OWNER'S MANUAL 2010
450 EXC USA
530 EXC USA
Art. no. 3211468en
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DEAR KTM CUSTOMER
1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Dealer's stamp
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, 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 spe-
cial equipment that does not belong to the regular scope of delivery.
© 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
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TABLE OF CONTENTS
2
TABLE OF CONTENTS
Important maintenance work to be carried out by an
Important maintenance work to be carried out by an
Important checks and maintenance work to be carried
Checking the basic suspension setting with the rider's
Adjusting the high-speed compression damping of the
Adjusting the low-speed compression damping of the
GENERAL TIPS AND HINTS ON PUTTING INTO
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TABLE OF CONTENTS
3
Changing engine oil and oil filter, cleaning engine oil
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MEANS OF REPRESENTATION
4
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 done in an authorized KTM workshop! There, your motorcycle 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.
Proprietary name
Denotes a proprietary name.
Name®
Denotes a protected name.
Brand™
Denotes a brand available on the open market.
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IMPORTANT INFORMATION
5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle is authorized for use on public roads in the homologated (reduced) version only.
In the derestricted version, the motorcycle must be used only on closed off properties remote from public road traffic.
The motorcycle is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance
A prerequisite for trouble free operation and avoiding premature wear is that the engine and suspension are maintained and adjusted
as described in this manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of compo-
nents.
Using a motorcycle in difficult conditions such as on sand or very wet and muddy ground can lead to excessive wear of components
such as the power train or 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. Observing these rules will vastly
increase the service life of your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation
and/or other changes to the 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 accessory products 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.
Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise
you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damageꢀThe parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazardꢀSome 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 engine.
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IMPORTANT INFORMATION
6
–
–
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
2
.1
300401-10
1
2
3
4
5
6
7
Type label for Canada
Type label for the USA
Fuel evaporative system information
Chain tension information
Information on putting into operation
Emission control information
Noise emission information
500250-01
Type label for Canada
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IMPORTANT INFORMATION
7
500251-01
Type label for the USA
Fuel evaporative system information
100841-01
500255-01
700210-01
Chain tension information
Information on putting into operation
100840-01
Emission control information
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IMPORTANT INFORMATION
8
100839-01
Noise emission information
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–
It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-
mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motor-
cycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on
servicing the motorcycle.
–
The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
Reporting of safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform
the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives similar complaints, it may open an investigation. If it finds that a safety defect exists in a group of vehicles, it may
order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or
KTM North America, Inc.
To contact NHTSA, you may either call the Vehicle Safety Hotline toll-free at 1–888–327–4236; or visit www.nhtsa.dot.gov; or write
to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590, USA. You can also obtain other infor-
mation about motor vehicle safety from the Hotline.
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise stan-
dards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telefon: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
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IMPORTANT INFORMATION
9
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1
The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device
or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate
purchaser or while it is in use; or
2
The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1
2
3
4
Removal of, or puncturing the muffler, baffles, header pipes or any other components which conducts exhaust gases.
Removal or puncturing of any part of the intake system.
Lack of proper maintenance.
Replacement of any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by
the manufacturer.
Operating noise warning
This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise,
the owner may become subject to penalties under state and local ordinances.
Consumer rights
Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Telefon: (440) 985–3553
www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441–4451 x 4250
www.ktmcanada.com
Different rights may apply, according to national or regional legislation.
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VIEW OF VEHICLE
10
3
.1
iew of the vehicle from the left front (example)
300399-10
1
2
3
4
5
6
7
8
Side stand
Shift lever
Chain guide
Fuel tap
Air filter box lid
Clutch lever
Light switch, headlight flasher button, flasher switch, horn button
Hand brake lever
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VIEW OF VEHICLE
11
3
.2
iew of the vehicle from the right rear (example)
300398-10
1
2
3
4
5
6
7
8
9
Level viewer for brake fluid, rear
Fork compression adjustment
Foot brake pedal
Kickstarter
Horn
Ignition switch
Fork rebound adjustment
Filler cap
Shock absorber compression adjustment
10
Shock absorber rebound adjustment
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LOCATION OF SERIAL NUMBERS
12
4
.1
The chassis number is stamped on the steering head on the right.
500127-10
4
.2
The type label USA is fixed to the front of the steering head.
300402-10
The type label Canada is fixed to the front of the front pipe.
300403-10
4
.3
ey number
The key number is provided on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
300397-10
4
.4
ngine number
The engine number is stamped on the left side of the engine under the engine
sprocket.
500072-10
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LOCATION OF SERIAL NUMBERS
13
4
.5
The fork part number is stamped on the inner side of the fork stub.
100801-10
4
.6
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
500129-10
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CONTROLS
14
5
.1
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
500133-10
400196-10
500144-10
300396-10
500144-12
5
.2
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
5.3
The emergency OFF switch is fitted on the left side of the handlebar.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.
5.4
The ignition switch is on the right behind the headlight mask.
Possible states
Ignition off – In this position, the ignition circuit is interrupted, a run-
ning engine stops, and a non-running engine will not start.
Ignition on – In this position, the ignition circuit is closed, and the
engine can be started.
5
Electric starter button is fitted on the right side of the handlebar.
Possible states
•
•
Electric starter button is in home position
Electric starter button is pressed – In this position, the electric starter is actu-
ated.
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CONTROLS
15
5
.6
Light switch is fitted on the left side of the handlebar.
Possible states
Low beam on – Light switch is turned downward. In this position, the
low beam and tail light are switched on.
