Name: KTM 525 XC ATV EU
Brand: KTM
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MAINTENANCE ON CHASSIS AND ENGINE 141

9.63Removing the front trim

– Remove the front cover. ( p. 140)

601063-10

– Remove screws .

– Raise the front trim and disconnect the plug-in connectors from the head light and the

emergency OFF switch with the rip cord.

– Remove the front trim.

Table of Contents5
Means of Representation9
Important Information10
View of Vehicle14
- View of the Vehicle from the Left Front (Example)14
- View of the Vehicle from the Right Rear (Example)16
Location of Serial Numbers18
- Chassis Number18
- Type Label18
- Key Number19
- Engine Number19
- Front Shock Absorber Part Number20
- Rear Shock Absorber Part Number20
Controls21
- Clutch Lever21
- Hand Brake Lever, Front Parking Brake22
- Steering Lock23
- Parking Brake Lever24
- Throttle Lever25
- Light Switch25
- Turn Signal Switch26
- Kill Switch26
- Horn Button27
- Ignition Switch27
- Electric Starter Button28
- Hazard Warning Flasher Switch/Hazard Warning Flasher28
- Indicator Lamp Overview29
- Emergency off Switch with Rip Cord29
- Speedometer30
- Speedometer Activation and Test30
- Tripmaster Switch31
- Setting Kilometers or Miles31
- Setting the Clock32
- Adjusting the Speedometer Functions33
- Querying the Lap Time34
- Display Mode SPEED (Speed)35
- Display Mode SPEED/H (Operating Hours)36
- Display Mode SPEED/CLK (Clock)37
- Display Mode SPEED/LAP (Lap Time)37
- Display Mode SPEED/ODO (Odometer)38
- Display Mode SPEED/TR1 (Trip Master 1)38
- Display Mode SPEED/TR2 (Trip Master 2)39
- Display Mode SPEED/A1 (Average Speed 1)40
- Display Mode SPEED/A2 (Average Speed 2)40
- Display Mode SPEED/S1 (Stop Watch 1)41
- Display Mode SPEED/S2 (Stop Watch 2)42
- Opening Filler Cap44
- Closing Filler Cap44
- Locking the Steering45
- Unlocking the Steering45
- Fuel Tap46
- Choke47
- Hot Start Button47
- Shift Lever48
- Foot Brake Lever49
General Tips and Hints on Putting into Operation50
- Advice on First Use50
- Running in the Engine52
Riding Instructions53
- Checks before Putting into Operation53
- Starting54
- Starting up56
- Shifting56
- Braking57
- Riding58
- Riding in Bends59
- Riding Downhill60
- Riding Uphill61
- Riding Perpendicular to the Slope62
- Turning on Slopes62
- Riding through Water64
- Switching off the Engine64
- Stopping, Parking66
- Refueling67
Service Schedule69
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop69
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop (as an Additional Order)71
- Important Checks and Maintenance Work to be Carried out by the Rider73
Maintenance on Chassis and Engine74
- Jacking up the Vehicle74
- Removing the Vehicle from the Work Stand74
- Basic Information on Changing the Chassis Settings74
- Front Shock Absorber - Adjusting the Compression Damping75
- Front Shock Absorber - Adjusting the Rebound Damping76
Front Shock Absorber - Adjusting the Cross over77
Front Shock Absorber - Adjusting the Spring Preload79
Rear Shock Absorber - Adjusting the Compression Damping81
Rear Shock Absorber - Adjusting the Rebound Damping82
Rear Shock Absorber - Adjusting the Spring Preload83
Removing the Rear Shock Absorber85
Installing the Rear Shock Absorber87
Checking the Toe87
Adjusting the Toe90
Checking/Adjusting the Camber92
Handlebar Position95
Adjusting the Handlebar Position96
Checking the Play in the Throttle Cable98
Adjusting Play in Throttle Cable99
Checking the Basic Setting of the Shift Lever99
Adjusting the Basic Position of the Shift Lever100
Checking Chain Dirt101
Cleaning the Chain101
Checking the Chain Tension102
Checking Rear Sprocket / Engine Sprocket for Wear103
Checking Chain Wear104
Adjusting Chain Tension105
Greasing the Rear Wheel Eccentric Element107
Checking Brake Discs107
Checking the Free Travel of the Hand Brake Lever108
Adjusting Basic Position of Hand Brake Lever109
Checking Front Brake Fluid Level109
Topping up the Front Brake Fluid110
Checking the Front Brake Linings112
Removing Front Brake Linings113
Mounting Front Brake Linings114
Changing the Front Brake Linings115
Checking Free Travel of Foot Brake Lever117
Adjusting Basic Position of Foot Brake Lever118
Checking Rear Brake Fluid Level119
Adding Rear Brake Fluid120
Checking Rear Brake Linings122
Removing Rear Brake Linings123
Mounting Rear Brake Linings124
Changing Rear Brake Linings126
Removing Wheel/Wheels127
Mounting Wheel/Wheels128
Checking the Tire Condition129
Checking the Tire Air Pressure130
Removing the Battery131
Installing the Battery132
Recharging the Battery132
Changing the Main Fuse134
Changing the Fuses of Individual Power Consumers135
Checking the Headlight Setting137
Adjusting the Headlight Range of the Headlight138
Removing the Seat138
Mounting the Seat139
Removing the Radiator Spoiler139
Installing the Radiator Spoiler140
Removing the Front Cover142
Installing the Front Cover142
Removing the Front Trim143
- Installing the Front Trim144
- Removing the Rear Fender144
- Installing the Rear Fender146
- Removing the Engine Guard148
- Installing the Engine Guard148
- Removing the Air Filter149
- Installing the Air Filter151
- Cleaning Air Filter152
- Adjusting Basic Position of Clutch Lever153
- Checking Fluid Level of Hydraulic Clutch153
- Cooling System154
- Radiator Fan154
- Checking the Antifreeze and Coolant Level155
- Checking the Coolant Level156
- Draining Coolant157
- Filling Coolant / Bleeding Cooling System159
- Carburetor - Idle161
- Carburetor - Adjusting Idle162
- Emptying the Carburetor Float Chamber164
- Checking the Engine Oil Level165
- Changing Engine Oil and Oil Filter, Cleaning Oil Screens166
- Draining Engine Oil, Cleaning Oil Screens166
- Removing the Oil Filter170
- Installing the Oil Filter172
- Filling up with Engine Oil172
- Adding Engine Oil173
Troubleshooting175
Cleaning180
- Cleaning the Vehicle180
Storage182
- Putting the Vehicle into Operation after Storage183
Technical Data - Engine184
- Capacity - Engine Oil185
- Capacity - Coolant185
Technical Data - Engine Tightening Torques186
Technical Data - Carburetor189
Technical Data - Chassis190
- Lighting Equipment192
- Tires192
- Capacity - Fuel193
Technical Data - Front Shock Absorber194
Technical Data - Rear Shock Absorber195
Technical Data - Tightening Torques for Chassis196
Substances198
Auxiliary Substances202
Standards205
Index206

Brand	KTM
Model	525 XC ATV EU
Category	Offroad Vehicle
Language	English

KTM 525 XC ATV EU User Manual

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