ktm 520 exc instrument panel globes

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KTM 125 EXC, EXC SIXDAYS 200 XC, XC-W, EXC 250 XC, XC-W, EXC, EXCSIXDAYS 300 XC, XC-W, EXC-E, EXC-ESIXDAYS OWNER'S MANUAL 2008

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Filed Under (KTM) by admin on 02-12-2010

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Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Enter this number on page 1. Clutch lever The clutch lever [1] is located on the left side of the handlebars. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hand brake lever The hand brake lever [2] is mounted on the handlebars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see maintenance work on chassis and engine). OPERATION INSTRUMENTS » 1 2 A B
ENGLISH 6 OPERATION INSTRUMENTS » 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. Electronic speedometer The display in the electronic speedometer is activated as soon as you press a button on the speedometer or an impulse is received from the wheel sensor. The display lights up when the engine is running. The display is cleared if no button is pressed for 1 minute or no impulse is received from the wheel sensor. The button is used to change between display modes. The + and – buttons are used to control various functions. SPEED display mode / H (service hours) Only the SPEED / H and SPEED / ODO display modes are activated in the condition at delivery. SPEED/H is displayed whenever the display is activated and the front wheel is not turning. It automatically changes to the SPEED/ODO display mode as soon as the front wheel starts turning. SPEED displays the speed. H displays the engine’s service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motorcycles, making the service hour counter a very practical function. SPEED / ODO display mode (odometer) The SPEED/ODO mode displays the speed and the total distance traveled. The display automatically changes to the SPEED/H display mode when the front wheel stops turning. + button no function – button no function briefly press buttonchanges to the next display mode hold button 3 secs. changes to the next display mode The electronic speedometer has a number of display modes (functions) that you can also activate (reveal) (see: Activating and deactivating display modes).
ENGLISH 7 OPERATION INSTRUMENTS » SPEED / LAP (lap time) display mode You can use the manual stop watch to stop and store up to 10 lap times, which you can view in the LAP/LAP display mode (see below). LAP displays the lap times in hours, minutes and seconds. + button Starts and stops the stop watch, lap time is not reset to 0 – button Stops the stop watch, stores the lap time and restarts the stop watch again. The time is reset to 0. A total of 10 lap times can be stored. If the lap time continues to run after you press the – button, all 10 memory locations are occupied.To clear all of the stored lap times, hold the button for 3 seconds in the SPEED/LAP mode.Up to 10 lap times can be stored in this way. briefly press buttonChanges to the next display mode.If no lap time is stored or the motorcycle is driving, the LAP/LAP mode will be skipped. hold button 3 secs. Clears all LAP figures SPEED / CLK (time) display mode CLK displays the time in hours, minutes and seconds. + button no function – button no function briefly press buttonchanges to the next display mode hold button 3 secs. set the clock menu To set the clock, see „Setting the clock”. Activating and deactivating display modes In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blinking function can be activated by pressing the + button and deactivated by pressing the – button. Press and hold the button 3 seconds to store the settings. If no button is pressed for 20 seconds, the setting will be stored automatically and the display will return to the SPEED/H mode. + button activates the blinking display – button deactivates the blinking display briefly press buttonchanges to the next display without changing any settings hold button 3 secs. starts the SETUP stores the settings and changes to the SPEED/H mode

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HARLEY DAVIDSON DASH PANEL EXTENSION KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-02-2011

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INSTALLATION 1. Remove the seat. 2. See Figure 1. Loosen the two socket head screws on the instrument panel console. Raise the console enough to access the two pushnuts holding the upper end of the leather insert. Remove and discard the pushnuts using pliers or a blade-type screwdriver. 3. Remove and discard the phillips head screw (3) and washer (4) securing the lower portion of the leather insert to the fuel tank. Remove the leather insert and discard it. 4. Obtain the dash panel extension (1) and the dash panel extension trim (2) from kit. Place the dash panel extension on the dash panel extension trim making sure the panel is centered and fits cleanly into the lips on both sides of the trim. 5. Gently lift up on the rear of the instrument panel console and install the dash panel extension with the rubber dash panel extension trim underneath, butting the two together. Make sure the rubber dash panel extension trim is aligned with the dash panel extension. Finger tighten the two socket head screws to hold down the instrument panel temporarily in place. NOTE The console rubber trim from a stock vehicle may need to be trimmed slightly to assure proper fit. NOTE When performing the next step, note that proper alignment is achieved when space is eliminated between the instrument panel console and/or between the dash panel extension trim piece and the fuel tank. Due to variances in fuel tank and instrument panel console fitments, the foam pads are used on “as needed” basis to achieve proper alignment. It may be necessary to experiment a few times using various combinations of pads to achieve the desired alignment. In some cases, pads may not be necessary while in others, it may be necessary to use all with one stacked above another. 6. Observe the overall fitment of the panels over the tank and determine whether the foam pads will be necessary to achieve the desired alignment. 7. If necessary, remove the dash panel extension assembly. Peel the adhesive backing and install the needed foam pads (5) to the raised areas extending from the front of the dash panel extension as shown. Re-install the panel. 8. When the proper alignment between the new kit and the fuel tank is achieved, tighten the rear mounting screw (3) with the washer (4) to the speed nut located on the tab at the rear of the fuel tank. 9. Tighten to 18-24 in-lbs (2.0-2.7 Nm). 10. Tighten the instrument panel console?s two socket head screws to 18-24 in-lbs (2.0-2.7 Nm). 11. Install the seat