High beam on – Light switch is turned upward. In this position, the
high beam and tail light are switched on.
500142-10
500143-10
500142-11
500142-12
500147-01
5
.7
Headlight flasher button is fitted on the left side of the handlebar.
Possible states
•
•
Headlight flasher button is in home position
Headlight flasher button is pressed – The headlight flasher is activated in this
position.
5
.8
Horn button is fitted on the left side of the handlebar.
Possible states
•
•
Horn button is in home position
Horn button is pressed – The horn is sounded in this position.
5
.9
lasher switch
Flasher switch is fitted on the left side of the handlebar.
Possible states
Flasher light off
Flasher light, left, on – Flasher switch is pressed to the left. The flasher
switch returns to the middle position after activation.
Flasher light, right, on – Flasher switch is pressed to the right. The
flasher switch returns to the middle position after activation.
To switch off the flasher, push the flasher switch toward the switch housing.
5
.10
Possible states
High beam indicator lamp lights up blue – High beam is switched on.
Turn signal indicator lamp flashes green – Turn signal light is switched
on.
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CONTROLS
16
5
.11
–
–
–
Press the key to change the display mode or change to one of the Setup menus.
Press the key to control different functions.
Press the key to control different functions.
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes
are activated.
400312-01
5
.12
Activating the speedometer:
The speedometer is activated when one of the keys is pressed or a signal is received
from the wheel speed sensor.
Display test
For the function test of the display, all display segments light up briefly.
400313-01
WS (wheel size)
After the display function test, the wheel size WS is displayed briefly.
Info
2205 mm corresponds to the size of the 21" front wheel with a series produc-
tion tire.
The display then changes to the last selected mode.
400314-01
5
.13
(Option: Tripmaster switch)
You can use the trip master switch to control the functions of the speedometer from the handlebar.
Info
The trip master is an optional accessory.
5
.14
etting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
The values TR1, TR2, A1, A2 and S1 are cleared when the unit of measure is changed.
Condition
The motorcycle is stationary.
–
Press the button briefly and repeatedly until H appears at the bottom right of the
display.
–
Press the button for 3 - 5 seconds.
The setup menu is displayed and the active functions shown.
Press the button repeatedly until the Km/h/Mph display flashes.
–
Km/h adjusting
–
Press the button
.
.
Mph adjusting
–
Press the button
400329-01
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CONTROLS
17
–
Press the button for 3 - 5 seconds.
The settings are stored and the setup menu is closed.
Info
If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.
5
.15
Condition
The motorcycle is stationary.
–
Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
–
Press the button for 3 - 5 seconds.
The hour display flashes.
–
–
Set the hour display with the button and/or button
Press the button briefly.
.
The next segment of the display flashes and can be set.
–
You can set the following segments in the same way as the hours by pressing
400330-01
the button and the button
.
Info
The seconds can only be set to zero.
–
Press the button for 3 - 5 seconds.
The settings are stored and the setup menu is closed.
Info
If no button is actuated for 20 seconds or there is no signal from the wheel
speed sensor, then the settings are automatically stored and the setup menu
closed.
5
.16
djusting the speedometer functions
Info
When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Condition
The motorcycle is stationary.
–
Press the button briefly and repeatedly until H appears at the bottom right of the
display.
–
Press the button for 3 - 5 seconds.
The Setup menu is displayed and the activated functions are shown.
Change to the desired function by pressing the button briefly.
–
The selected function flashes.
Activating a function
Press the button
–
.
400318-01
The symbol remains on the screen and the display changes to the next
function.
Deactivating the function
Press the button
–
.
The symbol on the screen goes out and the display changes to the next
function.
–
–
All desired functions are activated or deactivated accordingly.
Press the button for 3 - 5 seconds.
The settings are stored and the Setup menu is closed.
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CONTROLS
18
Info
If no button is pressed for 20 seconds, or if a pulse arrives from the wheel
speed sensor, the settings are stored automatically and the Setup menu is
closed.
5
.17
uerying the lap time
Info
This function can be called only if lap times are measured.
Condition
The motorcycle is stationary.
–
Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
–
Press the button briefly.
LAP 1 appears on the left side of the display.
–
–
–
Laps 1-10 can be displayed by pressing the button
The button has no function
.
Press the button briefly.
Next display mode
400321-01
Info
If an impulse is received from the wheel speed sensor, the left side of the
display changes back to the SPEED mode.
5
.18
–
Press the button briefly and repeatedly until SPEED appears on the left side of
the display.
The current speed is displayed in the SPEED display mode.
The current speed can be displayed in Km/h or Mph.
Info
Making the setting according to the country.
When an impulse comes from the front wheel, the left side of the speedometer
display changes to the SPEED mode and the current speed is shown.
400317-02
5
.19
isplay mode SPEED/H (service hours)
Condition
•
The motorcycle is stationary
–
Press the button briefly and repeatedly until H appears at the bottom right of the
display.
In display mode H, the service hours of the engine are displayed.
The service hour counter stores the total traveling time.
Info
The service hour counter is necessary for ensuring that maintenance work is car-
ried out at the right intervals.
400316-01
If the speedometer is in H display mode at the start of the journey, it automati-
cally changes to the ODO display mode.
The H display mode is suppressed during the journey.
Press the button
Press the button
.
.
No function
No function
Press the button
for 3 - 5 seconds.
The display changes to the Setup menu of the speedometer
functions.
Press the button
briefly.
Next display mode
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CONTROLS
19
5
.20
–
Press the button briefly and repeatedly until CLK appears at the bottom right of
the display.
