KTM 425XC and 525XC   Airbox   Engine Left side   Engine Rightside   Exhaust   Front suspension   Rear Suspension

The KTM brand philosophy of “Ready to Race” is embodied in the new KTM ATV line. The 450XC and 525XC set new standards for production race ready sport ATVs. Extensive ATV racing research and development with professional level riders combined with KTM‘s knowledge of engine performance and chassis development mated to premium race components have created the ultimate cross country race ready ATV.

450/525 Shared Components

• 39mm Keihin FCR Flat Slide Carb with TPS –ultra responsive and easy to tune
•  Electric Start–quick starts in any gear, less rider fatigue
•  Re-designed Engine Cases –wider to accommodate reverse gear
•  Dry Sump Design Without an External Oil Tank–increased engine performance due to dry sump design –low center of gravity –
• CaliforniaGreen Sticker Legal
• Engine Design Enhances Serviceability
• Easy Spark Plug Access –can be replaced without removing plastic or fuel tank
• Cylinder Head Design Offers 4-Valve and SOHC –offers easy access for valve adjustment and inspection
• Engine, Clutch and Gearbox use common oil lubrication –with easy access to oil filters
• Twin Oil Filters and Twin Bottom Oil Strainers–extends engine life under harsh conditions
• Engine Oil Sight Glass–easy to read for quick, accurate oil level checks
• Lightweight Curved Aluminum Radiator –shape increases the volume of water and improves air flow
• Utilizes a Thermostat and Electric Cooling Fan -–optimizes engine temperature for increased performance during race conditions
• Radiator Protection–race designed mud shields to keep the radiator clean under harsh conditions
• New 5 Speed Transmission With Reverse–allows for less shifting while racing with the convenience of reverse
• Reverse is Located “Below”First Gear
•  Left Handle Bar Mounted Reverse Lever–easy to operate without taking your hand off the handlebar
• Magura Hydraulic Clutch –offers light lever effort and automatic adjustment
• Quick Change Clutch Cover –offers quick clutch service under race conditions
• Stainless Steel Braided Clutch Line–reduces line flex and increases line durability
• Adjustable Lever With Integrated Break Point –improved rider ergonomics and race functionality
• Performance Tuned Exhaust With Aluminum Canister–Lightweight, high flow design
• Equipped With USFS Spark Arrestor-serviceable
• Unique HighFlow Airbox Design With Snorkel–allows for high airflow to the engine for maximum performance while drawing air from the highest point to reduce water & mud intake
• Quick Release Seat and an Airfilter Design That Requires No Tools for Service –offers quick change during race conditions
• Utilizes the Same Air Filter as the SX Motorcycles

Chassis

• Lightweight Chrome-moly Steel Design –utilizes proven SX main frame designand provides excellent durability and performance
• Chassis Design Places the Engine Low–for low center of gravity and provides the optimum countershaft to swingarm pivot position
• Removable Aluminum Subframe–Lightweight design for easy maintenance –incorporates ATV flag holder
• Removable Aluminum Rear Grab Bar
• Chrome-moly Steel Upper and Lower Control Arms–for increased durability
• Lower Control Arms Use a Swept Design–for increased ground clearance
• A-Arm Width Designed Specifically for Cross Country Racing
• Upper Control Arm with Replaceable Hym Joint Bearings –offers complete camber and caster adjustability
• Replaceable Upper and Lower Ball Joints –designed for easy maintenance
• Replaceable Lower Needle Bearings–designed for easy maintenance
• Industry ExclusiveSteering Stabilizer Mount –designed into the chassis for direct mount on the bottom of the steering stem
• Strong Chrome-moly Steel Rear Swingarm –excellent durability for tough race conditions
• Plastic Nylon Swingarm Skid Plate –lightweight, durable –offers good ground clearance and built it chain guide
• Plastic Nylon Full Length Chassis Skid Plate –Lightweight, durable, easily slides over obstacles
• Eccentric Chain Adjuster –quick easy chain adjustments
• High Quality Tapered Roller Bearings Support the Rear Axle–carrier includes easy access grease zerk for easy bearing lubrication
• Adjustable Axle Width for Race Conditions –Range 45.5”–48.5”
• Self Locking Rear Axle Nut–quick race tire changes

