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KTM
Offroad Vehicle
525 XC
KTM 525 XC User Manual
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OPERATIN
G
ELEMENTS
36
5.14
Opening
filler
cap
100012-10
–
Press
release
button
,
turn
filler
ca
p
counterclockwise
and
lift
it
free.
5.15
Closing
filler
cap
100012-11
–
Replace
the
filler
cap
and
turn
clockw
ise
until
the
release
button
locks
in
pla
ce.
–
Check
the
fuel
tank
breather
to
ensu
re
it
is
properly
seated.
»
If
the
fuel
tank
breather
is
at
an
angle
or
loose:
–
Correctly
mount
the
fuel
tank
brea
ther.
37
39
Table of Contents
Table of Contents
5
Means of Representation
9
Important Notes
10
Overview of Labels
14
View of Vehicle
24
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 Numbers
28
Chassis Number
28
Type Label
28
Key Number
29
Engine Number
29
Setting Number, Front Shock Absorber
30
Setting Number, Rear Shock Absorber
30
Operating Elements
31
Clutch Lever
31
Reverse Gear Release Lever
31
Handbrake Lever, Parking Brake
32
Throttle Lever
33
Light Switch
33
Light Switch
34
ENG. STOP Switch
34
ENG. STOP Switch
35
Electric Starter Button
35
Electric Starter Button
36
Ignition Switch
36
Indicator Lamp Overview
37
Emergency off Switch with Rip Cord
37
Opening Filler Cap
38
Closing Filler Cap
38
Fuel Tap
39
Choke
40
Hot Start Button
40
Shift Lever
41
Foot Brake Pedal
42
Tips on Putting into Operation
43
Advice on First Use
43
Running in the Engine
46
Riding Instructions
47
Checks before Putting into Operation
47
Starting
48
Starting up
50
Shifting
50
Shifting to Reverse Gear
51
Disengaging Reverse Gear
51
Braking
52
Riding
53
Riding in Bends
54
Riding Downhill
55
Riding Uphill
56
Riding Perpendicular to the Slope
57
Turning on Slopes
57
Riding through Water
59
Switching off the Engine
59
Stopping, Parking
60
Refueling
62
Service Schedule
63
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
63
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 Rider
67
Maintenance on Chassis and Engine
68
Jacking up the Vehicle
68
Removing the Vehicle from the Work Stand
68
Basic Information on Changing the Chassis Settings
68
Front Shock Absorber - Adjusting the Compression Damping
69
Front Shock Absorber - Adjusting the Rebound Damping
70
Front Shock Absorber - Adjusting the Cross over
72
Front Shock Absorber - Adjusting the Spring Preload
73
Rear Shock Absorber - Adjusting the Compression Damping
75
Rear Shock Absorber - Adjusting the Rebound Damping
77
Rear Shock Absorber - Adjusting the Spring Preload
78
Removing the Rear Shock Absorber
80
Installing the Rear Shock Absorber
82
Checking the Toe
82
Adjusting the Toe
85
Checking/Adjusting Camber
87
Fork Offset
89
Adjusting the Fork Offset
90
Toe Width of Rear Axle
90
Adjusting the Toe Width of Rear Axle
91
Handlebar Position
93
Adjusting Handlebar Position
94
Checking Play in Gas Bowden Cable
96
Adjusting Play in Gas Bowden Cable
97
Checking the Play in the Bowden Cable Using the Reverse
98
Gear Release Lever
98
Adjusting the Play in the Bowden Cable Using the Reverse Gear Release Lever
98
Checking Chain Dirt
99
Cleaning the Chain
99
Checking the Chain Tension
100
Checking Rear Sprocket / Engine Sprocket for Wear
101
Checking Chain Wear
101
Adjusting Chain Tension
103
Greasing the Rear Wheel Eccentric Element
105
Checking Brake Discs
105
Checking the Free Play of the Hand Brake Lever
106
Adjusting Basic Position of Handbrake Lever
107
Checking Front Brake Fluid Level
108
Topping up the Front Brake Fluid
108
Checking the Front Brake Linings
110
Removing Front Brake Linings
111
Mounting Front Brake Linings
112
Changing the Front Brake Linings
113
Checking Free Play of Foot Brake Lever
115
Adjusting Basic Position of Footbrake Lever
116
Checking Rear Brake Fluid Level
117
Topping up Brake Fluid of Front Brake
118
Checking Rear Brake Linings
120
Removing Rear Brake Linings
121
Mounting the Rear Brake Linings
122
Changing Rear Brake Linings
124
Removing Wheel/Wheels
125
Mounting Wheel/Wheels
126
Tire Condition Checking
127
Checking Tire Air Pressure
128
Removing the Battery
128
Installing the Battery
129
Recharging the Battery
130
Changing Main Fuse
132
Changing the Fuses of Individual Power-Consuming Components
133
Ignition Curve Plug Connection
135
Changing Ignition Curve
135
Removing the Seat
136
Mounting the Seat
136
Removing the Radiator Spoiler
137
Installing the Radiator Spoiler
138
Removing the Front Cover
139
Installing the Front Cover
140
Removing the Front Trim
140
Installing the Front Trim
142
Removing the Rear Fender
142
Installing the Rear Fender
144
Removing the Engine Guard
146
Installing the Engine Guard
146
Removing the Air Filter
147
Installing the Air Filter
149
Cleaning Air Filter
149
Adjusting Basic Position of Clutch Lever
150
Checking Fluid Level of Hydraulic Clutch
151
Cooling System
152
Radiator Fan
152
Checking Antifreeze and Coolant Level
153
Checking the Coolant Level
154
Draining Coolant
155
Filling Coolant / Bleeding Cooling System
158
Carburetor - Idle
160
Carburetor - Adjusting Idle
161
Emptying the Carburetor Float Chamber
163
Checking Engine Oil Level
164
Changing Engine Oil and Oil Filter, Cleaning Oil Screens
165
Draining Engine Oil, Cleaning Oil Screens
165
Removing the Oil Filter
168
Mounting the Oil Filter
170
Filling up with Engine Oil
170
Topping up Engine Oil
171
Troubleshooting
173
Cleaning
179
Cleaning the Vehicle
179
Storage
181
Putting the Vehicle into Operation after Storage
182
Technical Data - Engine
183
Capacity - Engine Oil
184
Capacity - Coolant
184
Technical Data - Engine Tightening Torques
185
Technical Data - Carburetor
188
Technical Data - Chassis
189
Lighting Equipment
191
Tires
191
Capacity - Fuel
191
Technical Data - Front Shock Absorber
192
Technical Data - Rear Shock Absorber
193
Technical Data - Chassis Tightening Torques
194
Substances
196
Auxiliary Substances
199
Standards
202
Index
203
4
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KTM 525 XC Specifications
General
Brand
KTM
Model
525 XC
Category
Offroad Vehicle
Language
English
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