2007 Ktm 250 400 450 525 Owner Manual (MT057013)

2007 Ktm 250 400 450 525 Owner Manual (MT057013)

• This manual presented for you in electronic format you can just print out the page you need then dispose of it when you have completed your task. This manual has detailed illustrations as well as step by step written instructions with the necessary diagrams or pictures. These manuals are your number one source for repair and service information, specifically written for the do-it-yourself as well as the experienced mechanics worldwide used to use this factory manual to fix your vehicle. Using this repair manual is an inexpensive way to keep your car working properly. it is this level of detail, along with illustrations, that guide the reader through each service, repairs, maintenance procedure.
• 2007 ktm
  
  250 XC-F, XCF-W, EXC-F,
  
  400 XC-W, EXC RACING,
  
  450 XC, XC-W, EXC RACING ,
  
  525 XC, XCW, EXCRACING,
  
  525 XC DESERT RACING,
  
  Owner Manual Manual DOWNLOAD
  
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  Models Covers:

  2007 ktm 250 XC-F, XCF-W, EXC-F
  
  2007 ktm 400 XC-W, EXC RACING
  
  2007 ktm 450 XC, XC-W, EXC RACING
  
  2007 ktm 525 XC, XC-W, EXC RACING
  
  2007 ktm 525 XC DESERT RACING

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  Downloadable: YES
  
  File Format: PDF
  
  Compatible: All Versions of Windows & Mac
  
  Language: English
  
  Requirements: Adobe PDF Reader

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  This Service Repair Manual Covers:

  INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
  
  IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .2
  
  SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .5
  
  Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .5
  
  Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
  
  OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . .6
  
  Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
  
  Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
  
  Short circuit button (XC) . . . . . . . . . . . . . . . . . . . . . . . . .6
  
  Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6
  
  Headlamp switch (XC-W) . . . . . . . . . . . . . . . . . . . . . . . . .7
  
  Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
  
  Starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
  
  Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . . .7
  
  Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
  
  Electronic speedometer . . . . . . . . . . . . . . . . . . . . . . . . . .8
  
  Activating and deactivating display modes . . . . . . . . . . . .9
  
  Overview of the electronic speedometer functions . . . . . .12
  
  Setting the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
  
  Filler cap (bayonet cap) . . . . . . . . . . . . . . . . . . . . . . . . .13
  
  Filler cap (screw cap) . . . . . . . . . . . . . . . . . . . . . . . . . .13
  
  Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
  
  Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
  
  Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
  
  Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
  
  Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
  
  Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
  
  Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
  
  Compression damping of fork . . . . . . . . . . . . . . . . . . . .15
  
  Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . .15
  
  Compression damping of shock absorber
  
  (XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
  
  Compression damping of shock absorber (XC-W, EXC) . . .16
  
  Rebound damping of shock absorber . . . . . . . . . . . . . . .16
  
  GENERAL TIPS AND WARNINGS FOR STARTING
  
  THE MOTORCYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
  
  Instructions for initial operation . . . . . . . . . . . . . . . . . . .17
  
  Running in the XC/EXC models . . . . . . . . . . . . . . . . . . .17
  
  DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .18
  
  Check the following before each start . . . . . . . . . . . . . . .18
  
  Starting when the engine is cold . . . . . . . . . . . . . . . . . .18
  
  Starting when the engine is warm . . . . . . . . . . . . . . . . .19
  
  What to do when the engine is flooded¡° . . . . . . . . . . . .19
  
  Starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
  
  Shifting/Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
  
  Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
  
  Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . .20
  
  Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
  
  PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .21
  
  MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . . . .27
  
  Changing the spring preloading of the shock absorber . . .27
  
  Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
  
  Basic suspension setup for the weight of the driver . . . . .28
  
  Checking the shock absorber and spring . . . . . . . . . . . . .28
  
  Determining the static sag of the shock absorber . . . . . . .28
  
  Determining the riding sag of the shock absorber . . . . . . .28
  
  Checking the basic setup of the telescopic fork . . . . . . . .29
  
  Changing the spring preload on the telescopic fork
  
  (XC, EXC SIXDAYS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
  
  Changing the spring preload on the telescopic fork
  
  (XC-W/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
  
  Replacing fork springs . . . . . . . . . . . . . . . . . . . . . . . . .29
  
  Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .30
  
  Cleaning the dust sleeves of the telescopic fork . . . . . . . .30
  
  Checking and adjusting the steering head bearing . . . . .30
  
  Changing the fork offset (caster) (XC, EXC SIXDAYS) . . . .31
  
  How to change the handlebar position . . . . . . . . . . . . . .32
  
  Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .33
  
  Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .33
  
  Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
  
  Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
  
  General information about KTM disc brakes . . . . . . . . . .35
  
  Adjusting the free travel at the hand brake lever . . . . . . .36
  
  Checking the brake fluid level – front brake . . . . . . . . . . .36
  
  Refilling the front brake fluid reservoir . . . . . . . . . . . . . .36
  
  Checking the front brake pads . . . . . . . . . . . . . . . . . . . .36
  
  Replacing the front brake pads . . . . . . . . . . . . . . . . . . .37
  
  Changing the basic position of the foot brake pedal . . . . .37
  
  Checking the rear brake fluid level . . . . . . . . . . . . . . . . .37
  
  Refilling the rear brake fluid reservoir . . . . . . . . . . . . . . .37
  
  Checking the rear brake pads . . . . . . . . . . . . . . . . . . . . .38
  
  Replacing the rear brake pads . . . . . . . . . . . . . . . . . . . .38
  
  Dismounting and mounting the front wheel . . . . . . . . . . .38
  
  Dismounting and mounting the rear wheel . . . . . . . . . . .39
  
  Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . . .39
  
  Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
  
  Check/set distance of the magnetic sensor . . . . . . . . . . .40
  
  Replacing the battery of the digital speedometer . . . . . . .40
  
  Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
  
  Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . .41
  
  Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
  
  Replacing headlight lamp/parking light lamp . . . . . . . . . .42
  
  Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
  
  Checking the coolant level . . . . . . . . . . . . . . . . . . . . . . .43
  
  Bleeding the cooling system (400/450/525) . . . . . . . . . .43
  
  Bleeding the cooling system (250-F) . . . . . . . . . . . . . . .44
  
  Replacing the glassfiber yarn packing of the silencer . . . .44
  
  Cleaning the spark arrester (XC-W USA) . . . . . . . . . . . . .44
  
  Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .45
  
  Adjusting the throttle cables . . . . . . . . . . . . . . . . . . . . .45
  
  Changing the original position of the clutch lever . . . . . . .46
  
  Checking the oil level of the hydraulic clutch
  
  (400/450/525) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
  
  Checking the oil level of the hydraulic clutch(250-F) . . .46
  
  Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .46
  
  Carburetor ¨C Adjust idling (Keihin-FCRMX 37/39/41) . . . .47
  
  Basic information on carburetor wear . . . . . . . . . . . . . . .47
  
  Adjusting the mixture control screw . . . . . . . . . . . . . . . .47
  
  Checking the float level (float height) . . . . . . . . . . . . . . .47
  
  Draining the float chamber of the carburetor . . . . . . . . . .48
  
  Oil circuit (400/450/525) . . . . . . . . . . . . . . . . . . . . . . .48
  
  Oil circuit (250-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
  
  Checking the engine oil level . . . . . . . . . . . . . . . . . . . . .48
  
  Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
  
  Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .49
  
  Changing the oil filters . . . . . . . . . . . . . . . . . . . . . . . . .50
  
  TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
  
  CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
  
  CONSERVATION FOR WINTER OPERATION . . . . . . . . . . . .53
  
  STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
  
  USE AFTER A PERIOD OF STORAGE . . . . . . . . . . . . . . . . .53
  
  TECHNICAL DATA ¨C ENGINE . . . . . . . . . . . . . . . . . . . . . . .54
  
  TECHNICAL DATA ¨C CHASSIS . . . . . . . . . . . . . . . . . . . . . .59
  
  HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
  
  WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . .appendix

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