The time is displayed in CLK display mode.
Press the button
Press the button
.
.
No function
No function
Press the button
for 3 - 5 seconds.
The display changes to the Setup menu of the clock.
Press the button
briefly.
Next display mode
400319-01
5
.21
isplay mode SPEED/LAP (lap time)
–
Press the button briefly and repeatedly until LAP appears at the bottom right of
the display.
In the LAP display mode, up to 10 lap times can be timed with the stop watch.
Info
If the lap time continues after you press the button , 9 memory locations are
already occupied.
Lap 10 must be timed with the button
.
400320-01
Press the button
Press the button
.
.
Starts or stops the clock.
Stops the current lap time and saves it, and the stop watch
starts the next lap.
Press the button
for 3 - 5 seconds.
The stop watch and the lap time are reset.
Press the button
briefly.
Next display mode
5
.22
isplay mode SPEED/ODO (odometer)
–
Press the button briefly and repeatedly until ODO appears at the bottom right of
the display.
In ODO display mode, the total number of kilometers ridden is displayed.
Press the button
Press the button
.
.
No function
No function
–
Press the button
for 3 - 5 seconds.
Press the button
briefly.
Next display mode
400317-01
5
.23
isplay mode SPEED/TR1 (trip master 1)
–
Press the button briefly and repeatedly until TR1 appears at the top right of the
display.
TR1 (trip master 1) runs constantly and counts to 999.9.
You can use it to measure trips or the distance between refueling stops.
TR1 is coupled with A1 (average speed 1) and S1 (stop watch 1).
Info
If 999.9 is exceeded, the values of TR1, A1 and S1 are automatically reset to
0.0.
400323-01
Press the button
Press the button
.
.
No function
No function
Press the button
for 3 - 5 seconds.
The TR1, A1 and S1 displays are reset to 0.0.
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CONTROLS
20
Press the button
briefly.
Next display mode
5
.24
isplay mode SPEED/TR2 (trip master 2)
–
Press the button briefly and repeatedly until TR2 appears at the top right of the
display.
TR2 (trip master 2) runs constantly and counts up to 999.9.
The displayed value can be set manually with the button and the button . A very
practical function when riding using the road book.
Info
The TR2 value can also be corrected manually during the journey with the but-
ton and the button
If 999.9 is exceeded, the value of TR2 is automatically reset to 0.0.
.
400324-01
Press the button
Press the button
.
.
Increases value of TR2.
Reduces value of TR2.
Deletes value of TR2.
Press the button
for 3 - 5 seconds.
Press the button
briefly.
Next display mode
5
.25
isplay mode SPEED/A1 (average speed 1)
–
Press the button briefly and repeatedly until A1 appears at the top right of the
display.
A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas-
ter 1) and S1 (stop watch 1).
The calculation of this value is activated by the first impulse of the wheel speed sensor
and ends 3 seconds after the last impulse.
Press the button
Press the button
.
.
No function
No function
400325-01
Press the button
for 3 - 5 seconds.
The TR1, A1 and S1 displays are reset to 0.0.
Press the button
briefly.
Next display mode
5
.26
isplay mode SPEED/A2 (average speed 2)
–
Press the button briefly and repeatedly until A2 appears at the top right of the
display.
A2 (average speed 2) shows the average speed on the basis of the current speed if the
stop watch S2 (stop watch 2) is running.
Info
The displayed value can differ from the actual average speed if S2 was not
timed after the ride.
400326-01
Press the button
Press the button
.
.
No function
No function
–
Press the button
for 3 - 5 seconds.
Press the button
briefly.
Next display mode
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CONTROLS
21
5
.27
isplay mode SPEED/S1 (stop watch 1)
–
Press the button briefly and repeatedly until S1 appears at the top right of the
display.
S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an
impulse is received from the wheel speed sensor.
The calculation of this value starts with the first impulse of the wheel speed sensor and
ends 3 seconds after the last impulse.
Press the button
Press the button
.
.
No function
No function
400327-01
Press the button
for 3 - 5 seconds.
Displays of TR1, A1 and S1 are reset to 0.0.
Press the button
briefly.
Next display mode
5
.28
isplay mode SPEED/S2 (stop watch 2)
–
Press the button briefly and repeatedly until S2 appears at the top right of the
display.
S2 (stop watch 2) is a manual stop watch.
If S2 is running in the background, the S2 display flashes in the speedometer display.
Press the button
Press the button
.
.
Starts or stops S2.
No function
Press the button
for 3 - 5 seconds.
Displays of S2 and A2 are reset to 0.0.
400328-01
Press the button
briefly.
Next display mode
Table of functions
Display
Press the button
.
Press the button
.
Press the button for 3 - Press the button
5 seconds.
briefly.
Display mode SPEED/H
(service hours)
No function
No function
The display changes to
the Setup menu of the
speedometer functions.
Next display mode
Display mode SPEED/CLK No function
(clock)
No function
The display changes to
the Setup menu of the
clock.
Next display mode
Next display mode
Display mode SPEED/LAP Starts or stops the
Stops the current lap
time and saves it, and
the stop watch starts
the next lap.
The stop watch and the
lap time are reset.
(lap time)
clock.
Display mode
SPEED/ODO (odometer)
No function
No function
–
Next display mode
Display mode SPEED/TR1 No function
(trip master 1)
No function
The TR1, A1 and S1 dis- Next display mode
plays are reset to 0.0.
Display mode SPEED/TR2 Increases value of TR2.
