User manual KTM 525 SX 2005

[. . . ] BEDIENUNGSANLEITUNG2005 250 EXC RACING 400 EXC RACING 450 SX, MXC, EXC RACING 525 SX, MXC, EXC RACING OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART. 3. 211. 39 IMPORTANT » Please 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 attention to notices that are marked as follows: ­ IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB! Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. [. . . ] Tap gently on the lower triple clamp with a rubber hammer to loosen the steering stem [5] out of the bearing seat. Take the lower triple clamp with the steering stem out of the steering head. 4 2 5 Remove the collar screw from the lower triple clamp and pull out the steering stem. Turn the steering stem 180° and insert it in the triple clamp, tighten the collar screw all the way to the stop. ­ A PLASTIC INSERT IN THE COLLAR SCREW THREAD MAKES THE COLLAR SCREW SELF-LOCKING. REPLACE IF THE COLLAR SCREW CAN BE SCREWED IN BY HAND. ­ DO NOT CONFUSE THE COLLAR SCREW WITH THE BLIND SCREW. THE COLLAR SCREW IS SELF-LOCKING. 2 Grease the steering head bearing and sealing elements. ENGLISH 29 MAINTENANCE WORK ON CHASSIS AND ENGINE » Mount the lower triple clamp, upper steering head bearing, protection ring, O-ring, upper triple clamp and the blind screw. Tighten the collar screw on the lower triple clamp to 80 Nm. Mount the fork legs and tighten the clamp screws on the lower triple clamp to 10 Nm in 3 stages. Adjust the steering head bearing without clearance (see: Checking and adjusting the steering head support) and tighten the clamp screws on the upper triple clamp to 15 Nm in 3 stages. Mount Mount Mount Mount the the the the front wheel fender and tighten the screws to 10 Nm. hand brake cylinder and tighten the screws to 10 Nm. front wheel (see: Dismounting and mounting the front wheel). ENGLISH 30 Checking and adjusting the steering head bearing * Check steering head bearing for play periodically. To check, put the motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. For readjusting, 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. With a plastic hammer, lightly tap on the triple clamp to release tension. Retighten the five pinch bolts to 15 Nm (SX) / 20 Nm (EXC, MXC). IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCYCLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL. IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED. 3 4 The steering head bearings should be regreased at least once a year (e. g. Motorex Long Therm 2000). 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). [. . . ] Damping action during compression of shock absorber (SX) Determining the riding sag of the shock absorber . Determining the static sag of the shock absorber . Dismounting and mounting the front wheel . Dismounting and mounting the rear wheel . [. . . ]