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DRIVING INSTRUCTIONS
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Starting off
Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open the throttle at the same time.
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (hill size etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever in and shift to the next higher gear. Let clutch lever go again and accelerate.
If you turned on the choke, make sure you turn it off again as soon as engine is warm.
When you reach full speed through opening the throttle all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Only give as much gas as the engine can handle. Through quick and high revving of the throttle, the fuel usage increases.
By shifting down, use the brakes if necessary and close the throttle at the same time. Pull the clutch lever and shift down to the next gear. Let clutch lever go slowly and open the throttle or shift down again.
NOTE:
Dedicated to nothing but offroad racing, 250/450 SX-F-models make no compromises in their design. As such, they do not include any radiator fan, and the size of the radiator is dimensioned for optimum ergonomics.
In normal racing, the cooling system is sufficient.
If you use your motorbike in other conditions, please note that: turn off the engine if you intend to run your motorcycle in idle or at a standstill for longer periods of time (more than 2 minutes).
Avoid letting the clutch slip frequently and for extended periods.
This would cause the engine oil to heat up, thereby heating up the cooling system. You should drive at low speeds (4-stroke style letting the engine pull you) and not at high speeds not by letting the clutch slip (2-stroke style).
– In case of rain, after washing the motorcycle, after rides through water and in case of rides on wet off-road tracks, humid or dirty brake discs can delay the braking effect. The brakes must be pulled until they are dry or clean.
– Dirty brake discs cause increased tear of brake pads and brake discs.
– When you brake, the brake discs, brake pads, brake caliper and brake fluid heat up. The hotter these parts get, the weaker the breaking effect. In extreme cases, the entire braking system can fail.
– If the resistance in the hand brake lever or foot brake pedal feels “spongy” (too much play), this is an indication that something is wrong with the brake system. Don’t ride your motorcycle anymore without first having the brake system looked over by a KTM dealer.
Stopping and parking
Apply the brakes fully and put the engine into neutral. To turn off the engine, push the short-circuit button with the engine at idling speed until the engine stops. Turn the fuel tap to the OFF position, park on an area where the ground is firm.
Motorcycle engines produce a great amount of heat while running.
The engine, exhaust pipe, muffler, brake rotors, and shock absorbers can become very hot. Do not touch any of these parts after operating the motorcycle, and take care to park it where pedestrians are not likely to touch it and get burned.
– After falling with the motorcycle, check all functions thoroughly before starting up operations again.
– A twisted handlebar must always be replaced. Do not adjust the handlebar, it will lose stability.
– Close the fuel tap when leaving your vehicle.Otherwise the carburettor can flood and fuel will enter the engine.
– Never park your motorcycle in places where there are fire hazards due to dry grass or other easily flammable materials.
Fuel
The racing engine needs unleaded fuel with at least RON 95 (USA
= Premium RON 91).
– High rpm rates when the engine is cold have an adverse effect on the life of your engine. We recommend you run the engine in a moderate rpm range for a few miles giving it a chance to warm up. After that no further precautions in this respect need to be taken. The engine has reached its operating temperature as soon as the radiators become warm.
– Never have the throttle wide open when changing down to a lower gear. The engine will over-rev, damaging the valves. In addition, the rear wheel locks so that the motorcycle can easily get out of control.
– If any abnormal vibrations occur while driving, check that the engine fastening bolts are tight.
– In the event that, while riding on your motorcycle, you notice any unusual operation-related noise, stop immediately, turn the engine off, and contact an authorized KTM dealer.
Braking
Close throttle and apply the hand and foot brakes at the same time.
When driving on sandy, wet or slippery ground use mainly the rear wheel brake. Always brake with feeling, blocking wheels can cause you to skid or fall. Always finish braking before you enter a curve.
Also change down to lower gears depending on your speed.
When driving down hill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the engine.
In this way, you will not need to brake so much and the brakes will not overheat.
Use leaded or unleaded premium grade gasoline (95 octanes). Never use gasoline having less than 95 octanes because it may damage the engine.