(trip master 2)
Reduces value of TR2.
No function
Deletes value of TR2.
Next display mode
Display mode SPEED/A1
No function
The TR1, A1 and S1 dis- Next display mode
(average speed 1)
plays are reset to 0.0.
Display mode SPEED/A2
(average speed 2)
No function
No function
–
Next display mode
Display mode SPEED/S1
(stop watch 1)
No function
No function
Displays of TR1, A1 and Next display mode
S1 are reset to 0.0.
Display mode SPEED/S2
(stop watch 2)
Starts or stops S2.
No function
Displays of S2 and A2
are reset to 0.0.
Next display mode
Table of conditions and menu activation
Display
The motorcycle is
stationary
Menu can be acti-
vated
Display mode SPEED/H (service hours)
•
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CONTROLS
22
Table of conditions and menu activation
Display
The motorcycle is
stationary
Menu can be acti-
vated
Display mode SPEED/CLK (clock)
•
•
•
•
•
•
•
•
Display mode SPEED/LAP (lap time)
Display mode SPEED/TR1 (trip master 1)
Display mode SPEED/TR2 (trip master 2)
Display mode SPEED/A1 (average speed 1)
Display mode SPEED/A2 (average speed 2)
Display mode SPEED/S1 (stop watch 1)
Display mode SPEED/S2 (stop watch 2)
5
.29
The fuel tap is on the left of the fuel tank.
With tap handle on the fuel tap, you can open or close the supply of fuel to the car-
buretor.
Possible states
•
•
Fuel supply closed OFF – No fuel flows from the tank to the carburetor.
Fuel supply open ON – Fuel flows from the tank to the carburetor. The fuel tank
empties down to the reserve.
•
Reserve fuel supply open RES – Fuel flows from the tank to the carburetor. The
fuel tank empties completely.
500137-10
400199-10
400199-11
5
.30
–
Press release button , turn filler cap counterclockwise and lift it upwards and
remove.
5
.31
–
Replace the filler cap and turn clockwise until the release button locks in place.
Info
Route the fuel tank breather hose without kinking.
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CONTROLS
23
5
.32
hoke
Choke is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
•
•
Choke function activated – The choke lever is pulled out to the stop.
Choke function deactivated – The choke lever is pushed in to the stop.
500135-10
5
.33
hift lever
Shift lever is mounted on the left side of the engine.
500138-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
500138-11
5
.34
Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
500139-10
5
.35
The kick starter is fitted on the right of the engine.
The engine can be started with either the kick starter or the electric starter.
The upper part of the kick starter can be swung out.
Info
Before riding, swing the upper part of the kick starter inwards towards the
engine.
500148-10
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CONTROLS
24
5
.36
ide stand
Note
Danger of damageꢀThe parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Material damageꢀDamage and destruction of components by excessive load.
–
The side stand is designed for the weight of the motorcycle only. Do not sit on the
motorcycle when it is supported by the side stand only. The side stand and/or the
frame could be damaged and the motorcycle could fall over.
500140-10
To park the motorcycle, press side stand to the ground with your foot and lean the
motorcycle on it.
When you are riding, side stand must be folded up and secured with rubber
band .
500141-10
5
.37
teering lock
Steering lock is fitted on the left side of the steering head.
The steering lock is used to lock the steering. Steering, and therefore riding, is no
longer possible.
500126-10
5
.38
Note
Danger of damageꢀThe parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
–
–
Park the vehicle.
Turn the handlebar as far as possible to the right.
Insert the key in the steering lock, turn it to the left, press it in and turn it to the
right. Remove the key.
Steering is no longer possible.
Info
Never leave the key in the steering lock.
400732-01
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
26
6
.1
dvice on first use
Danger
Danger of accidentsꢀDanger arising from the rider's judgement being impaired.
–
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injuryꢀMissing or poor protective clothing present an increased safety risk.
–
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashingꢀPoor vehicle handling due to different tire tread patterns on front and rear wheels.
–
The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidentsꢀCritical riding behavior due to inappropriate riding.
–
Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidentsꢀAccident risk caused by presence of a passenger.
–
Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidentsꢀFailure of brake system.
–
If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidentsꢀUnstable riding behavior.
–
Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriationꢀUsage by unauthorized persons.
–
Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
–
Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
Before your first trip, read the entire operating instructions carefully.
Get to know the controls.
–
–
–
–
–
–
–
x
Adjust the basic position of the shift lever.
Adjust the basic position of the foot brake lxever.
Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Off-road, you should be accompanied by another person on another machine so that you can help each other.
–
–
–
–
Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
Do not make any off-road trips that over-stress your ability and experience.
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis-
tribution between the front and rear wheels.
Info
Motorcycles react sensitively to any changes of weight distribution.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
27
–
Do not exceed the overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight
Maximum permissible front axle load
Maximum permissible rear axle load
335 kg (739 lb.)
145 kg (320 lb.)
190 kg (419 lb.)
–
–
Info
The spoke tension must be checked after half an hour of operation.
Run-in the engine.
6
.2
unning-in the engine
–
During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first 3 service hours
Maximum engine performance
During the first 3 service hours
During the next 12 service hours
7,000 rpm
≤ 50 %
≤ 75 %
–
Avoid fully opening the throttle!
6
.3
reparing vehicle for arduous riding conditions
–
Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.
Arduous riding conditions are:
–
–
–
–
–
6
.4
–
Check the radiator cap.
