2003 KTM 250 EXC Racing 450 525 SX EXC MXC Racing Motorcycle Owners Handbook

Description

This 2003 KTM 250 EXC Racing 450 525 SX EXC MXC Racing Owners Handbook is an authorized reproduction of the original, out of print manual. It provides detailed service information, step-by-step repair instruction and maintenance specifications for 2003 KTM 250 EXC Racing, 450/525 SX EXC MXC Racing models.

Table of Contents

SERIAL NUMBER LOCATIONSChassis numberEngine number, engine type

OPERATION INSTRUMENTSClutch leverHand decompression leverHand brake leverDigital speedometer, indicator lampsElectronic speedometerTripmaster switchShort circuit button (SX/MXC)Combination switch (EXC)Headlamp switch (EXC USA)Flasher switchEmergency OFF button (EXC)Emergency OFF switch (EXC Australia)Filler capFuel tapChokeHot start deviceShift leverKickstarterFoot brake pedalSide standCompression damping of forkRebound damping of forkDamping action during compression of shock absorber (SX)Compression damping of shock absorber (MXC, EXC)Rebound damping of shock absorber (SX, MXC, EXC)Steering lock

GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE

DRIVING INSTRUCTIONS

PERIODIC LUBRICATION AND MAINTENANCE-SCHEDULE

MAINTENANCE WORK ON CHASSIS AND ENGINEChecking and adjusting the steering head bearingBreather plug front forkCleaning the dust sleeves of the telescopic forkAdjusting the spring preload on the fork (SX)Basic suspension setup for the weight of the driverHow to change the handlebar positionChanging the spring preload of the shock absorberPivot bearingCheck chain tensionCorrect chain tensionChain maintenanceChain wearGeneral information about KTM disc brakesAdjusting the free travel at the hand brake leverPageChecking the brake fluid level – front brakeRefilling the front brake fluid reservoirChecking the front brake padsReplacing the front brake padsChanging the basic position of the brake pedalChecking the rear brake fluid levelRefilling the rear brake fluid reservoirChecking the rear brake padsReplacing the rear brake padsDismounting and mounting the front wheelDismounting and mounting the rear wheelTires, air pressureChecking the spoke tensionReplacing the battery of the digital speedometerSetting the clockKilometers or milesChecking/setting distance of the magnetic sensorBattery (MXC/EXC)Charging the batteryFuse (MXC/EXC)Replacing the headlight/parking light lampCooling systemChecking the coolant levelBleeding the cooling systemReplacing the glassfiber yarn packing of the silencerCleaning the spark arrestor (MXC/EXC USA)Cleaning the air filterChecking adjustment of the hand decompression release cableAdjusting the throttle cablesChanging the original position of the clutch leverChecking the oil level of the hydraulic clutchBleeding of the hydraulic clutchCarburetor adjustmentAdjusting the mixture control screwChecking the float levelDraining the float chamber of the carburetorOil circuitChecking the engine oil levelEngine oilChanging the engine oil

TROUBLESHOOTINGCLEANING

CONSERVATION FOR WINTER OPERATION

STORAGEUsing after storage

TECHNICAL SPECIFICATIONS – ENGINE

TECHNICAL SPECIFICATIONS – CHASSIS

INDEX

WIRING DIAGRAMS