User manual KTM 525 XC

[. . . ] OWNER'S MANUAL 2007 250 XC-F, XCF-W, EXC-F 400 XC-W, EXC RACING 450 XC, XC-W, EXC RACING 525 XC, XC-W, EXC RACING 525 XC DESERT RACING ART. 3. 211. 145 EN ENGLISH INTRODUCTION » 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 motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer All information contained is without obligation. [. . . ] Mount the handlebar and handlebar clamps, and tighten screws [3] to 20 Nm (15 ft. lbs). The gap between the handlebar support and the handlebar clamps should be the same size in the front and in the rear. The screws [4] must be secured with loctite 243. mm 15 2 3, 5 mm 1 MAINTENANCE WORK ON CHASSIS AND ENGINE » Check chain tension A Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Press the chain upward at the end of the chain sliding component. The distance between the chain and the swing arm should be approx. In the course of this procedure, the upper chain portion [A] must be taut (see drawing). If necessary, correct the chain tension. ­ Excessive tensioning of the chain will put additional load on the components of the secondary drivetrain (chain, bearings of transmission and rear wheel). Aside from resulting premature wear, if worst comes to worst the chain may rupture or the countershaft of the transmission may break. ­ Too much slack in the chain, on the other hand, can result in the chain jumping off the chain wheels. If this happens, the chain could also block the rear wheel or damage the engine. ­ In either case the operator is likely to lose control of the motorcycle. 8-1 0m m/ 0. 30. 4 in Correct chain tension B 1 3 2 Loosen collar nut [1], loosen lock nuts [2], and turn right and left adjusting screws [3] equally far. To ensure the correct alignment of the rear wheel, the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks [B]. Tighten the counter nut of the adjusting screws. Clean and grease the adjusting screws regularly (Motorex Long Term Grease 2000). Before tightening the collar nut, verify that the chain adjusters [4] are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. ­ If you don't happen to have a torque wrench at hand, make sure you have the tightening torque corrected by a KTM dealer as soon as possible. A loose axle may lead to an unstable driving behavior of your motorcycle. ­ Tighten the collar nut with the required torque. A loose wheel spindle may lead to an unstable behavior of your motorcycle. NOTE: The large adjusting range of the chain adjusters (32mm) allows you to use different secondary ratios in combination with the same chain length. The chain adjusters [4] can be rotated by 180°. 4 2 4 B 3 ENGLISH 33 MAINTENANCE WORK ON CHASSIS AND ENGINE » Chain maintenance For a long chain life, good maintenance is very important. [. . . ] Determining the static sag of the shock absorber . Dismounting and mounting the front wheel . Dismounting and mounting the rear wheel . Draining the float chamber of the carburetor . [. . . ]