Value on radiator cap
1.8 bar (26 psi)
»
If the displayed value does not correspond to specifications:
Warning
Danger of scaldingꢀDuring motorcycle operation, the coolant gets
very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
600872-10
–
Change the radxiator cap.
–
–
Seal the air filter box.
Tip
Seal the air filter box on the edges against dirt.
Clean the air filter.
x
Info
Check the air filter approx. every 30 minutes.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
28
–
Fit a dust protection device on the air filter.
Dust protection device for air filter (59006019000)
Info
See the KTM PowerParts fitting instructions.
600869-01
–
–
Fit a sand screen device on the air filter.
Sand protection device for air filter (59006022000)
Info
See the KTM PowerParts fitting instructions.
Adjust the carburetor jetting and settings.
Info
600871-01
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
–
–
Clean the chain.
Fit the steel sprocket.
Tip
Do not grease the chain.
–
–
Clean radiator fins.
Straighten bent radiator fins carefully.
600868-01
6
.5
–
Check the radiator cap.
Value on radiator cap
1.8 bar (26 psi)
»
If the displayed value does not correspond to specifications:
Warning
Danger of scaldingꢀDuring motorcycle operation, the coolant gets
very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
600872-10
–
Change the radxiator cap.
–
–
Seal the air filter box.
Tip
Seal the air filter box on the edges against dirt.
Clean the air filter.
x
Info
Check the air filter approx. every 30 minutes.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
29
–
Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
–
Adjust the carburetor jetting and settings.
Info
600870-01
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
–
–
Clean the chain.
Fit the steel sprocket.
Tip
Do not grease the chain.
–
–
Clean radiator fins.
Straighten bent radiator fins carefully.
600868-01
6
.6
reparing for riding on wet and muddy surfaces
–
Seal the air filter box.
x
Tip
Seal the air filter box along the edges to prevent the ingress of dirt.
–
–
Clean the air filter.
x
Info
Check the air filter approx. every 30 minutes.
Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
–
Adjust the carburetor jetting and settings.
Info
600870-01
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
–
–
–
Fit the steel sprocket.
Straighten bent radiator fins carefully.
600868-01
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
30
6
.7
–
Check the radiator cap.
Value on radiator cap
1.8 bar (26 psi)
»
If the displayed value does not correspond to specifications:
Warning
Danger of scaldingꢀDuring motorcycle operation, the coolant gets
very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
600872-10
–
Change the radxiator cap.
–
–
–
Seal the air filter box.
Tip
Seal the air filter box on the edges against dirt.
Clean the air filter.
x
Info
Check the air filter approx. every 30 minutes.
Adjust the secondary drive to the road conditions.
Info
The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.
–
Clean the chain.
–
–
–
Clean radiator fins.
600868-01
Straighten bent radiator fins carefully.
6
.8
reparing for rides at low temperatures or in snow
–
Seal the air filter box.
x
Tip
Seal the air filter box on the edges against dirt.
–
–
Clean the air filter.
x
Info
Check the air filter approx. every 30 minutes.
Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
–
Adjust the carburetor jetting and settings.
Info
600870-01
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
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RIDING INSTRUCTIONS
31
7
.1
hecks before putting into operation
Info
Make sure that the motorcycle is in a perfect technical condition before use.
Info
In the interests of riding safety, make a habit of making a general check before you ride.
–
–
–
–
–
–
–
–
–
–
–
–
–
Check the brake system function.
Check the settings of all controls and ensure that they can be operated smoothly.
Check the functioning of the electrical equipment.
7
.2
tarting
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failureꢀHigh engine speeds in cold engines have a negative effect on the service life of the engine.
–
Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause may be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
Motorcycle has been out of use for more than 1xweek
–
Empty the carburetor float chamber.
–
Fuel can flow from the fuel tank to the carburetor.
Raise the motorcycle off of the stand and secure the stand with rubber band .
Shift transmission to neutral.
–
–
–
–
Turn the key in the ignition switch to the position
Turn the emergency OFF switch to the position
.
.
The engine is cold
Pull choke lever out as far as possible.
–
100842-10
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RIDING INSTRUCTIONS
32
–
Press the electric starter button or press the kickstarter robustly through its full
range.
Info
Do not rev up.
400733-01
7
.3
tarting up
Info
If your bike has lights, switch them on before riding. You will then be seen earlier by other motorists.
When you are riding, the side stand must be folded up and secured with the rubber band.
–
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
7
.4
hifting, riding
Warning
Danger of accidentsꢀIf you change down at high engine speed, the rear wheel can lock up.
–
Do not change into a low gear at high engine speed. The engine overspeeds and the rear wheel can block.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
–
When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
–
–
If the choke function was activated, deactivate it after the engine has warmed up.
When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces
vehicle speed but lowers fuel consumption considerably.
–
–
–
–
Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.
To shift down, brake and close the throttle at the same time.
Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
Switch off the engine if you expect to be stationary for a long time.
Guideline
≥ 2 min
–
–
Avoid frequent and prolonged slipping of the clutch. This causes heat build-up in the engine oil, the engine and the cooling sys-
tem.
Ride at lower engine speeds instead of high revs and a slipping clutch.
7
.5
raking
Warning
Danger of accidentsꢀIf you brake too hard, the wheels can lock.
–
Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidentsꢀReduced braking efficiency caused by spongy pressure point of front or rear brake.
–
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidentsꢀReduced braking efficiency due to wet or dirty brakes.
–
Clean or dry dirty or wet brakes by riding and braking gently.
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RIDING INSTRUCTIONS
33
–
–
–
On sandy, wet or slippery surfaces, use the rear brake.
