KTM 525 XC ATV EU User manual

OWNER'S MANUAL 2010
525 XC ATV EU
Art. no. 3211487en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous
pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 16) Dealer's stamp
Engine number ( p. 17)
Key number ( p. 17)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing devel-
opment and design can however not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of delivery.

DEAR KTM CUSTOMER 2
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 3
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................... 7
IMPORTANT INFORMATION ................................................... 8
VIEW OF VEHICLE................................................................ 12
View of the vehicle from the left front (example).................. 12
View of the vehicle from the right rear (example) ................. 14
LOCATION OF SERIAL NUMBERS ......................................... 16
Chassis number................................................................ 16
Type label........................................................................ 16
Key number ..................................................................... 17
Engine number................................................................. 17
Front shock absorber part number...................................... 18
Rear shock absorber part number....................................... 18
CONTROLS.......................................................................... 19
Clutch lever ..................................................................... 19
Hand brake lever, front parking brake ................................. 20
Steering lock.................................................................... 21
Parking brake lever ........................................................... 22
Throttle lever.................................................................... 23
Light switch ..................................................................... 23
Turn signal switch ............................................................ 24
Kill switch ....................................................................... 24
Horn button ..................................................................... 25
Ignition switch ................................................................. 25
Electric starter button ....................................................... 26
Hazard warning flasher switch/hazard warning flasher .......... 26
Indicator lamp overview .................................................... 27
Emergency OFF switch with rip cord................................... 27
Speedometer.................................................................... 28
Speedometer activation and test ........................................ 28
Tripmaster switch ............................................................. 29
Setting kilometers or miles ................................................ 29
Setting the clock .............................................................. 30
Adjusting the speedometer functions.................................. 31
Querying the lap time ....................................................... 32
Display mode SPEED (speed) ............................................ 33
Display mode SPEED/H (operating hours) ........................... 34
Display mode SPEED/CLK (clock) ...................................... 35
Display mode SPEED/LAP (lap time) .................................. 35
Display mode SPEED/ODO (odometer)................................ 36
Display mode SPEED/TR1 (trip master 1) ........................... 36
Display mode SPEED/TR2 (trip master 2) ........................... 37
Display mode SPEED/A1 (average speed 1)......................... 38
Display mode SPEED/A2 (average speed 2)......................... 38
Display mode SPEED/S1 (stop watch 1) ............................. 39
Display mode SPEED/S2 (stop watch 2) ............................. 40
Opening filler cap............................................................. 42
Closing filler cap .............................................................. 42
Locking the steering ......................................................... 43
Unlocking the steering ...................................................... 43
Fuel tap........................................................................... 44
Choke.............................................................................. 45
Hot start button................................................................ 45
Shift lever........................................................................ 46
Foot brake lever................................................................ 47
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................... 48
advice on first use ............................................................ 48
Running in the engine....................................................... 50

TABLE OF CONTENTS 4
RIDING INSTRUCTIONS ....................................................... 51
Checks before putting into operation .................................. 51
Starting ........................................................................... 52
Starting up ...................................................................... 54
Shifting ........................................................................... 54
Braking ........................................................................... 55
Riding ............................................................................. 56
Riding in bends................................................................ 57
Riding downhill ................................................................ 58
Riding uphill.................................................................... 59
Riding perpendicular to the slope....................................... 60
Turning on slopes ............................................................. 60
Riding through water ........................................................ 62
Switching off the engine ................................................... 62
Stopping, parking ............................................................. 64
Refueling......................................................................... 65
SERVICE SCHEDULE............................................................ 67
Important maintenance work to be carried out by an
authorized KTM workshop ................................................. 67
Important maintenance work to be carried out by an
authorized KTM workshop (as an additional order) ............... 69
Important checks and maintenance work to be carried out
by the rider...................................................................... 71
MAINTENANCE ON CHASSIS AND ENGINE ........................... 72
Jacking up the vehicle ...................................................... 72
Removing the vehicle from the work stand .......................... 72
Basic information on changing the chassis settings.............. 72
Front shock absorber - adjusting the compression
damping .......................................................................... 73
Front shock absorber - adjusting the rebound damping......... 74
Front shock absorber - adjusting the cross over.................... 75
Front shock absorber - adjusting the spring preload ............. 77
Rear shock absorber - adjusting the compression damping ... 79
Rear shock absorber - adjusting the rebound damping.......... 80
Rear shock absorber - adjusting the spring preload x......... 81
Removing the rear shock absorber x................................. 83
Installing the rear shock absorber x.................................. 85
Checking the toe x......................................................... 85
Adjusting the toe x......................................................... 88
Checking/adjusting the camber x..................................... 90
Handlebar position ........................................................... 93
Adjusting the handlebar position x................................... 94
Checking the play in the throttle cable................................ 96
Adjusting play in throttle cable .......................................... 97
Checking the basic setting of the shift lever ........................ 97
Adjusting the basic position of the shift lever x................. 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....................................................... 102
Adjusting chain tension................................................... 103
Greasing the rear wheel eccentric element ........................ 105
Checking brake discs ...................................................... 105
Checking the free travel of the hand brake lever ................ 106
Adjusting basic position of hand brake lever...................... 107
Checking front brake fluid level........................................ 107
Topping up the front brake fluid x.................................. 108
Checking the front brake linings....................................... 110

