Name: KTM 525 XC
Brand: KTM
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OWNER'S MANUAL 2009

450 XC ATV

525 XC ATV

ART. NO. 3211377en

Table of Contents5
Means of Representation9
Important Notes10
- Overview of Labels14
View of Vehicle24
- View of the Vehicle from the Left Front (Symbol Display)24
- View of the Vehicle from the Right Rear (Symbol Display)26
Location of Serial Numbers28
- Chassis Number28
- Type Label28
- Key Number29
- Engine Number29
- Setting Number, Front Shock Absorber30
- Setting Number, Rear Shock Absorber30
Operating Elements31
- Clutch Lever31
- Reverse Gear Release Lever31
- Handbrake Lever, Parking Brake32
- Throttle Lever33
- Light Switch33
- Light Switch34
- ENG. STOP Switch34
- ENG. STOP Switch35
- Electric Starter Button35
- Electric Starter Button36
- Ignition Switch36
- Indicator Lamp Overview37
- Emergency off Switch with Rip Cord37
- Opening Filler Cap38
- Closing Filler Cap38
- Fuel Tap39
- Choke40
- Hot Start Button40
- Shift Lever41
- Foot Brake Pedal42
Tips on Putting into Operation43
- Advice on First Use43
- Running in the Engine46
Riding Instructions47
- Checks before Putting into Operation47
- Starting48
- Starting up50
- Shifting50
- Shifting to Reverse Gear51
- Disengaging Reverse Gear51
- Braking52
- Riding53
- Riding in Bends54
- Riding Downhill55
- Riding Uphill56
- Riding Perpendicular to the Slope57
- Turning on Slopes57
- Riding through Water59
- Switching off the Engine59
- Stopping, Parking60
- Refueling62
Service Schedule63
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop63
- Important Maintenance Work to be Carried out by an Authorized KTM Workshop. (as Additional Order)65
- Important Checks and Maintenance Work to be Carried out by the Rider67
Maintenance on Chassis and Engine68
- Jacking up the Vehicle68
- Removing the Vehicle from the Work Stand68
- Basic Information on Changing the Chassis Settings68
- Front Shock Absorber - Adjusting the Compression Damping69
- Front Shock Absorber - Adjusting the Rebound Damping70
- Front Shock Absorber - Adjusting the Cross over72
- Front Shock Absorber - Adjusting the Spring Preload73
- Rear Shock Absorber - Adjusting the Compression Damping75
- Rear Shock Absorber - Adjusting the Rebound Damping77
- Rear Shock Absorber - Adjusting the Spring Preload78
- Removing the Rear Shock Absorber80
- Installing the Rear Shock Absorber82
- Checking the Toe82
- Adjusting the Toe85
- Checking/Adjusting Camber87
- Fork Offset89
- Adjusting the Fork Offset90
- Toe Width of Rear Axle90
- Adjusting the Toe Width of Rear Axle91
- Handlebar Position93
- Adjusting Handlebar Position94
- Checking Play in Gas Bowden Cable96
- Adjusting Play in Gas Bowden Cable97
Checking the Play in the Bowden Cable Using the Reverse98
Gear Release Lever98
Adjusting the Play in the Bowden Cable Using the Reverse Gear Release Lever98
Checking Chain Dirt99
Cleaning the Chain99
Checking the Chain Tension100
Checking Rear Sprocket / Engine Sprocket for Wear101
Checking Chain Wear101
Adjusting Chain Tension103
Greasing the Rear Wheel Eccentric Element105
Checking Brake Discs105
Checking the Free Play of the Hand Brake Lever106
Adjusting Basic Position of Handbrake Lever107
Checking Front Brake Fluid Level108
Topping up the Front Brake Fluid108
Checking the Front Brake Linings110
Removing Front Brake Linings111
Mounting Front Brake Linings112
Changing the Front Brake Linings113
Checking Free Play of Foot Brake Lever115
Adjusting Basic Position of Footbrake Lever116
Checking Rear Brake Fluid Level117
Topping up Brake Fluid of Front Brake118
Checking Rear Brake Linings120
Removing Rear Brake Linings121
Mounting the Rear Brake Linings122
Changing Rear Brake Linings124
Removing Wheel/Wheels125
Mounting Wheel/Wheels126
Tire Condition Checking127
Checking Tire Air Pressure128
Removing the Battery128
Installing the Battery129
Recharging the Battery130
Changing Main Fuse132
Changing the Fuses of Individual Power-Consuming Components133
Ignition Curve Plug Connection135
Changing Ignition Curve135
Removing the Seat136
Mounting the Seat136
Removing the Radiator Spoiler137
Installing the Radiator Spoiler138
Removing the Front Cover139
Installing the Front Cover140
Removing the Front Trim140
Installing the Front Trim142
Removing the Rear Fender142
Installing the Rear Fender144
Removing the Engine Guard146
Installing the Engine Guard146
Removing the Air Filter147
Installing the Air Filter149
Cleaning Air Filter149
Adjusting Basic Position of Clutch Lever150
Checking Fluid Level of Hydraulic Clutch151
Cooling System152
- Radiator Fan152
- Checking Antifreeze and Coolant Level153
- Checking the Coolant Level154
- Draining Coolant155
- Filling Coolant / Bleeding Cooling System158
- Carburetor - Idle160
- Carburetor - Adjusting Idle161
- Emptying the Carburetor Float Chamber163
- Checking Engine Oil Level164
- Changing Engine Oil and Oil Filter, Cleaning Oil Screens165
- Draining Engine Oil, Cleaning Oil Screens165
- Removing the Oil Filter168
- Mounting the Oil Filter170
- Filling up with Engine Oil170
- Topping up Engine Oil171
Troubleshooting173
Cleaning179
- Cleaning the Vehicle179
Storage181
- Putting the Vehicle into Operation after Storage182
Technical Data - Engine183
- Capacity - Engine Oil184
- Capacity - Coolant184
Technical Data - Engine Tightening Torques185
Technical Data - Carburetor188
Technical Data - Chassis189
- Lighting Equipment191
- Tires191
- Capacity - Fuel191
Technical Data - Front Shock Absorber192
Technical Data - Rear Shock Absorber193
Technical Data - Chassis Tightening Torques194
Substances196
Auxiliary Substances199
Standards202
Index203

Brand	KTM
Model	525 XC
Category	Offroad Vehicle
Language	English

KTM 525 XC User Manual

Table of Contents

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KTM 525 XC Specifications

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