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to brake far less and the brakes do not overheat.
7
.6
topping, parking
Warning
Risk of misappropriationꢀUsage by unauthorized persons.
–
Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Warning
Danger of burnsꢀSome vehicle components get very hot when the vehicle is in use.
–
Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
Note
Danger of damageꢀThe parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazardꢀSome 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.
Note
Material damageꢀDamage and destruction of components by excessive load.
–
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side
stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
–
–
–
–
–
Brake the motorcycle.
Shift transmission to neutral.
Turn the key in the ignition switch to the position while the engine is idling.
Park the motorcycle on firm ground.
7
.7
efueling
Danger
Fire hazardꢀFuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoningꢀFuel is poisonous and a health hazard.
–
Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazardꢀImproper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
–
–
Switch off engine.
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RIDING INSTRUCTIONS
34
–
–
Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of
35 mm (1.38 in)
Total fuel tank
capacity, approx.
9.2 l
(2.43 US gal)
Super unleaded (ROZ 95 / RON 95 /
A
400382-10
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SERVICE SCHEDULE
35
8
.1
S3N
•
S15A
S30A
Engine
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Change the engine oil and oil filter and clean the engine oil screen.
x
•
Change the gear oil and clean the gear oil screen.
Replace spark plug.
x
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the valve clearance.
Check engine mounting screws for tightness.
Clean spark plug connectors and check for tightness.
x
Check that the screws in the shift lever and the kickstarter are tight.
Check carburetor connection boots for cracks and leakage.
Check vent hoses for damage and routing without sharp bends.
Check idle.
Carburetor
•
•
•
•
Attachments
Check the cooling system for leakage.
Check the exhaust system for leakage and looseness.
Check the cables for damage, smooth operation and routing without sharp bends.
•
•
•
Clean the air filter.
x
Check cables for damage and routing without sharp bends.
Check that the electrical equipment is functioning properly.
•
Brakes
•
•
•
•
•
•
•
•
•
•
•
Check brake lines for damage and leakage.
Check brake system function.
Check shock absorber and fork for leakage and functioning.
Check screws and guide bolts of brake system for tightness. x
suspension
Check the frame and swingarm for damage.
Check the swingarm bearing.
x
Check all screws to see if they are tight.
Check the wheel hubs for damage.
Check rim run-out.
•
•
•
Wheels
•
•
•
•
•
•
•
•
Check the wheel bearing for play.
x
Clean and grease adjusting screws of chain adjuster.
S3N: Once after 3 operating hours
S15A: Every 15 operating hours/after every race
S30A: Every 30 operating hours
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SERVICE SCHEDULE
36
8
.2
Competition use
Hobby use
S60A
S15N
S45A
J1A
S15A
S30A
S45A
S30A
S90A
•
•
Perform a fork service.
x
•
•
x
Perform a shock absorber service. x
•
•
•
•
•
•
Grease the steering head bearing.
Treat electric contacts with contact spray.
x
Change the hydraulic clutch fxluid.
Change the front brake fluid.x
Change the rear brake fluxid.
Clean the spark arrestor.
•
•
•
•
•
•
•
•
x
Check the clutch.
Check wear of clutxch discs.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
x
Change the piston.
Check the camshaft.
Change the camshaft bearing.
Check the valve spring seat.
Check/measure the xcylinder.
x
x
x
Check the cylinder head.
Check the valves.
Check the valve springs.
x
x
x
Check txhe radial clearance of the rocker arm
•
•
rollers.
Check the timing-chain tensioner function.
Check the balancer shaft.
Check the crankshaft run-out at the bearing
pin.
Change the connecting rod, conrod bearing and
crank pin.
•
•
•
•
x
x
•
•
•
•
x
x
•
•
•
•
•
•
x
Check the transmission.
Check the shift mechanism.
Change the crankshaft mxain bearing.
x
Check the sxpring length of the oil pressure regu-
Change gxlass fiber yarn filling of main
•
•
lator valve.
•
•
silencer.
Replace foot brake cylinder seals.
Check/adjust the carburetor components.
•
•
•
•
x
•
x
S15A: Every 15 operating hours/after every race
S30A: Every 30 operating hours
S45A: Every 45 operating hours
S60A: Every 60 operating hours
S90A: Every 90 operating hours
S15N: Once after 15 operating hours
J1A: Annually
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SERVICE SCHEDULE
37
8
.3
NB1A
Check and adjust the cables.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Clean the air filter.
Empty the carburetor float chamber.
Check all controls for smooth operation.
Check braking.
x
Check all screws, nuts and hose clamps regularly for tightness.
NB1A: Depending on conditions of use according to requirements.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
38
9
.1
Note
Danger of damageꢀThe parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
–
Jack up the motorcycle underneath the engine. The wheels should no longer touch
the ground.
Work stand (54829055000)
Secure the motorcycle against falling over.
500074-01
9
.2
Note
Danger of damageꢀThe parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
–
Remove the motorcycle from the work stand.
Remove the work stand.
9
.3
hecking the basic suspension setting with the rider's weight
Info
When adjusting the basic suspension setting, first adjust the shock absorber and then the fork.
–
–
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic set-
tings of the suspension components must match your body weight.
As delivered, KTM off-road motorcycles are adjusted for a standard rider weight (with full protective clothing).
Guideline
Standard rider weight
75… 85 kg (165… 187 lb.)
–
–
If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accord-
ingly.
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the
springs must be replaced.