Suspension and Brakes

• Front Suspension / Ohlins –premium ATV suspension with high brand and industry awareness
• Dual Rate Springs With Adjustable Crossover -Fully Adjustable for Rider Preference and Style–Pre-load, compression and rebound –11”of front suspension travel –excellent big bump capability and small bump compliance
• Lightweight Aluminum Bodies With Aluminum Piggyback Reservoirs –low unsprung weight for improved suspension action
• Powerful Mugura Four Piston Front Brakes –utilizes a fixed caliper design
• Large 180mm Floating Brake Discs–vented for cooling and wave design for cleaning capability
• Stainless Steel Braided Brake Line–greatly reduces line flex for increased performance
• Adjustable Lever With Integrated Break Point and Lightweight Parking Brake –improved rider ergonomics and race functionality
• Rear Suspension / Ohlins –premium ATV suspension with high brand and industry awareness
• Position Damping System (PDS) with No Link Design –provides excellent shock action with lower weight and increased ground clearance –easy shock maintenance
• Fully Adjustable for Rider Preference and Style–pre-load, compression and rebound –11”of front suspension travel
• Lightweight Aluminum Body With Aluminum Piggyback Reservoir –low unsprung weight for improved suspension action
•  Powerful Mugura Single Piston Rear Brake –utilizes a floating caliper design
•  Large 200mm Brake Disc–vented for cooling and cleaning capability
•  Integrated Reservoir Master Cylinder–durable, lightweight system
•  Stainless Steel Braided Brake Line–greatly reduces line flex for increased performance
•  Lightweight Aluminum Rear Brake Pedal–mounted inside the frame rail on a ball bearing with dual adjustment for height and free play

Ready to Race Components

• Race Ready Maxxis Razor Tires –race proven tires with aggressive XC tread design –4-ply rating
• Front Tire–21x7x10”
• Rear Tire–20x11x9”
• Race Ready Douglas Aluminum Rims –Lightweight, rolled edge for strength with common industry bolt pattern
• High Quality 520 Low Drag X-Ring Chain –designed to minimize maintenance and adjustments for long life in race conditions
• Aluminum Sprockets–quick change sprocket design for easy gearing changes
• Race Designed Oversized Fuel Tank –ergonomically designed to help hold the rider in turns -high fuel capacity for XC races –3.5 gallons –includes petcock with reserve
• Quick Release ¼Turn Fuel Cap–quick release for mid-race fueling
• Performance Engineered Heel Guards –large holes to release mud and water –designed to flex slightly to prevent breakage
• Extra Wide Serrated Foot Pegs–provide excellent stability with angled outside edge –designed for bolt on nerf bars
•  Magura Aluminum Handlebar –Tapered handlebar to add strength and reduce vibration –hand guard compatible
• Adjustable Steering Stem Clamp and Handlebar Clamps–new industry standard provides 4 position adjustability for improved rider ergonomics
• Race Ready Safety Lanyard –automatic engine shut off when pulled with press button engine kill
• Key and Light Panel–provides information and security
• Multi-Reflector Headlight –super bright headlight with daytime running lamp –powered by a 200 watt charging coil which allows for auxiliary lighting
• LED Brake and Taillight–lightweight light is small and compact and well protected
• Removable Front Fenders –for specific race applications
• Removable Front and Rear Plastic–designed for easy removal for chassis and engine service
• Rider Ergonomics -narrow design –comfortable seat –adjustable levers/ bars