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HARLEY DAVIDSON LEATHER FUEL TANK PANEL INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 07-02-2011

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INSTALLATION Softail Models NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2 3 1 is00927 1. Instrument panel 2. Nut 3. Masking tape Figure 1. Leather Fuel Tank Panel Installed 2. See Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 3. Place a shop towel under instrument panel and set instrument panel on fuel tank. 4. See Figure 2. Remove lower mounting screw and washer (1) and retain for reinstallation. 5. Lay leather tank panel on tank in desired position. 6. Install screw and washer saved in Step 4 into hole on tank panel. Tighten screw finger tight. 1 is02467 1. Save screw and nut for reinstallation Figure 2. Softail Tank Panel Installs With Original Screw And Nut 7. See Figure 1. Install instrument panel (1) and tighten nut (2) to 8 ft-lb (11 Nm) . 8. Tighten lower mounting screw. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 9. Install seat on the motorcycle by inserting the tab at front of seat into slot at the rear of fuel tank. Secure seat to fender with screw. INSTALLATION FXDWG and FXDC NOTE Generic leather tank panel shown for illustration purposes. 1. Refer to Owner’s manual for removal of seat. 2. 1993-2003 Models: Figure 1. Remove nut (2) securing instrument panel (1). Gently lift instrument panel up and turn it so stock fuel tank panel front end is uncovered. 2004 and later Models: See Figure 4.

2006 KTM 250 SX-F 250 EXC RACING 400 EXC RACING 450 SX, XC, EXC RACING 525 SX, XC, EXC RACING, REPAIR MANUAL

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

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Hot start lever (250 SX-F) If you pull the red hot start lever [1] during the starting procedure backward, a bore in the carburetor will be opened through which the engine may take in additional air. The result is a „lean” fuel-air mixture of the type needed for hot starts.
ENGLISH 7 OPERATION INSTRUMENTS » Headlamp switch (EXCUSA) 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 (EXC) Pushing the black starter button [2] will actuate the E-starter. 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. 2 3 4 5 6 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

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KTM 125 SX, EXC 200 EXC, XC, XC-W 250 SX, EXC, XC, XC-W 300 EXC, XC, XC-W OWNER'S MANUAL

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Filed Under (KTM) by admin on 27-11-2010

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Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Combination switch (EXC) The light switch has 2, respectively 3 switch positions. [A] = Light off (this function is not available in all models) [B] = Low beam on [C] = High beam on You may use button [2] to actuate the horn. The red short circuit button [3] serves to switch off the engine. Leave the switch pressed until the engine stops. Headlamp switch (XC-W) In this model the headlamp is switched on with the pull switch [4] . 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 Emergency OFF switch (Australia) The emergency OFF switch [5] is located next to the throttle grip. Primarily designed as safety or emergency OFF switch, it should normally not be in its activated state. In this position, the ignition circuit is shorted; if the engine is running, it will stall immediately, if it is at standstill, it will not start. In this position, the ignition circuit is enabled; the engine should start. 1 2 3 5 A B C 4
ENGLISH 12 Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [1] without kinks. Filler cap (XC, XC-W) To open the filler cap: Turn the filler cap 45 ° counter-clockwise. To close the filler cap: Put the filler cap on and turn it 45 ° clockwise. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carbure- tor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. With the twist grip in this position the tank will be emptied until only the reserve is left. RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position. Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time, too. Reserve of the 8.5 l tank . . . . . . 1.3 l (0.32 USgallons) Reserve of the 10 l tank . . . . . .1.7 l (0.45 USgallons

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

KTM 250 EXC RACING 450 SX, MXC, EXC RACING 525 SX, MXC, EXC RACING OWNER`S MANUAL

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Filed Under (KTM) by admin on 28-11-2010

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Digital speedometer, indicator lamps The green control lamp 1 flashes in the same rhythm as the flashing indicator when the indicator is working. The blue control lamp 2 lights up when the high beam is on. Electronic speedometer The electronic speedometer display is activated as soon as the engine is switched on and the motorcycle starts to move. The engine must be started in order for the speedometer to be supplied with electricity from the generator. An impulse must be received from the wheel sensor to activate the display; the front wheel must turn at least one time. TEST All of the display elements will light up for 1 second for the function test. WS (wheel size) The display will change and briefly show the diameter of the front wheel in millimeters. If the front wheel does not turn, the display will automatically change to the SPEED/H mode. If the front wheel turns, the display will automatically change to the SPEED /ODO mode. SPEED/H (hours) display mode When you stop driving and no impulses are sent from the wheel sensor, the display mode will automatically change from SPEED/ODO to SPEED/H. H shows the operating hours. The operating hour counter starts to count as soon as you start the engine. The displayed figure cannot be cleared. Service intervals are indicated in operating hours for some KTM offroad motorcycles, making the operating hour counter a very practical function. SPEED/ODO display mode The SPEED/ODO mode shows the speed and the total kilometers traveled. When the front wheel stops turning, the display will automatically change to the SPEED/H mode. The information will disappear in the display when the front wheel stops turning for 1 minute. NOTE: A Tripmaster switch (part no 583.14.069.244) is available as an accessory and enhances the electronic speedometer by providing the following functions: 2x Tripmaster 2x chronometer for the lap time Average speed Maximum speed Clock Display in miles