9
.4
ompression damping of shock absorber
The shock absorber can regulate compression damping separately in the low-speed and high-speed ranges (Dual Compression Control).
The terms low-speed and high-speed refers to the movement of the shock absorber during compression and not to the riding speed of
the motorcycle.
Changes in the settings in the low-speed range have an impact on the high-speed range and vice versa.
9
.5
djusting the high-speed compression damping of the shock absorber
Danger
Danger of accidentsꢀDisassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
39
–
Turn adjusting screw clockwise with a socket wrench until it stops.
Info
Do not loosen nut !
–
Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
400208-10
Comfort
Standard
Sport
2 turns
1.5 turns
1.25 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
9
.6
djusting the low-speed compression damping of the shock absorber
Danger
Danger of accidentsꢀDisassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
–
Turn adjusting screw clockwise with a screwdriver up to the last perceptible
click.
Info
Do not loosen nut !
–
Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
400209-10
Compression damping, low-speed
Comfort
Standard
Sport
22 clicks
20 clicks
15 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
9
.7
djusting rebound damping of the shock absorber
Danger
Danger of accidentsꢀDisassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
40
–
Turn adjusting screw clockwise up to the last perceptible click.
Info
Do not loosen nut !
–
Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
400210-10
Comfort
Standard
Sport
26 clicks
24 clicks
22 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
9
.8
easuring rear wheel sag unloaded
–
–
Measure the distance – as vertical as possible – between the rear axle and a fixed
point, for example, a mark on the side cover.
–
–
Make a note of the value as measurement .
0A
400220-10
9
.9
hecking static sag of shock absorber
–
–
–
–
Ask someone to help you by holding the motorcycle upright.
Measure the distance between the rear axle and the fixed point again.
Make a note of the value as measurement .
0A
Info
The static sag is the difference between measurements and .
–
Check the static sag.
Static sag
35 mm (1.38 in)
»
If the static sag is less or more than the specified value:
–
Adjust the spring preload of the shock absorber.
x
0B
400221-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
41
9
.10
hecking riding sag of shock absorber
–
–
With the help of another person holding the motorcycle, the rider, wearing com-
plete clothing, sits on the motorcycle in a normal position (feet on footrests) and
rocks up and down a few times so that the rear wheel suspension levels out.
0A
–
–
The other person now has to measure the distance between the rear axle and a
fixed point.
Make a note of the value as measurement .
Info
The riding sag is the difference between measurements and .
–
Check the riding sag.
Riding sag
105 mm (4.13 in)
»
If the riding sag differs from the specified measurement:
C
–
Adjust the riding sag.
x
400222-10
9
.11
djusting spring preload of the shock absorber
x
Danger
Danger of accidentsꢀDisassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
–
Remove shock absorber.
x
–
–
–
After removing the shock absorber, clean it thoroughly.
Unscrew screw .
Turn adjusting ring until the spring is no longer under tension.
2
Combination wrench (50329080000)
Hook wrench (T106S)
1
A
–
–
Measure the overall spring length when not under tension.
Tighten the spring by turning adjusting ring to measurement .
Guideline
Spring preload
9 mm (0.35 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
–
–
Tighten screw .
Guideline
Screw, shock absorber adjusting ring
M6
5 Nm (3.7 lbf ft)
Install the shock absorber.
x
400216-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
42
9
.12
djusting riding sag
x
–
–
–
Remove shock absorber.
x
After removing the shock absorber, clean it thoroughly.
Choose and fit a suitable spring.
Guideline
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)
Weight of rider: 75… 85 kg (165… 187 lb.)
Weight of rider: 85… 95 kg (187… 209 lb.)
69 N/mm (394 lb/in)
72 N/mm (411 lb/in)
76 N/mm (434 lb/in)
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.
–
–
–
–
x
9
.13
emoving the shock absorber
x
–
–
Remove screw and lower the rear wheel with the swing arm as far as possible
without blocking the rear wheel. Fix the rear wheel in this position.
–
Remove screw , push splash protector to the side, and remove the shock
absorber.
800023-10
9
.14
nstalling the shock absorber
x
–
–
Push splash protector to the side and position the shock absorber. Mount and
tighten screw .
Guideline
Screw, top shock absorber M12
80 Nm
(59 lbf ft)
Loctite® 243™
Loctite® 243™
Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M12
80 Nm
(59 lbf ft)
800023-11
Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
43
9
.15
hecking basic setting of fork
Info
For various reasons, no exact riding sag can be determined for the forks.
–
–
As with the shock absorber, smaller weight differences can be compensated by the
spring preload.
However, if your fork is often overloaded (hits the bump stops on compression), it is
recommended to fit stiffer springs to avoid damage to the fork and frame.
400189-01
9
.16
djusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
–
–
Remove protection covers .
Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make sure the setting is identical on both fork legs.
–
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
100020-10
Compression damping
Comfort
Standard
Sport
26 clicks
22 clicks
18 clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
–
Mount protection covers .
9
.17
Info
The hydraulic rebound damping determines the fork suspension behavior.
–
Turn adjusting screws clockwise until they stop.
Info
The adjusting screws are located at the top end of the fork legs.
Make sure the setting is identical on both fork legs.
–
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
800017-10
Comfort
Standard
Sport
24 clicks
20 clicks
20 clicks
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MAINTENANCE WORK ON CHASSIS AND ENGINE
44
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
9
.18
djusting spring preload of the fork
–
–
Turn adjusting screws counterclockwise until they stop.
Info
Make sure the setting is identical on both fork legs.
Turn back clockwise by the number of turns corresponding to the fork type.
