KTM DC CONVERSION HARNESS Removal and Installation Manual

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Filed Under (KTM) by admin on 06-02-2012

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STEP 3: Install the battery in the battery box. If using the Trail Tech 040-BATT3.7, use the two included 8″ zip ties as shown. If using the Yuasa YTX4l-BS, use a KTM battery strap, STEP 4: Screw the battery box into place on the rear fender. Use the 3 provided screws. The bottom screw hole may not line up on some older models. If so, use alternate opening as shown. STEP 5: Begin installing the wiring harness at the Ground Ring Terminal. Remove the forward coil Bolt (on older models, use the regulator mount), and re-install with ring terminal. Rotate all connectors towards the rear of bike before tightening bolt. Zip- tie the wire harness to the lower frame rail, routing the zip tie through the available slot in the coil mount (as shown). STEP 6: Route the positive(+) battery and tail light connectors under the frame rails, then through the wiring notch in the air- box plastic. If installing a tail light, connect it now

2007 KTM 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 INSTALLATION MANUAL

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Filed Under (KTM) by admin on 05-02-2012

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Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [1] . Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike off-road, you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. Flasher left Flasher right Starter button Pushing the black starter button [2] will actuate the E-starter. Indicator lamps The green control lamp [5] flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp [6] lights up when the high beam is on. ENGLISH 7 2 Emergency OFF switch (EXC Australia) The red emergency-OFF switch [3] is arranged adjacent to the throttle grip. In this position, the E-starter is operational and the engine can be started. In this position, the E-starter and ignition circuits are interrupted.The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter. Pushing the black starter button [4] will actuate the E-starter. 3 4 5 6 1 OPERATION INSTRUMENTS » ENGLISH 8 TEST All of the display segments briefly light up for the display function test. WS (wheel size) The display changes and the circumference of the front wheel is briefly displayed in millimeters (2205 mm corresponds to a front wheel circumference of 21″ with production tires). Afterwards the display will return to the previous display mode

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2000-2003 MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 05-02-2012

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1. Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side anels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees

KTM 250 – 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 04-02-2012

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KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER -Put the index into the binder. -Put the front page of the repair manual (210×297 mm) into the transparent pocket provided for this purpose on the outside of the binder. -Put the spine label (170×45 mm) into the transparent pocket provided for this purpose on the spine of the binder. -Put the summary list of contents (150×297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. -Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3″. -Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents.

KTM 2010 450 EXCUSA 530 EXCUSA INSTALLATION MANUAL

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Filed Under (KTM) by admin on 03-02-2012

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Clutch lever 500133-10 The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. Hand brake lever 400196-10 Hand brake lever  is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. EmergencyOFFswitch 500144-10 The emergency OFF switch  is fitted on the left side of the handlebar. Possible states Ignition off-In this position, the ignition circuit is interrupted, a run- ningenginestops, and anon-running engine will not start. Ignition on-In this position, the ignition circuit is closed, and the engine can be started. Ignition switch 300396-10 The ignition switch  is on the right behind the headlight mask. Possible states Ignition off-In this position, the ignition circuit is interrupted, a run- ningenginestops, and anon-running engine will not start. Ignition on-In this position, the ignition circuit is closed, and the engine can be started. Electrics tarter button 500144-12 Electric starter button  is fitted on the right side of the handlebar. Possible states •Electric starter button is in home position •Electric starter button is pressed-In this position, the electric starter is actu

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KTM 2010 50 SX 50 SXMini OWNER'S MANUAL

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Filed Under (KTM) by admin on 03-02-2012

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To give your child a feel for the brake, you should push your child at first. Do not start the engine until your child can is able to apply the necessary brake pressure. At the start, let your child ride to another person who can help him or her stop and turn. -Erect obstacles for your child to navigate around to accustom your child to handling the vehicle. -Yourchildshould also try to ride as slowly as possible and in a standing position to geta better feeling for the vehicle. -Donotletyour child try any off-road rides that would exceed the ability and experience of your child. -Yourchildshould hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding. -Donotexceedthe maximum allowable rider weight. Guideline Maximum rider weight <35 kg (<77 lb.) Maximum rider size Checkthegearoil level. (p. 57) (50 SXMini) -Checktheoillevel. (p. 55) -Checkthechain tension. (p. 34) -Checkthechain dirt accumulation. (p. 33) -Checkthetire condition. (p. 47) -Checkthetireair pressure. (p. 47) -Checkthefront brake fluid level. (p. 37) -Checktherear brake fluid level. (p. 42) -Checkthefront brake linings. (p. 39) -Checktherear brake linings. (p. 43) -Checkthefunction of the brake system. -Checkthecoolant level. (p. 49) -Checkthesettings of all controls and ensure that they can be operated smoothly. -Checkthe functioning of the electrical equipment. Starting Danger Danger of poisoning  Exhaust gases are poisonous and can result in unconsciousness and/or death. -When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an effective exhaust extraction system. Note Engine failure  High engine speeds in cold engines have a negative effect on the service life of the engine. -Always warmup the engine at low engine speeds. Info If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after along time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately.