TABLE OF CONTENTS 5
Removing front brake linings x...................................... 111
Mounting front brake linings x....................................... 112
Changing the front brake linings x................................. 113
Checking free travel of foot brake lever ............................. 115
Adjusting basic position of foot brake lever x.................. 116
Checking rear brake fluid level......................................... 117
Adding rear brake fluid x.............................................. 118
Checking rear brake linings ............................................. 120
Removing rear brake linings x........................................ 121
Mounting rear brake linings x........................................ 122
Changing rear brake linings x........................................ 124
Removing wheel/wheels................................................... 125
Mounting wheel/wheels ................................................... 126
Checking the tire condition.............................................. 127
Checking the tire air pressure .......................................... 128
Removing the battery...................................................... 129
Installing the battery....................................................... 130
Recharging the battery x............................................... 130
Changing the main fuse .................................................. 132
Changing the fuses of individual power consumers............. 133
Checking the headlight setting......................................... 135
Adjusting the headlight range of the headlight................... 136
Removing the seat.......................................................... 136
Mounting the seat .......................................................... 137
Removing the radiator spoiler .......................................... 137
Installing the radiator spoiler ........................................... 138
Removing the front cover................................................. 140
Installing the front cover ................................................. 140
Removing the front trim .................................................. 141
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 x............................................... 147
Installing the air filter x................................................ 149
Cleaning air filter x....................................................... 150
Adjusting basic position of clutch lever............................. 151
Checking fluid level of hydraulic clutch ............................ 151
Cooling system ............................................................... 152
Radiator fan................................................................... 152
Checking the antifreeze and coolant level ......................... 153
Checking the coolant level............................................... 154
Draining coolant x........................................................ 155
Filling coolant / bleeding cooling system x...................... 157
Carburetor - idle ............................................................. 159
Carburetor - adjusting idle x.......................................... 160
Emptying the carburetor float chamber x........................ 162
Checking the engine oil level ........................................... 163
Changing engine oil and oil filter, cleaning oil
screens x..................................................................... 164
Draining engine oil, cleaning oil screens x...................... 164
Removing the oil filter x................................................ 168
Installing the oil filter x................................................ 170
Filling up with engine oil x............................................ 170
Adding engine oil ........................................................... 171
TROUBLESHOOTING.......................................................... 173

TABLE OF CONTENTS 6
CLEANING......................................................................... 178
Cleaning the vehicle ....................................................... 178
STORAGE .......................................................................... 180
Storage.......................................................................... 180
Putting the vehicle into operation after storage.................. 181
TECHNICAL DATA - ENGINE............................................... 182
Capacity - engine oil ....................................................... 183
Capacity - coolant........................................................... 183
TECHNICAL DATA - ENGINE TIGHTENING TORQUES........... 184
TECHNICAL DATA - CARBURETOR...................................... 187
TECHNICAL DATA - CHASSIS ............................................. 188
Lighting equipment ........................................................ 190
Tires ............................................................................. 190
Capacity - fuel................................................................ 191
TECHNICAL DATA - FRONT SHOCK ABSORBER................... 192
TECHNICAL DATA - REAR SHOCK ABSORBER..................... 193
TECHNICAL DATA - TIGHTENING TORQUES FOR
CHASSIS ........................................................................... 194
SUBSTANCES.................................................................... 196
AUXILIARY SUBSTANCES................................................... 200
STANDARDS...................................................................... 203
INDEX ............................................................................... 204

