2004 KTM 250 EXC Racing 450 525 SX MXC EXC Owners Handbook

Description

This 2004 KTM 250 EXC Racing 450 525 SX MXC EXC Racing Owners Handbook is an authorized reproduction of the original, out of print manual. It provides maintenance information and instructions for the proper operation and care of 2004 KTM 250 EXC Racing, 450/525 SX EXC MXC Racing motorcycles.

2004 KTM 250 EXC Racing 450 525 SX MXC EXC Owners Handbook Table Of Contents

IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATIONSERIAL NUMBER LOCATIONSChassis numberEngine number, engine typeOPERATION INSTRUMENTSClutch leverHand decompression leverHand brake leverShort circuit button (SX/MXC)Combination switch (EXC)Headlamp switch (EXC USA)Flasher switchStarter button (EXC)Digital speedometer, indicator lampsElectronic speedometerTripmaster switchSetting the clockActivating/deactivating the display modesKilometers or milesEmergency OFF switch (EXC Australia)Filler capFuel tapChokeHot start device (/ SX)Shift 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 lockGENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLEInstructions for initial operation Running in the Racing modelsDRIVING INSTRUCTIONSCheck the following before each startStarting when the engine is coldStarting when the engine is warmWhat to do when the engine is floodedStarting offShifting/RidingFuelBrakingStopping and parkingPERIODIC MAINTENANCE SCHEDULEMAINTENANCE 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 preloading of the shock absorberPivot bearingCheck chain tensionCorrect chain tensionChain maintenanceChain wearGeneral information about KTM disc brakesAdjusting the free travel at the hand brake leverChecking the brake fluid level – front brakeRefilling the front brake fluid reservoirChecking the front brake padsReplacing the front brake padsChanging the basic position of the foot 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 wheelChecking spoke tensionTires, air pressureCheck/set distance of the magnetic sensorReplacing the battery of the digital speedometerBattery (MXC/EXC)Charging the batteryFuse (MXC/EXC)Replacing headlight lamp/parking light lampCooling systemChecking the coolant levelBleeding the cooling systemReplacing the glassfiber yarn packing of the silencerCleaning the spark arrester (MXC/EXC USA)Cleaning the air filterChecking the 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 – Adjust idling (Keihin-FCRMX //)Adjusting the mixture control screwChecking the float level (float height)Draining the float chamber of the carburetorOil circuitChecking the engine oil levelEngine oilChanging the engine oilTROUBLESHOOTINGCLEANINGCONSERVATION FOR WINTER OPERATIONSTORAGEUSE AFTER A PERIOD OF STORAGETECHNICAL DATA – ENGINETECHNICAL DATA – CHASSISHEAD WORD INDEXWIRING DIAGRAM

2004 KTM 250 EXC Racing 450 525 SX MXC EXC Owners Handbook Index of Topics

Activating/deactivating the display modesAdjusting the free travel at the hand brake leverAdjusting the mixture control screwAdjusting the spdng preload on the fork (SX)Adjusting the throttle cablesBasic suspension setup for the weight of the drtverBattery (MXC/EXC)Bleeding of the hydraulic clutchBleeding the cooling systemBrakingBreather plug front forkCarburetor – Adjust Idling (Kelhln-FCRMX 37/39/41)Chain maintenanceChain wearChanging the basic position of the foot brake pedalChanging the engine oilChanging the odglnal position of the clutch leverChanging the spdng preloading of the shock absorberCharging the batteryChassis numberCheck chain tensionCheck the following before each startCheck/set distance of the magnetic sensorChecking and adjusting the steedng head bearingChecking spoke tensionChecking the adjustment of the hand decompressionrelease cableChecking the brake fluid level – front brakeChecking the coolant levelChecking the engine oil levelChecking the float level (float height)Checking the front brake padsChecking the oil level of the hydraulic clutchChecking the rear brake fluid levelChecking the rear brake padsChokeCleaningCleaning the air filterCleaning the dust sleeves of the telescopic forkCleaning the spark arrester (MXC/EXC USA)Clutch leverCombination switch (EXC)Compression damping of forkCompression damping of shock absorber (MXC EXC)Conservation for winter operationCooling systemCorrect chain tensionDamping action dudng compression of shock absorber (SX)Digital speedometer, indicator lampsDismounting and mounting the front wheelDismounting and mounting the rear wheelDraining the float chamber of the carburetorDriving instructionsElectronic speedometerEmergency OFF switch (EXC Australia)Engine number, engine typeEngine oilFiller capFlasher switchFoot brake pedalFuelFuel tapFuse (MXC/EXC)General information about KTM disc brakesGeneral tips and warnings for starting the motorcycleHand brake leverHand decompression leverHeadlamp switch (EXC USA)Hot start device (450/525 SX)How to change the handlebar positionImportant limited warranty and limited guaranteeinformationInstructions for initial operationKlckstarterKilometers or milesMaintenance work on chassis and engineOH circuitOperation instrumentsPeriodic maintenance schedule 2004Pivot beartngRebound damping of forkRebound damping of shock absorber (SX, MXC, EXC)Refilling the front brake fluid reservoirRefilling the rear brake fluid reservoirReplacing headlight lamp/parking light lampReplacing the battery of the digital speedometerReplacing the front brake padsReplacing the glassfiber yam packing of the silencerReplacing the rear brake padsRunning in the Racing modelsSenal number locationsSetting the clockShift leverShifting/RidingShort circuit button (SX/MXC)Side standStarter button (EXC)Starting offStarting when the engine is coldStarting when the engine is warmSteeflng lockStopping and parkingStorageTechnical data – chassisTechnical data- engineTires, air pressureTripmaster switchTroubleshootingUse after a period of storageWhat to do when the engine is flooded