what is compression adjustment on a ktm

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2005-2007 KTM MOTORCYCLE REPAIR MANUAL

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Filed Under (KTM) by admin on 21-11-2010

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 2 2-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B 2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork Dismounting the fork -Place your motorcycle on a stand. -Notice the position of the front fork in the triple-clamps. NOTE: To remove the front fork. Read your KTM Instruction Manual or Workshop Manual. 3-3 Mounting the fork -Clean the innerside of the triple-clamps with brake cleaner. -Slide both fork legs into the triple-clamps. NOTE: Pay attention to the position of the fork legs. Standard riding height! NOTE: The maximum riding height is the level of the second groove! -Tighten the middle bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the first bolt of the lower triple clamp to a torque of 17 Nm! -Tighten the third bolt of the lower triple clamp to a torque of 17 Nm!

KTM WP FORK 4860 MXMA CLOSED CARTRIDGE REPAIR MANUAL

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Filed Under (KTM) by admin on 13-02-2011

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Adjustments -Take notice of the position of the compression adjustment 1 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -Remove the rubber cap out of the axleclamp. -Take notice of the position of the rebound adjustment 2 ! -Count the amount of clicks by turning the adjustment screw clockwise till fully closed. -For the standard position see setting list. Position of the compression and rebound adjustment -Set the rebound position 1 , see KTM-Owners manual. -Assemble the rubber cap. -Set the compression position 2 , see KTM-Owners manual. 1 22-22 Repair manual WP Fork “Closed Cartridge” Art.No.: 3.211.199-E Explanation of the spring preload -Total spring length without the spacers, see chapter inspection of the spring! -Spring length with spacers 1 , see setting list. -Spring with the spacers. 1 . -The spring is assembled in the front fork leg. NOTE: the distance of “B” is less then the length of “A”. A – B = Spring preload A 1 1 B2-23 Air release screw -Place the motorcycle on the stand. NOTE: the front wheel must be lift of the floor! -Unscrew the air release screw 1 of the screw cap on top of the front fork and tighten after approx. 10 seconds the air release screw. Recommended periodic maintenance and inspection of the 4860 SX/SXS/SMR front fork 1 A 100 liter fuel consumption is equivalent to approx. 15 operating hours Clean dust scrapers (after 1 hour) Bleed fork legs regularly – after every cleaning Check the inner tubes on scratches / leakage Visual check of damaging of the outer-tubes / replace if necessary Complete service without disass. the closed cartridge of the fork Complete service including the closed cartridge of the front fork

KTM 125/ 200/ 250/ 300 SX, MXC, EXC SERVICE MANUAL

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Filed Under (KTM) by admin on 28-11-2010

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Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping. STANDARD ADJUSTMENT: -Turn the adjusting screw clockwise to the stop. -Then turn the adjusting screw counterclockwise, counting the number of clicks that corresponds to the respective type of shock absorber. Type White Power 1218X757…………..17 clicks Type White Power 1218X759…………..17 clicks * WARNING * THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH – COMPRESSION NITROGEN . NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN – ANCE WORK YOURSELF . SEVERE INJURIES COULD BE THE RESULT . NEVER UNSCREW THE BLACK SCREW 2 CONNECTION (24 MM ). Rebound damping of shock absorber (SX, MXC, EXC) By using the adjusting screw 3 , the degree of damping of the rebound can be adjusted. Turn the knob to the right side to increase damping, turn it to the left side to reduce damping during rebounding. STANDARD ADJUSTMENT: -Turn the adjusting screw clockwise to the stop. -Then turn the adjusting screw counterclockwise, counting the number of clicks that corresponds to the respective type of shock absorber. Type White Power 1218X756…………..28 clicks Type White Power 1218X757…………..28 clicks Type White Power 1218X759…………..26 clicks * WARNING * THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH – COMPRESSION NITROGEN . N EVERTRYTOTAKETHESHOCKABSORBERAPARTORTODOANYMAINTE – NANCE WORK YOURSELF . SEVERE INJURIES COULD BE THE RESULT . NEVER UNSCREW THE BLACK SCREW 4 CONNECTION (15 MM )

HARLEY DAVIDSON PREMIUM SUSPENSION KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 09-03-2011