MEANS OF REPRESENTATION 7
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your
own safety, have these jobs performed at an authorized KTM workshop! There, your vehicle will be serviced optimally
by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT INFORMATION 8
Use definition
The vehicle is designed and constructed to withstand the usual demands of regular traffic and use on gentle terrain (unpaved roads), but
not for use on race tracks.
Info
The ATV is authorized for public road traffic in the homologous version only.
Maintenance
A prerequisite for trouble-free operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of
components.
Using the vehicle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the trans-
mission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service
schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessories are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.

IMPORTANT INFORMATION 9
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses.
E.g.: valve spring mounter (59029019000)
When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must
be replaced with new parts.
If a thread locker (e.g. Loctite®) is used for screw connections, follow the instructions for use from the manufacturer.
Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear. Replace damaged or worn
parts.
After finishing the repair and maintenance work, ensure that the vehicle is roadworthy.
Transport
Note
Danger of damage Danger of damage from accidental rolling of vehicle.
–Park the vehicle on a surface that is as horizontal as possible and apply the parking brakes.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
–Switch off the engine.
–Turn the handle of the fuel tap to OFF. (Figure 100013-10 p. 44)
–Use straps or other suitable devices to secure the vehicle against accidents or falling over.
–Fold down the parking brake lever . (Figure 601044-10 p. 22)

IMPORTANT INFORMATION 10
–Pull the hand brake lever, push the locking pawl down and release the hand brake lever. (Figure 100006-10 p. 20)
Environment
ATV riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for
the environment and can lead to conflicts with other persons. If you use your ATV responsibly, you can ensure that such problems and con-
flicts do not have to occur. Make sure that you use your ATV legally, display environmental consciousness, and respect the rights of others.
Rider training
If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the
first time.
A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain.
Your KTM dealer will be glad to advise you.
Warning notes
Be sure to pay attention to the notes and warnings given here.
Info
Various notes and warning stickers are attached to the vehicle. Do not remove any warning labels. If they are missing, you or others
may not recognize dangers and may therefore be injured.

IMPORTANT INFORMATION 11
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains a lot of information
and tips to help you operate and handle your vehicle. Only then will you find out how to customize the vehicle ideally for your own use
and how you can protect yourself from injury. The owner's manual also contains important information on servicing the vehicle.
–The owner's manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE 12
3.1View of the vehicle from the left front (example)
601023-10

VIEW OF VEHICLE 13
1 Hand brake lever
2 Fuse box
3 Headlight
4 Front left turn signal
5 Front bumper
6 Steering lock
7 Front left shock absorber
8 Clutch lever
9 Emergency OFF switch with rip cord
10 Heel protector
11 Left footrest
12 Shift lever
13 Outside brake disk guard

VIEW OF VEHICLE 14
3.2View of the vehicle from the right rear (example)
601039-10

VIEW OF VEHICLE 15
1 Light switch, turn signal switch, kill switch, horn button
2 Electric starter button
3 Parking brake lever
4 Filler cap
5 Main silencer
6 License plate holder
7 Rear shock absorber
8 Rear sprocket with chain
9 Rear brake
10 Foot brake lever
11 Oil level viewer
12 Fuel tap
13 Throttle lever
14 Ignition switch

LOCATION OF SERIAL NUMBERS 16
4.1Chassis number
100002-10
The chassis number is stamped on the right side of the frame in the vicinity of the upper
control arm.
4.2Type label
601045-10
The type label is located on the frame tube on the right in front of the radiator.

LOCATION OF SERIAL NUMBERS 17
4.3Key number
100089-10
The key number is indicated on the KEYCODECARD.
Info
You need the key number to order a replacement key. Keep the KEYCODECARD in a
safe place.
4.4Engine number
601047-10
The engine number is stamped on the left side of the engine under the engine sprocket.

LOCATION OF SERIAL NUMBERS 18
4.5Front shock absorber part number
601024-10
The shock absorber part number is stamped on the top part of the shock absorber.
4.6Rear shock absorber part number
601083-10
The shock absorber part number is stamped on the top part of the shock absorber.