Art.Nr. 3.210.
IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR WARNING IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.
Introduction We would like to congratulate you on your purchase of a KTM motorcycle. ENGLISH 2 You are now the owner of a state-of-the-art sport motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. An improperly tuned chassis can lead to damage and breakage of the chassis components. The service work specified in the "Lubrication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation.
Index ENGLISH 4 Page SERIAL NUMBER LOCATIONS .............................................5 Chassis number ................................................................5 Engine number, engine type.............................................5 OPERATION INSTRUMENTS ...............................................5 Clutch lever ......................................................................5 Hand decompression lever................................................5 Hand brake lever .................
SERIAL NUMBER LOCATIONS Chassis number Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket. Write this number into the relevant area on page 1. ENGLISH The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1. 5 OPERATION INSTRUMENTS 1 Clutch lever The clutch lever 1 is located on the left side of the handlebar.
Indicator lamps 3 The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp 2 lights up when the high beam is on. The orange indicator lamp 3 will light when the ignition is switched on. 2 1 ENGLISH Indicator lamp (USA) 4 The orange indicator lamp 4 will light when the ignition is switched on.
+ MODE Tripmaster switch – MODE – + The switch has 3 buttons: MODE, + (plus) and – (minus). The tripmaster switch is mounted on the outer left of the handlebar on the USA models. The switch is located to the left of the speedometer on European models but can also be mounted on the outer left of the handlebar with a retaining clamp (ET.NO. 583.14.069.350). WARNING DO NOT TRY TO CHANGE THE MODE OR READ THE SETTINGS WHILE DRIVING.
LAP/LAP display mode The lap number is shown at the top and the lap time in hours, minutes and seconds at the bottom of the display. If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. Hold the MODE button for 3 seconds in the SPEED/LAP mode to clear the stored lap times. + BUTTON changes to the next lap time.
SPEED/STP1 (stop 1) display mode STP1 shows the traveling time based on TRP1 and continues to count whenever it receives impulses from the wheel sensor. The calculation of this figure is activated by the first impulse received from the wheel sensor and stops 3 seconds after the last impulse is received. SPEED/TRP2 (trip 2) display mode The TRP2 trip meter is always active and counts to 999.9. Contrary to TRP1, the displayed figure can be changed using the + and – buttons.
Driving motorcycle Standing motorcycle OVERVIEW OF TRIPMASTER FUNCTIONS Display Press + Press – Press MODE Hold MODE for 3 sec ENGLISH X SPEED / ODO no function no function next display mode no function X X SPEED / MAX no function no function next display mode resets MAX to 0 X X SPEED / LAP starts / stops LAP figure LAP remains stops LAP, stores LAP figure, resets LAP to 0 next display mode clears all LAP figures LAP / LAP next figure no function next display mode next displ
Ignition lock Switch positions of ignition lock 1: Ignition off, light off (engine can't be started) Ignition on, light off (engine can be started) Ignition on, light on (engine can be started) 3 2 B Combination switch The light switch has 2 switch positions. A = Low beam light B = High beam light The red short circuit button 2 serves to switch off the engine. Leave the switch pressed, until the engine stops. With the button 3 the horn will sound.
Fuel tap OFF ON RES RES RES O FF NO O FF FUEL FUEL FUEL NO O FF RES OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON When using the motorcycle, the rotating handle must be set to the ON position. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx. 2,5 liters. RES The reserve tank, approximately 2,5 liters, cannot be tapped until the rotating handle is turned to the RES position.
Kickstarter Foot brake pedal The foot brake pedal is located in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). ENGLISH The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. 13 Handlebar lock The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw.
Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing cap A. By using the knob 1 (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression.
15 ENGLISH
GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation ENGLISH 16 – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). – Read these operating instructions carefully before your first ride. – Enter the chassis, engine and key numbers on page 1. – Familiarize yourself with the operating elements. – Adjust the hand brake lever and foot brake lever to your most comfortable position.
DRIVING INSTRUCTIONS Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 2 FUEL Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.
Starting when the engine is cold 1 2 3 4 5 6 Open the fuel tap 1 Switch on ignition (turn ignition key 2 into position Swing up the side stand or center stand Put the gear in neutral Operate the choke 5 Do not accelerate; operate starter button 3 ) WARNING – TO – 1 AVOID INJURIES, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE KICKSTARTER. DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH.
– – – ! – HIGH – – – – WARNING ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EASILY LOSE CONTROL OF YOUR MOTORCYCLE. WHEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE. AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN. A BENT HANDLEBAR MUST ALWAYS BE REPLACED.
PERIODIC MAINTENANCE SCHEDULE 2003 1.
VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ENGLISH Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean a
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER. AT KTM YOUR MOTORCYCLE WILL RECIEVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS. CAUTION ! ! CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC.