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REMOVAL Front Fork Assembly 1. Refer to the XR model section of the service manual and remove the front forks. INSTALLATION Front Fork Assembly 1. Install front forks from kit to motorcycle according to service manual instructions but do not tighten the fork bracket pinch screws at this time. 2. See Figure 1. Measure the distance from the top of upper fork bracket to top of fork assembly. Both sides must be exactly the same and measure 0.388-0.468 inch (9.85- 11.89 mm) above the top fork bracket. Align the adjustment screws inline with the handlebars (see Figure 5). is06083a Figure 1. Fork Installation Height Measurement. NOTE If new pinch screws are not readily available, use a wire grinder wheel to remove all remaining lock patch from original pinch screws, wash screws in clean solvent and dry thoroughly. Apply two drops of LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads. 3. Install pinch screws to upper and lower fork brackets. 4. Verify fork tube installation measurement is 0.388-0.468 inch (9.85-11.89 mm). 5. Tighten pinch screws to 30-35 ft-lbs ( (40.7-47.5 Nm)) See Figure 2. The top edge of reflector should be 1-1/2 inches (38.10 mm) below the lower edge of the bottom fork clamp. 6. Remove the adhesive backing. Place reflector in position and press reflector firmly into place to activate the adhesive. Repeat for reflector on opposite fork. REMOVAL OEM Rear Shock Absorbers 1. Refer to the XR model section of the service manual and remove the rear shock absorbers. INSTALLATION Rear Shock Absorbers 1. See Figure 3. Install the rear shock absorbers according to service manual instructions. The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts. is06142 Figure 3. Install Thick Side Of Grommet To Frame Rail SUSPENSION ADJUSTMENTS Front Fork Suspension Adjustment Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a) Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. (00124c) Compression and rebound adjusting valves may be damaged if too much force is used at either end of the adjustment range. (00237a) NOTES Damping is set at the factory for the average solo rider under normal riding conditions. The rider may make adjustments to compensate for individual riding styles and varying road conditions. Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully. The front and rear preload setting will need to be adjusted for the rider’s weight and cargo. This adjustment should be made before the motorcycle is ridden any distance and after changing the overall vehicle weight (adding saddlebags, etc.). If the preload adjustment is correct, and you have the rebound and compression damping set at the factory recommended points, the motorcycle should handle and ride properly. Changes in the load carried requires changes in the preload setting(s). Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload. The following tools are needed to make suspension adjust- ments. • 5 mm hex key (front fork preload adjustment tool). • Spanner wrench with extension handle (shock absorber preload adjustment). • Screw driver (front fork damping adjustment). 1. Front fork preload adjustment: a. See Figure 4 and Table 1. Using the 5 mm hex key, turn the preload adjuster counterclockwise until it stops. This is the minimum preload setting. b. Turn the preload adjuster clockwise the recommended amount specified for the rider weight

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KTM KINETO TRACKING MOUNT – MODEL K433 Installation and Removal Manual

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Filed Under (KTM) by admin on 30-01-2012

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the KTM meets the needs of a wide variety of test range and scientific applications:  On-board operator, or remote analog or digital control  Payloads up to 1200 pounds (unmanned) or 600 pounds (manned)  Mission configuration with four (manned) or six (unmanned) payload positions  Complete turnkey systems available  Detailed installation documentation FIELD-PROVEN RUGGED AND RELIABLE The KTM consistently demonstrates its performance and durability:  Weather tight seals designed to withstand harsh range environments  The KTM’s direct drive axis design delivers smooth, jitterfree tracking to ensure precise Time, Space and Position Information (TSPI)  Self-contained and trailer-mounted, the KTM is quickly and easily deployed via highway and unimproved roads to remote tracking sites  Digital Control System (DCS) that guarentees system reliability WHEN THE RANGES REQUIRED PRECISE AND RELIABLE OPTICAL TRACKING MOUNTS, THEY SELECTED THE BRASHEAR KINETO TRACKING MOUNT MORE THAN 150 TIMES. Recognized Standard for Tracking Systems Worldwide THE KTM DIGITAL CONTROL SYSTEM (DCS) INCLUDES:  High speed communication via an Ethernet interface to provide remote operation  Advanced servo loop control to optimize tracking performance  Built-in error correction to ensure precision tracking accuracy  Versatile chassis architecture that accommodates additional PC104 cards suchas an “Automatic Video Tracker” (AVT) to satisfy specific customer requirements and missions