Availability

• Limited Availability Early Fall
• Full Season Deliveries to Start Late Fall

Specifications 2008 450 XC
Technical Fasts and Figures

ENGINE & DRIVETRAIN

• Engine: single cylinder, 4-stroke, SOHC, 4-valve, liquid cooled
• Displacement: 447.92cc
• Bore/Stroke: 89/72mm
• Compression Ratio: 11:1
• Starter/Battery: electric starter/4 Ah
• Transmission: 5-speed XC semi-close-ratio + reverse
• Carburetor: Keihin FCR-MX 39
• Engine Lubrication: dry sump, pressure lubrication with 2 Eaton pumps
• Engine Oil: 1.8 I fully synthetic 10W-50
• Primary Ratio: 31:78
• Drive Chain: 520 x-ring chain 5/8 x 1/4"
• Cooling: liquid cooled
• Clutch: wet multi-disc clutch, operated hydraulically
• Ignition: Kokusan digital

CHASSIS

• Frame: chromoly (25CRM04)
• Subframe: aluminum 7020
• Handlebar: Magura tapered aluminum, 0 28 mm
• Front Suspension: Ohlins fully adjustable – dual rate w/crossover, chromoly twin A-arms
• Rear Suspension: Ohlins PDS mono-shock, fully adjustable, chromoly swingarm
• Suspension Travel Front/Rear: 257/265mm / 10.1/10.4"
• Front Brake: 180mm/7.08" floating WAVE discs, 4-piston fixed caliper x 2
• Rear Brake: 200mm/7.87" disc, single piston floating caliper
• Front/Rear Rims: 5.0" x 10.0" / 8.0" x 9.0" Douglas
• Front/Rear Tires: 21" x 7"- 10" / 20" x 11"- 9" MAXXIS Razor
• Final Drive: 14:38
• Main Silencer: aluminum XC w/spark arrestor
• Length/Width/Height: 1810/ 1148/ 1125mm – 71.26"/45.20"/44.29"
• Wheelbase: 1280mm / 50.39"
• Ground Clearance (Unloaded): 290mm/11.42"
• Seat Height: 820mm/32.2"
• Fuel Capacity: approx. 13.4 liters / 3.54 U.S. gallons
• Total Weight (Without Fuel): approx. 162 kgs / 357.1 lbs

Specifications 2008 525 XC
Technical Fasts and Figures

ENGINE & DRIVETRAIN

• Engine: single cylinder, 4-stroke, SOHC, 4-valve, liquid cooled
• Displacement: 51O.4cc
• Bore/Stroke: 95/72mm
• Compression Ratio: 11:1
• Starter/Battery: electric starter/4 Ah
• Transmission: 5-speed XC semi-close-ratio + reverse
• Carburetor: Keihin FCR-MX 39
• Engine Lubrication: dry sump, pressure lubrication with 2 Eaton pumps
• Engine Oil: 1.8 I fully synthetic 1OW-50
• Primary Ratio: 31:78
• Drive Chain: 520 x-ring chain 5/8 x 1/4"
• Cooling: liquid cooled
• Clutch: wet multi-disc clutch, operated hydraulically
• Ignition: Kokusan digital

CHASSIS

• Frame: chromoly (25CRMO4)
• Subframe: aluminum 7020
• Handlebar: Magura tapered aluminum, 0 28 mm
• Front Suspension: Ohlins fully adjustable – dual rate w/crossover, chromoly twin A-arms
• Rear Suspension: Ohlins PDS mono-shock, fully adjustable, chromoly swingarm
• Suspension Travel Front/Rear: 257/265mm / 10.1/10.4"
• Front Brake: 18Omm/7.O8" floating WAVE discs, 4-piston fixed caliper x 2
• Rear Brake: 2OOmm/7.87" disc, single piston floating caliper
• Front/Rear Rims: 5.0" x 10.0" / 8.0" x 9.0" Douglas
• Front/Rear Tires: 21" x 7"- 10" / 20" x 11"- 9" MAXXIS Razor
• Final Drive: 14:38
• Main Silencer: aluminum XC w/spark arrestor
• Length/Width/Height: 181O/1148/1125mm – 71.26"/45.20"/44.29"
• Wheelbase: 128Omm/5O.39"
• Ground Clearance (Unloaded): 29Omm/ 11.42"
• Seat Height: 82Omm/32.2"
• Fuel Capacity: approx. 13.4 liters / 3.54 U.S. gallons
• Total Weight (Without Fuel): approx. 162 kgs / 357.1 lbs