Gasoline is highly flammable and poisonous. Extreme caution should be used when handling gasoline. Do not refuel the motorcycle near open flames or burning cigarettes. Always switch off the engine before refuelling. Be careful not to spill gasoline on the engine or exhaust pipe while the engine is hot. Wipe up spills promptly.
If gasoline is swallowed or splashed in the eyes, seek a doctor’s advice immediately.
Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).
35 mm
13
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Table of contents
- 3 IMPORTANT INFORMATION
- 6 SERIAL NUMBER LOCATIONS
- 6 Chassis number
- 6 Engine number, engine type
- 6 OPERATION INSTRUMENTS
- 6 Clutch lever
- 6 Hot start lever
- 7 Hand brake lever
- 7 Short circuit button
- 7 Starter button (450 SX-F)
- 7 Filler cap
- 7 Fuel tap
- 8 Choke
- 8 Shift lever
- 8 Kickstarter (250 SX-F)
- 8 Foot brake pedal
- 8 Plug in stand
- 9 Compression damping of fork
- 9 Rebound damping of fork
- 9 Compression damping of shock absorber
- 10 Rebound damping of shock absorber
- 11 MOTORCYCLE
- 11 Instructions for initial operation
- 11 Running in the Racing models
- 12 DRIVING INSTRUCTIONS
- 12 Check the following before each start
- 13 Starting when the engine is cold
- 13 Starting when the engine is warm
- 13 What to do when the engine is "flooded
- 14 Starting off
- 14 Shifting/Riding
- 14 Braking
- 14 Stopping and parking
- 15 PERIODIC MAINTENANCE
- 17 MAINTENANCE WORK ON CHASSIS AND ENGINE
- 17 Pivot bearing
- 18 Basic suspension setup for the weight of the driver
- 18 Checking the shock absorber and spring
- 18 Determining the static sag of the shock absorber
- 18 Determining the riding sag of the shock absorber
- 19 Checking the basic setup of the telescopic fork
- 19 Changing the spring preload on the telescopic fork
- 19 Replacing fork springs
- 19 Breather plug front fork
- 19 Cleaning the dust sleeves of the telescopic fork
- 20 Changing the fork offset (caster)
- 21 Checking and adjusting the steering head bearing
- 21 Checking the throttle cable installation
- 22 How to change the handlebar position
- 22 Check chain tension
- 23 Correct chain tension
- 23 sprocket teeth
- 24 Chain maintenance
- 24 Chain wear
- 25 General information about KTM disc brakes
- 26 Adjusting the free travel at the hand brake lever
- 26 Checking the brake fluid level - front brake
- 26 Refilling the front brake fluid reservoir
- 26 Checking the front brake pads
- 27 Replacing the front brake pads
- 27 Checking the rear brake fluid level
- 27 Refilling the rear brake fluid reservoir
- 28 Changing the basic position of the foot brake pedal
- 28 Checking the rear brake pads
- 28 Replacing the rear brake pads
- 29 Dismounting and mounting the front wheel
- 30 Dismounting and mounting the rear wheel
- 30 Checking spoke tension
- 31 Tires, air pressure
- 31 Battery (450 SX-F)
- 32 Charging the battery (450 SX-F)
- 32 Fuse (450 SX-F)
- 33 Cooling system
- 33 Checking the coolant level
- 33 Bleeding the cooling system
- 35 Cleaning the air filter
- 35 Adjusting the throttle cables
- 36 Changing the original position of the clutch lever
- 36 Checking the oil level of the hydraulic clutch
- 36 Bleeding of the hydraulic clutch
- 37 Carburetor - Adjust idling
- 37 Basic information on carburetor wear
- 37 Checking the float level (float height)
- 38 Draining the float chamber of the carburetor
- 38 Checking the engine oil level
- 39 Engine oil
- 39 Changing the engine oil
- 40 Changing the oil filter
- 41 TROUBLESHOOTING
- 43 CLEANING
- 43 STORAGE
- 44 TECHNICAL DATA - ENGINE
- 45 TECHNICAL DATA - CHASSIS
- 48 HEAD WORK INDEX