2008 KTM 125 SX, 144 SX, 250 SX OWNER'S MANUAL

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Filed Under (KTM) by admin on 25-11-2010

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Short circuit button (SX) The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: Press the release button [2] and turn the tank cap in a counterclockwise direction. To close it: Put the tank cap back on and turn in a clockwise direction until the release button snaps into place. Install tank breather hose [3] without kinks. Fuel tap OFF In this position the fuel tap is closed. No fuel can flow to the carburetor. ON During operation the twist grip must be turned to ON. This means that the fuel can flow to the carburetor. Choke knob When pulling the choke knob [4] fully towards the top, a bore is opened in the carburetor. Through this bore the engine can take in additional fuel. This results in a rich fuel-air mixture, that is needed for a cold start. When pressing the choke knob downward in the carburetor, the bore is closed again. ON OFF 4 1 2 3 ENGLISH 7 Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. OPERATION INSTRUMENTS » Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot brake pedal The foot brake pedal is disposed in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work). 1 N 2,3,4,5, (6) 2 3 1 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. Turn the screw [1] clockwise to increase damping, turn it counterclockwise to reduce damping during compression. STANDARD ADJUSTMENT: -turn adjusting screw clockwise as far as it will go -turn it back by as many clicks as are specified for the relevant type of fork Typ WP Suspension 14187D01 . . . . .14 clicks Typ WP Suspension 14187D03 . . . . .14 clicks

KTM 60 SX / 65 SX REPAIR MANUAL ENGINE

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Filed Under (KTM) by admin on 12-11-2010

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Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures  choose leaner carburetor adjustment low altitude or low temperatures  choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer

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Harley-Davidson Evolution Engines, Hydraulic Lifter Limited Travel Kit Installation Manual

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Filed Under (Harley Davidson) by admin on 23-10-2010

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Remove tappet assemblies from engine being sure that each one is kept with it’soriginal tappet block. NOTE: This procedure is the preferred method of installation. However, kit can be installed without removing lifters from engine. 2. Remove hydraulic piston retaining wire clip from one assembly at a time. Be careful not to bend wire clip during disassembly. 3. Completely disassemble tappet removing all parts. 4. Thoroughly clean all parts including tappet body. Remove any oil which might prevent hydraulic unit from fully collapsing during adjustment. 5. Insert one spacer from S&S HL 2 Tkit in tappet body. 6. Reassemble tappet in reverse order making sure original parts arereturned to their original positions. See Picture1. 7. Replace wire retaining clip in tappet body. 8. Put tappet back in original tappet block. 9. Repeat Steps 2 through 8 for three remaining tappets. 10. Reassemble engine with modified tappets. 11. Adjust pushrods. NOTE – In all cases engine must be cold and lifter must be at lowest point of travel for pushrod adjustment To prevent accidents, remove ground cable from battery. A. Remove spark plugs. B. Bring piston to TDC on compression stroke in cylinder to be adjusted. Normally both tappets will be at their lowest point of travel. C. Extend pushrod adjustment, collapsing lifter until piston assembly is in contact with HL 2 Tspacer and pushrod is tight. If tappets contain oil, as when pushrods are readjusted after engine has been run, or if all oil was not removed during installation, extend pushrod adjustment until valve is open (about five additional turns of adjusting screw). Allow 5 minutes for hydraulic unit to bleed down. If pushrod can be turned with fingers after bleeding down, lifter is not completely collapsed, and this step must be repeated. NOTE – perform this operation on one cylinder at a time. Do not turn engine until pushrod adjustment is complete. Turning engine while valve is held off the seat could result in valve to valve or valve to piston contact and serious valve train damage. D. Loosen pushrod adjustment until pushrod can be rotated with the fingers with slight drag. NOTE – Shortening adjuster an additional six flats or full turn from zero lash often results in quieter pushrod operation. This provides additional travel for the hydraulic piston assembly, which can improve the ability of the hydraulic unit to maintain zerolash under normal operating conditions. E. Tighten lock nut. F. Follow the same procedure for all four push rods. G. Recheck pushrod adjustment after a few hundred miles. NOTES ● It is a good idea to recheck pushrod adjustment in a new engine as valve train may tighten up due to gasket compression and valve seat wear. ● Upon initial start up after modification, HL 2 Tequipped lifters may be somewhat noisy for 10-20 miles. If lifters are still noisy after 20 miles it is recommended that pushrods be adjusted 1⁄2 turnlooser. See step D

