-F, 450/525 SX 250/400/450/525 XC/EXC 450/525 XC, EXC USAFrame Central tube chrome-moly-steel frameFo

ENGLISH60TECHNICAL DATA – CHASSIS »TIGHTENING TORQUES – CHASSISCollar screw, front wheel spindle M24x1,5 40 NmBrake caliper, front M8 Loctite 243 + 25

ENGLISH61HEAD WORD INDEX »Page PageActivating and deactivating display modes . . . . . . . . .9Adjusting the free travel at the hand brake lever . .

ENGLISH62

ANHANG – APPENDICEAPPENDIX – APÉNDICE1SCHALTPLAN » WIRING DIAGRAM60/5002 F-XS 0525002.20.02pu kcipG3rotarenegnottub potsCDIlioc noitingi000.230.93.495

ANHANG – APPENDICEAPPENDIX – APÉNDICE2SCHALTPLAN » WIRING DIAGRAM60-5002 525-054 XS5002.20.02pu kcipG3rotarenegnottub potsCDIlioc noitingi000.230.93.4

ANHANG – APPENDICEAPPENDIX – APÉNDICE3SCHALTPLAN » WIRING DIAGRAM6002 gnicaR CXEmmargaid gniriwssenrah niam051.570.11.4955002.30.50hctiws rehsalfpu kc

ANHANG – APPENDICEAPPENDIX – APÉNDICE4SCHALTPLAN » WIRING DIAGRAM60-5002 ASU gnicaR CXEmmargaid gniriwssenrah niam001.570.11.4955002.20.52pu kciplioc

ANHANG – APPENDICEAPPENDIX – APÉNDICE5SCHALTPLAN » WIRING DIAGRAMENGLISH DEUTSCH ITALIANOBattery Batterie BatteriaCooling fan Lüftermotor Motorino ven

ANHANG – APPENDICEAPPENDIX – APÉNDICE6SCHALTPLAN » WIRING DIAGRAMENGLISH FRANCAIS ESPANOLBattery Batterie BateríaCooling fan Ventilateur Motor del ven

OPERATION INSTRUMENTS »ENGLISH6Hand decompression lever (450/525 SX)The hand decompression lever [2] is needed only if the carburetor overflowsafter a

KTM-Sportmotorcycle AG A–5230 Mattighofenwww.ktm.atKTM Group Partner5/2005 FOTO: MITTERBAUER

ENGLISH7OPERATION INSTRUMENTS »Headlamp switch (EXC USA)In this model the headlamp is switched on with the pull switch [1].Flasher switchThe flasher s

ENGLISH8OPERATION INSTRUMENTS »TESTAll of the display segments briefly light up for the display function test. WS (wheel size)The display changes and