Check and adjust steering head bearing * Check steering head bearing for play periodically. To check this put motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. To adjust, loosen the five pinch bolts 1 of the top triple clamp and turn steering stem bolt 2 clockwise until there is no more play. Don’t tighten the steering stem bolt all the way, otherwise the bearings will be damaged.
How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar to the position that is the most convenient for you. The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm (0,6 in) from one another. The bores at the handlebar support 2 are offset from the center by 3.5 mm (0.13 in). Accordingly, you can mount the handlebar in 4 different positions.
Checking rubber ring on the WP rear shock absorber min. 2,5 mm A rubber ring mounted on the rear shock absorber serves as a vibration damper. This ring gets pressed together with time and loses its shock absorbing function. Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit.
Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use brushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Shell Advance Bio Chain).
General information about KTM disc brakes BRAKE PADS: The motorcycles are delivered with organic brake pads and have also been type-coded with these pads. Said pads are suitable for almost the entire range of application of these motorcycles.It is only for competitive racing in extremely dirty conditions (e.g., water in combination with sand and mud) that we recommend brake pads that have sintered linings.
Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1. In this way, the position of the point of pressure (i.e., the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. 1 ! min. 3 mm CAUTION ! THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM.
Replacing front brake pads * 1 1 Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips 1 and pull out bolt 2. Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and grease guide bolts if necessary. Mount the right brake pad and fix it with the bolt. Mount the left brake pad and insert the bolt until it stops. Mount the clips.
Changing the basic position of the brake pedal * 1 A The basic setting of the foot brake pedal can be changed by turning the end stop roller 1. Using the push rod 2, the free play on the foot brake pedal must be set. Measured on the outside, the foot brake pedal must have 3-5 mm of free play, before the push rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal). To keep the stop roller from turning while tightening, insert a hexagon wrench in bore A.
Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws 1 on the left fork leg. Then loosen the collar nuts 2 before loosening the clamp screws 1 on the right fork leg. Hold the front wheel and withdraw the wheel spindle 3. 2 1 Note: The wheel spindle can be withdrawn more easily by turning it moderately with a 6 mm ALLAN/IMBUS key while pulling.
Tires, air pressure Tire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. Tire size can be found in the technical specifications and in their homologation certificate Tire condition has to be checked every time you want to ride your motorcycle. Before leaving, check tires for punctures and nails or other sharp objects that might have become embedded in them.
Check/set distance of the magnetic sensor The distance between magnet 2 and sensor 1 must be 2-4 mm, otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing in or off the sensor 1. KMH: WS = mm x 3.14 mm x 3.14 ENGLISH 1 2 MPH: WS = (mm x 3.14) : 1.61 33 Wheel circumference with standard tires = 2205 mm 1 Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the MODE button for 3 seconds.
Battery The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. 1 Removing the battery: Remove screws 1 and swing retaining bracket and voltage regulator out of the way. First disconnect the negative and then the positive pole of the battery. Remove battery. When replacing, connect first the positive and then the negative pole.
Fuses Fuse box A is located under the seat. See "Removing the seat" to remove and mount the seat. The fuses are numbered on the inside of the fuse box. The fuses marked "RES" are spare fuses. Main fuse 1 (20 amperes) protects all power consumers against short circuits.
Exchanging the brake light and tail light bulb Remove the cap 1 on the underside of the license plate retainer. 1 ENGLISH 2 Turn the lamp socket 2 approximately 30° counterclockwise and pull it out of the tail light housing. Slightly depress the bulb, turn it approx. 30° counterclockwise and pull it out of the socket. To mount the lamp reverse the worksteps indicated above. 36 Cooling system Coolant is circulated by a water pump located in the engine.
Checking the coolant level The coolant should be 10 mm (0,4 in) above the radiator fins when the engine is cold (see illustr.). In the event of the coolant being drained, always fill and bleed the system. 10 mm Cleaning the air filter * It is very important for the engine's life expectancy to clean the air filter regularly. To clean the air filter, remove screws 1 and the filter box cover. Detach retaining clip 2 and remove the air filter 3 including the filter holder 4 from the filter box.
Exhaust system * Aluminium silencers are filled with glass fiber yarn. If exposed to heat for longer periods of time, however, the glass fiber yarn pack will come unravelled, which can reduce both overall performance and the performance of the silencer. Experience has shown that the front glass fiber pack 1 must be replaced more often than the rear pack 2. To replace the front glass fiber yarn pack, remove the silencer.
Adjusting the throttle cable * 3 1 KEIHIN FCR-MX41: To adjust the throttle cables, dismount the seat and the tank together with spoilers. Slide back the protection cover 1. Loosen the counter nut 2 and turn the adjusting screw 3 accordingly. Turning the adjusting screw counterclockwise will reduce the backlash, turning the adjusting screw clockwise will increase the backlash. Tighten the counter nut and check whether the throttle grip can be actuated smoothly. Mount tank and seat.