KTM EXC Enduro & SX Motocross REPAIR MANUAL

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Filed Under (KTM) by admin on 06-03-2012

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Thanks to a history of competition successes, particularly in off-road racing, KTM motorcycles enjoy a large and loyal following. Established in 1953, KTM (from Kraftfahrzeuge Trunkenpolz Mattighofen where founder, Hans Trunkenpolz, had his engineering works) went through difficult times in the early 1990s. After a takeover, the Austrian company emerged as KTM Sportmotorcycle AG and has gone from strength to strength in recent years. Mainstay of their range are their Enduro and Motocross models, the EXC and SX, and these are covered in the latest new manual from Haynes. Models covered are the 250, 400, 450, 520 and 525 EXC and SX with 4-stroke sohc engines, 2000 to 2007. Information has also been included on the SMR Supermoto versions and MXC/XC derivatives. Haynes Manuals for cars and motorcycles are so popular that 150 million have been sold worldwide. Lay them end-to-end and they would circle the globe at the equator! The new manual begins with essential pre-ride checks, competition prep and routine maintenance tasks before moving on to more major repairs. There are comprehensive, fully illustrated, instructions for overhauling the engine, transmission, brakes, suspension and electrical system. Useful reference pages include colour wiring diagrams, fault-finding charts and a comprehensive section on tools and workshop tips. Because all Haynes Manuals are based on a complete stripdown and rebuild, not only are the procedures written from first-hand experience, but there is information about special tools required for each job, and its complexity, plus Haynes tips for saving time and money. The new Haynes KTM EXC Enduro & SX Motocross Manual is the only complete manual for owners of these motorcycles.

KTM ATV 525 XC specification

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Filed Under (KTM) by admin on 12-11-2010

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Engine ] Pure power for Enduro enthusiasts. The power of the 525 XC is the indisputable benchmark in the ATV Enduro sector. Its acceleration and top speed cast a shadow over all its predecessors. Variable ignition curves and perfect maintenance features like simple valve play adjustment and the removable clutch cover are even further highlights of the XC engine that make the KTM Enduro quads so superior. First Oil Filling for all KTM Engines. [ CarburEttor ] The Keihin carburettor, which has been proven multiple times in racing, with 39 mm and the Throttle Positioning System guarantees a uniform, forceful power delivery in all speed ranges. It ensures an unrivalled response behavior and perfect service-friendliness at all times. [ StartEr ] Packed in a space-saving manner into the free space behind the cylinder head, the small, light electric starter motor is ready for use. It brings every KTM ATV up to speed reliably and comfortably even when racing becomes hectic. [ rEar SuSPENSIoN ] Premium-quality ÖHLINS suspension components specially designed for tough Enduro use are provided as standard – both at the front and the rear. Easy to adjust, they guarantee optimal tuning for the most varied of terrains. Another highlight: the front and rear spring travel of 275 mm and 272 mm respectively is 100 % trend-setting for an Enduro ATV! [ alumINIum SubFramE ] The rear subframe is made of aluminium and is extremely light and easy to remove. [ FramE ] The lightweight, extremely durable frame sets the benchmark in the quad racing segment and is made of high-strength, powder-coated Chromoly steel. [ haNDlEbar ] An ultra-durable tapered aluminium Magura® handlebar comes standard that is four-position adjustable to suit your preferred ergonomics. Further highlights are the functional and individually adjustable operating levers for brake and hydraulic clutch. In addition, the chassis has an integrated mount for a steering damper – available as a PowerPart accessory. [ CurvED raDIator ] Best cooling by means of its curved shape and the resulting maximized surface area. [ rImS / tIrES ] MAXXIS Razr tyres on light, stable DWT aluminium rims. [ ExhauSt ] The powerful XC silencer is made of light-weight aluminium.