Harley-Davidson FLH Accent Panel Installation Manual

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Filed Under (Harley Davidson) by admin on 16-02-2011

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1 Install Accent Panels Note: See hardware list on Page 4 for usage and descriptions. 1.1 Elevate the rear of the vehicle and support with jack stands under the rear differential tubes. 1.2 Remove the rear wheels 1.3 Remove the passenger foot rests. 1.4 Remove front fairing (for wiring later in installation) . 1.5 Install cross brace and frame clamps to frame in the approximate position shown in Figure 1. 1.6 Note orientation of cross brace (Figure 2). Flat side of the brace against bottom of frame tubes. Outboard tabs up and to the rear of the vehicle. 1.7 Leave the bolts loose to allow the bracket’s position to be adjusted later in installation. 1.8 Install front brackets to vehicle between the frame and crash bars as shown, using the supplied hardware (the left side bracket is longer than the right. Figure 3 1.9 Leave the bolts loose to allow the bracket’s position to be adjusted later in installation. 1.10 Position the accent panel to vehicle. Figure 4 1.11 Install supplied hardware to front and cross brackets. Figure 5 &Figure 6 1.12 Leave the bolts loose to allow the accent panel’s position to be adjusted later in installation. 1.13 If not already preinstalled to your accent panel, install rubber bead edge molding between trike body (fender) and accent panel. Bead edge molding 1.14 Clamp the accent panel to the body (fender). Check position of accent panel and ensure proper positioning of bead edge molding. 1.15 Four holes will be drilled though body (fender) and accent panel in the approximate positions shown (both left and right accent panels). Figure 8 Note: Hole location dimension in Figure 8 are approximations. Your drill location may and can vary. Note: Hole position should be as high an possible on the accent panel, allowing space to install hardware 1.16 With accent panel and bead edge molding properly positioned and clamped to body (fender), Drill the two outboard holes in the approximate position shown from inside the fender well through mounting surface of accent panel. Note: Drill outboard hole first and install hardware to reduce risk of accidental movement. Figure 9 1.17 Drill remaining two inboard holes from the accent panel mounting surface through the body (fender). Figure 10 1.18 With both left and right accent panels installed, tighten all hardware at the left and right front mounting positions. 1.19 Trim off excess bead edge molding. 1.20 With left and right front mounting secure, check position and alignment of cross bar and accent panel mid mounts and tighten all hardware. 1.21 With fairing removed, crimp supplied xxx to the black, purple and blues wires of the vehicle’s turn signal wire loom. 1.22 Crimp one of the supplied male spade connectors to the end each wire from the accent panel. 1.23 Connect wiring as indicated in Table 1 below. Accent Panel Wire Color Vehicle Turn Signal Loom Wire Color Yellow Purple (Signal) Orange Blue (Running) Black Black (Ground) Table 1

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KTM EXC Enduro & SX Motocross REPAIR MANUAL

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Filed Under (KTM) by admin on 06-03-2012

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Thanks to a history of competition successes, particularly in off-road racing, KTM motorcycles enjoy a large and loyal following. Established in 1953, KTM (from Kraftfahrzeuge Trunkenpolz Mattighofen where founder, Hans Trunkenpolz, had his engineering works) went through difficult times in the early 1990s. After a takeover, the Austrian company emerged as KTM Sportmotorcycle AG and has gone from strength to strength in recent years. Mainstay of their range are their Enduro and Motocross models, the EXC and SX, and these are covered in the latest new manual from Haynes. Models covered are the 250, 400, 450, 520 and 525 EXC and SX with 4-stroke sohc engines, 2000 to 2007. Information has also been included on the SMR Supermoto versions and MXC/XC derivatives. Haynes Manuals for cars and motorcycles are so popular that 150 million have been sold worldwide. Lay them end-to-end and they would circle the globe at the equator! The new manual begins with essential pre-ride checks, competition prep and routine maintenance tasks before moving on to more major repairs. There are comprehensive, fully illustrated, instructions for overhauling the engine, transmission, brakes, suspension and electrical system. Useful reference pages include colour wiring diagrams, fault-finding charts and a comprehensive section on tools and workshop tips. Because all Haynes Manuals are based on a complete stripdown and rebuild, not only are the procedures written from first-hand experience, but there is information about special tools required for each job, and its complexity, plus Haynes tips for saving time and money. The new Haynes KTM EXC Enduro & SX Motocross Manual is the only complete manual for owners of these motorcycles.

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

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Filed Under (KTM) by admin on 08-02-2012

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00-’03 KTM 400/450/520/525 EXC & MXC Dual Sport Kit Installation Manual 1. 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

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