Checking the oil level of the hydraulic clutch 2 1 3 To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws 1 and cover 2 together with the rubber boot 3 . The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (e.g. Shell Naturelle HF-E15).Biodegradable hydraulic oil is available from your KTM dealer (50ml).
Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2. The adjusting wheel is used to adjust the basic setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system.
CARBURETOR – Adjust idling (Mikuni BST 40) * 1 Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. Use the adjusting screw 1 to adjust the basic position of the throttle valve and, thus, the idle speed.
Engine oil API: SG, SH – 0°C 32°F 10W 40 10W 50 + CAUTION ! ! INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. 15W 40 15W 50 Checking the engine oil level The engine oil level can be checked when the engine is cold or warm. To check, place the motorcycle in an upright position on a level surface (center stand). B If the engine is cold, the oil level should be visible at the lower edge A of the inspection glass.
Changing the engine oil * The engine oil change is to be carried out when the engine is still warm. WARNING AN 1 ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT NOT BURN YOURSELF. A - DO Place the motorbike on a horizontal surface. Remove the two plugs (1 and 2), and drain oil into a container. CAUTION ! ! THE SCREW PLUG A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE.
Changing oil filter * 2 Replace the oil filter when changing the engine oil. Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible. Remove banjo bolt 1 and the three screws. Remove oil filter cover 2 and oil filter. Clean the filter case, oil filter cover and sealing areas. Make sure the oil duct in the oil filter cover is not clogged.
TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. ENGLISH TROUBLE CAUSE REMEDY Engine doesn’t crank. (E.
TROUBLE CAUSE REMEDY Engine does not rev high Carburetor fuel level too high because Dismount carburetor and check if worn out Float needle is dirty or worn out Replace float needle Float leaks Replace float Defective membrane of slide Replace membrane (Mikuni BST40) Carburetor leaking Check vacuum hose and venting hose of carburetor for correct position (no kinks) Loose carburettor jets Tighten jets Electronic ignition timing faulty Have ignition system checked Fuel supply partically inte
ENGLISH 48 TROUBLE CAUSE REMEDY Headlight and parking light fail Blown fuse Replace fuse (5) Flasher lights, brake light and horn fail Blown fuse Replace fuse (4) The battery is discharged The ignition (power consumer) hasn’t been switched off Recharge the battery according to the relevant instructions. The battery isn’t charged by the generator because Remove seat and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer.
CLEANING 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 trade washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet. CAUTION ! ! CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC.
TECHNICAL SPECIFICATIONS – ENGINE 625 SXC 2003 ENGLISH 50 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio 625 SXC Liquid-cooled single cylinder 4-stroke engine with balancer shaft 625 ccm 101 / 78 mm 11,5 : 1 unleaded premium gasoline with a least RON 95 4 valves over rock
BASIC CARBURATOR SETTING Type Carburator-setting number Main jet Jet needle Idling jet Main air jet Idling air jet Needle position Starting jet Mixture control screw open Slide Performance restrictor Stop pump membrane Hot start device Keihin FCR-MX 41 4138A 165 OBDVT 42 200 100 5. rd from top 85 2 15 Slide stop 858 / 2,15 mm 3,8 mm BASIC CARBURETOR SETTING 625 SXC USA Type Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Mikuni BST40-266 152,5 X-6 689 45 6G5 3.
TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2003 ENGLISH Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. offroad Air press. road Tyres rear Air press offroad Air press.
M16x1,5 M20x1,5 M10 (10.9) M10 (10.9) M6 (10.9) M6 (10.
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. WARNING STATEMENT: AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW. 1) Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases. 2) Removal or puncturing of any part of the intake system.
IMPORTANT To avoid oil spill through crankcase breather, never exceed top mark at operating temperature! WARNING THIS SHOCK ABSORBER CONTAINS NITROGEN GAS UNDER HIGH PRESSURE. DO NOT ATTEMPT REFILLING OR REBUILDING THE SHOCK, SINCE THE SHOCK MAY BE DAMAGED.
DATE 02/06 MADE IN AUSTRIA 770 lbs 350 kg 331 lbs 150 kg WITH 90/90-21 TIRE, 54S TT TYPE, 1,60-21 RIM, AT 22 psi 1.5 bar COLD GAWR REAR 551 lbs 250 kg WITH 140/80-18 TIRE, 70R TT TYPE, 2,50-18 RIM, AT 29 psi 2.0 bar COLD THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
Page Page Activating/deactivating the display modes ..........................33 Driving instructions .............................................................17 Adjusting of free travel at the hand brake lever...................28 Electronic speedometer .........................................................6 Adjusting the mixture control screw ....................................41 Emergency OFF button .......................................................11 Adjusting the throttle cable ...
1 ANHANG APPENDIX
ANHANG APPENDIX 2
3 ANHANG APPENDIX
5230 Mattighofen Austria Internet: www.ktm.
