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525 XC ATV EU
KTM 525 XC ATV EU User Manual
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MAINTENA
NCE
ON
CHASSIS
AND
ENGINE
142
9.64
Installing
the
front
trim
601064-10
–
Connect
the
plug-in
connectors
of
the
head
light
and
the
emergency
OFF
switch
with
the
rip
cord
and
position
the
front
trim.
–
Mount
all
screws.
–
Fully
tighten
screws
.
Guideline
Screw
on
fuel
tank
M6
6
Nm
(4.4
lbf
ft)
–
Fully
tighten
screws
.
Guideline
Remaining
screws,
chassis
M6
10
Nm
(7.4
lbf
ft)
–
Install
the
front
cover.
(
p.
140)
9.65
Removing
the
rear
fender
–
Remove
the
seat
(
p.
136)
143
145
Table of Contents
Table of Contents
5
Means of Representation
9
Important Information
10
View of Vehicle
14
View of the Vehicle from the Left Front (Example)
14
View of the Vehicle from the Right Rear (Example)
16
Location of Serial Numbers
18
Chassis Number
18
Type Label
18
Key Number
19
Engine Number
19
Front Shock Absorber Part Number
20
Rear Shock Absorber Part Number
20
Controls
21
Clutch Lever
21
Hand Brake Lever, Front Parking Brake
22
Steering Lock
23
Parking Brake Lever
24
Throttle Lever
25
Light Switch
25
Turn Signal Switch
26
Kill Switch
26
Horn Button
27
Ignition Switch
27
Electric Starter Button
28
Hazard Warning Flasher Switch/Hazard Warning Flasher
28
Indicator Lamp Overview
29
Emergency off Switch with Rip Cord
29
Speedometer
30
Speedometer Activation and Test
30
Tripmaster Switch
31
Setting Kilometers or Miles
31
Setting the Clock
32
Adjusting the Speedometer Functions
33
Querying the Lap Time
34
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 Cap
44
Closing Filler Cap
44
Locking the Steering
45
Unlocking the Steering
45
Fuel Tap
46
Choke
47
Hot Start Button
47
Shift Lever
48
Foot Brake Lever
49
General Tips and Hints on Putting into Operation
50
Advice on First Use
50
Running in the Engine
52
Riding Instructions
53
Checks before Putting into Operation
53
Starting
54
Starting up
56
Shifting
56
Braking
57
Riding
58
Riding in Bends
59
Riding Downhill
60
Riding Uphill
61
Riding Perpendicular to the Slope
62
Turning on Slopes
62
Riding through Water
64
Switching off the Engine
64
Stopping, Parking
66
Refueling
67
Service Schedule
69
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
69
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 Rider
73
Maintenance on Chassis and Engine
74
Jacking up the Vehicle
74
Removing the Vehicle from the Work Stand
74
Basic Information on Changing the Chassis Settings
74
Front Shock Absorber - Adjusting the Compression Damping
75
Front Shock Absorber - Adjusting the Rebound Damping
76
Front Shock Absorber - Adjusting the Cross over
77
Front Shock Absorber - Adjusting the Spring Preload
79
Rear Shock Absorber - Adjusting the Compression Damping
81
Rear Shock Absorber - Adjusting the Rebound Damping
82
Rear Shock Absorber - Adjusting the Spring Preload
83
Removing the Rear Shock Absorber
85
Installing the Rear Shock Absorber
87
Checking the Toe
87
Adjusting the Toe
90
Checking/Adjusting the Camber
92
Handlebar Position
95
Adjusting the Handlebar Position
96
Checking the Play in the Throttle Cable
98
Adjusting Play in Throttle Cable
99
Checking the Basic Setting of the Shift Lever
99
Adjusting the Basic Position of the Shift Lever
100
Checking Chain Dirt
101
Cleaning the Chain
101
Checking the Chain Tension
102
Checking Rear Sprocket / Engine Sprocket for Wear
103
Checking Chain Wear
104
Adjusting Chain Tension
105
Greasing the Rear Wheel Eccentric Element
107
Checking Brake Discs
107
Checking the Free Travel of the Hand Brake Lever
108
Adjusting Basic Position of Hand Brake Lever
109
Checking Front Brake Fluid Level
109
Topping up the Front Brake Fluid
110
Checking the Front Brake Linings
112
Removing Front Brake Linings
113
Mounting Front Brake Linings
114
Changing the Front Brake Linings
115
Checking Free Travel of Foot Brake Lever
117
Adjusting Basic Position of Foot Brake Lever
118
Checking Rear Brake Fluid Level
119
Adding Rear Brake Fluid
120
Checking Rear Brake Linings
122
Removing Rear Brake Linings
123
Mounting Rear Brake Linings
124
Changing Rear Brake Linings
126
Removing Wheel/Wheels
127
Mounting Wheel/Wheels
128
Checking the Tire Condition
129
Checking the Tire Air Pressure
130
Removing the Battery
131
Installing the Battery
132
Recharging the Battery
132
Changing the Main Fuse
134
Changing the Fuses of Individual Power Consumers
135
Checking the Headlight Setting
137
Adjusting the Headlight Range of the Headlight
138
Removing the Seat
138
Mounting the Seat
139
Removing the Radiator Spoiler
139
Installing the Radiator Spoiler
140
Removing the Front Cover
142
Installing the Front Cover
142
Removing the Front Trim
143
Installing the Front Trim
144
Removing the Rear Fender
144
Installing the Rear Fender
146
Removing the Engine Guard
148
Installing the Engine Guard
148
Removing the Air Filter
149
Installing the Air Filter
151
Cleaning Air Filter
152
Adjusting Basic Position of Clutch Lever
153
Checking Fluid Level of Hydraulic Clutch
153
Cooling System
154
Radiator Fan
154
Checking the Antifreeze and Coolant Level
155
Checking the Coolant Level
156
Draining Coolant
157
Filling Coolant / Bleeding Cooling System
159
Carburetor - Idle
161
Carburetor - Adjusting Idle
162
Emptying the Carburetor Float Chamber
164
Checking the Engine Oil Level
165
Changing Engine Oil and Oil Filter, Cleaning Oil Screens
166
Draining Engine Oil, Cleaning Oil Screens
166
Removing the Oil Filter
170
Installing the Oil Filter
172
Filling up with Engine Oil
172
Adding Engine Oil
173
Troubleshooting
175
Cleaning
180
Cleaning the Vehicle
180
Storage
182
Putting the Vehicle into Operation after Storage
183
Technical Data - Engine
184
Capacity - Engine Oil
185
Capacity - Coolant
185
Technical Data - Engine Tightening Torques
186
Technical Data - Carburetor
189
Technical Data - Chassis
190
Lighting Equipment
192
Tires
192
Capacity - Fuel
193
Technical Data - Front Shock Absorber
194
Technical Data - Rear Shock Absorber
195
Technical Data - Tightening Torques for Chassis
196
Substances
198
Auxiliary Substances
202
Standards
205
Index
206
Other manuals for KTM 525 XC ATV EU
Setup Instructions
15 pages
4
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KTM 525 XC ATV EU Specifications
General
Brand
KTM
Model
525 XC ATV EU
Category
Offroad Vehicle
Language
English
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