KTM SX50/ SX50R MOUNTING INSTALLATION MANUAL

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Filed Under (KTM) by admin on 02-02-2012

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top out” too easily and fail to allow enough travel for appropriate rebound from bumps. If the ride height is too low, the shock can bottom too easily, resulting in a harsh ride. The spring rates are set up for the full amount of travel. If the preload is too little, the combined rate is not enough to resist bottoming. Generally speaking, the vehicle should settle 1/4 to 1/3 of its wheel travel with the rider on board for off road use. The proper way to measure the ride height: 1. Support the vehicle on a frame stand or center stand with the rear wheel clear of the ground. 2. Have an assistant measure and record the vertical distance between the rear axle and a point directly above it (seat, fender, frame, muffler, etc.). 3. Take the motorcycle off the stand and sit on it in a normal riding posture, with one foot on the peg and the motorcycle balanced so as to have minimal weight on your other foot. 4. Have the assistant carefully measure from the same two points. Subtract the second measurement from the first. The difference is the amount of settling or “sag.” NITROGEN PRESSURES CAUTION: The pressure in these shocks cannot successfully be checked. Concerns with the gauge volume and the gas volume in the shock body create a situation where you cannot accurately determine what pressure was in the shock. In addition, the gas is in a column on top of the oil, and when the pressure is lowered (i.e. checking the pressure) the gas will emulsify into the oil. This will cause the gas and some of the shock oil to escape into the gauge. It is possible to lose a large percentage of the shock oil by depressing the core of a charged shock to the atmosphere. Please note that in order to check the pressure, some of the gas must escape and fill the gauge assembly. The volume of the gas pocket is about the size of your thumb, so a very small volume change results in a large pressure drop. Because the gauges’ volumes vary, it is not possible to deduce the actual pressure in the shock prior to attaching the gauge. Therefore it is imperative that any attempt to check pressure be accompanied by the capability of refilling the shock. In other words: If you don’t have a nitrogen source handy, don’t check the pressure

KTM ELECTRICAL SYSTEMS INSTALLATION, REPAIR

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Filed Under (KTM) by admin on 02-02-2012

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DC SYSTEMS STEP DC1 – REGULATOR/RECTIFIER: PRE-2005 KTM If the stock regulator looks like below (the stock connector will not plug into the Trail Tech regulator/rectifier) then the provided stub connector must be soldered into the bike’s wire harness. For models without a stock battery, mount the reg/rec and plug the stub connector into it. Run the red and black wires directly to the (aftermarket) battery, and the yellow wires to the stator. SEE DC CIRCUIT DIAGRAM ON REVERSE SIDE OF PAGE. MODELS WITHOUT A STOCK BATTERY Move stock light to the DC circuit: divert lighting wire from AC circuit to DC circuit. In stock form, the lights are powered by the AC half of the electrical system. In order to continue to use the stock light, find the yellow wire (runs to stock headlight) shown below (wire bundles are found underneath gas tank) and cut the smaller gauge yellow wire. 1. Connect aftermarket light: Wire the light’s red(+) light lead to the positive(+) battery terminal, and the black(-) light lead to the negative(-) battery terminal. Trail Tech lights should use a 10-20 amp fuse as close to the positive(+) battery terminal as possible.

2009 KTM 250 SX-F & XC-F Piston Kits REMOVAL, INSTALLATION

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Filed Under (KTM) by admin on 02-02-2012

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Features* Benefits •*Dedicated*forging ………………………….. •*Light*weight,*superior*strength,*optimized*design •*Stock*Compression ………………………… •*Matches*OEM*compression*ratio •*Dome*design …………………………………. •*Improved*flame*travel*to*maximize*air/*fuel*burn*efficiency •*Chrome*plated*piston*pin ……………….. •*Reduced*friction,*improved*scuff*resistance •*Horizontal*slot*pin*oiling …………………. •*Improved*lubrication,*better*pin*oiling,*reduced*friction •*Pressure*seal*groove ………………………. •*Maximum*ring*seal •*Skirt*coated …………………………………… •*Reduced*friction,*quieter*operation,*improved*scuff*resistance •*Dedicated*rings ……………………………… *Optimized*for*each*application,*light*weight,*high*perfromance,*better*oil*control •*Experience ……………………………………. •*68*years*as*the*industry*leader*in*forged*piston*technology

2000-2003 KTM MXC / EXC Dual Sport Kit Installation Manual

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Filed Under (KTM) by admin on 01-02-2012

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Get a degree in Mechanical and Electrical Engineering. (Just kidding!) 2. Remove the seat, fuel tank, and side panels. Stock switch Bracket Photo 2 EXC – Unplug and remove the stock headlight. (Photo 2.) Unplug the stock three-pin taillight connector and pull the taillight wires back to the rear of the airbox temporarily. MXC – Remove the stock front number plate. 3. Make sure the stock battery is oriented in its mounting bracket as shown with the positive terminal on the left side of the bike (as viewed if sitting on the bike). If not, remove and spin it 180 degrees. Photo 3 4. MXC ONLY! (EXC skip this step.) Locate the stock lighting wiring harness zip-tied under the frame back-bone (See Photo 4). Remove the securing zip-ties and route this wiring forward to the area behind the headlight. Route along right side of frame using factory wire- guide clamp. 5. Brake Light Switch Installation: The KTM kit uses a hydraulic brake-switch. This requires replacing the rear master cylinder banjo bolt with a specially made switch. Installing the switch requires bleeding the brake. If you do not feel competent bleeding your rear brake, please refer this job to a qualified mechanic, as failure to do it correctly will make the brake inoperable. Remove the stock banjo bolt and replace with the hydraulic switch as shown. Make sure to install