Guideline
Spring preload - Preload Adjuster
Comfort
Standard
Sport
0 turn
800015-10
2 turns
4 turns
Info
Turn clockwise to increase spring preload, turn counterclockwise to reduce
spring preload.
Adjusting the spring preload has no influence on the absorption setting of
the rebound damping.
Basically, however, you should set the rebound damping higher with a
higher spring preload.
9
.19
leeding fork legs
–
–
Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
Mount and tighten bleeder screws.
–
–
100021-10
9
.20
leaning the dust boots of the fork legs
–
–
–
Push dust boots of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, there is an ingress of dirt inside the boots. If this dirt is
not removed, it may cause the oil seals to leak.
Warning
Danger of accidentsꢀReduced braking efficiency due to oil or grease on the
brake discs.
500088-10
–
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–
–
Clean and oil the dust boots and inner fork tube of both fork legs.
Press the dust boots back into their normal position.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
45
–
–
–
Remove excess oil.
9
.21
–
–
–
Remove screws and remove the clamp.
Remove screws on the left fork leg. Push the fork protector downwards.
Remove the screws on the right fork leg. Push the fork protector downwards.
600875-11
9
.22
–
Position the fork protector on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
–
Position the brake line and wiring harness. Put the clamp on, and mount and
tighten screws .
Position the fork protector on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
600875-10
9
.23
hecking steering head bearing play
Warning
Danger of accidentsꢀUnstable vehicle handling from incorrect steering head bearing play.
–
Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
Info
If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can
be damaged after time.
–
–
Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
»
If there is noticeable play present:
–
Adjust play of the steering head bearing.
x
–
–
Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
400387-10
»
If click positions are noticeable:
–
Adjust play of the steering head bearing.
x
–
Check the steering head bearing and replace if required.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
46
9
.24
djusting play of steering head bearing
x
–
–
–
Loosen screw . Remove screw .
Loosen and retighten screw .
Guideline
Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
–
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Fully tighten screw .
Guideline
Screw, top triple clamp
M8
17 Nm
800022-10
(12.5 lbf ft)
–
–
Mount and tighten screw .
Guideline
Screw, top steering stem
M8
17 Nm
(12.5 lbf ft)
Loctite® 243™
9
.25
emoving the fork legs
x
–
–
–
–
Remove front wheel.
x
Remove screws and remove the clamp.
Remove cable clip , remove screw and remove the brake caliper.
Allow the brake caliper and brake line to hang tension-free to the side.
100802-10
–
–
Unscrew screws . Take out the left fork leg.
Unscrew screws . Take out the right fork leg.
100803-10
9
.26
nstalling fork legs
x
–
Position the fork legs.
Info
The topmost milled groove in the fork leg must be flush to the upper edge of
the upper triple clamp.
Position bleeder screws toward the front.
100021-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
47
–
Fully tighten screw .
Guideline
Screw, top triple clamp
M8
M8
17 Nm
(12.5 lbf ft)
–
Tighten screws .
Guideline
Screw, bottom triple clamp
12 Nm (8.9 lbf ft)
100803-11
–
Position brake caliper, mount and tighten screws .
Guideline
Screw, front brake caliper
M8
25 Nm
Loctite® 243™
(18.4 lbf ft)
–
–
Mount cable clip .
Position the brake line and wiring harness. Put the clamp on, mount and tighten
screws .
–
Install the front wheel.
x
100802-11
9
.27
emoving the fork protector
x
–
–
–
Remove the fork legs.
x
Remove screws on the left fork leg. Remove the fork protector upwards.
Remove the screws on the right fork leg. Remove the fork protector upwards.
600878-10
9
.28
nstalling the fork protector
x
–
–
–
Position the fork protection on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Install the fork legs.
x
600878-10
9
.29
emoving the lower triple clamp
x
–
–
–
–
Remove the fork legs.
x
Remove screws and hang the CDI control unit to the side.
Info
Do not unplug the CDI control unit.
–
Remove screw . Remove screw , take off top triple clamp with the handlebar
and place it on one side.
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
500099-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
48
–
–
–
Remove o-ring . Remove protector ring .
Remove the lower triple clamp with the steering stem.
Remove the upper steering head bearing.
500100-10
9
.30
nstalling the lower triple clamp
x
–
–
Clean the bearing and sealing elements, check for damage, and grease.
Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
03
02
01
Info
Check whether the top steering head seal is correctly positioned.
–
Push up protective ring and o-ring .
500098-10
–
–
Position the upper triple clamp with the steering.
Mount and tighten screw .
Guideline
Screw, top steering head
M20x1.5
10 Nm (7.4 lbf ft)
–
Position the clutch line, wiring harness and CDI control unit. Mount and tighten
screws .
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
500099-11
–
–
–
–
x
Mount and tighten screw .
Guideline
Screw, top steering stem
M8
17 Nm
Loctite® 243™
(12.5 lbf ft)
–
–
Check the cable harness, cable, brake and clutch line for free movement and free
laying.
500103-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
49
9
.31
reasing the steering head bearing
x
–
–
x
Install the lower triple clamp.
Remove the lower triple clampx.
800010-10
600692-10
600692-10
9
.32
–
–
Remove screws . Remove the front fender.
Make sure the spacers remain in place.
9
.33
–
–
Ensure that the spacers are mounted in the fender.
Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the start number plate or headlight
mask.
9
.34
–
Switch off all electrical equipment.
–
–
Remove screw and take off clamp.
Loosen the rubber band . Push up the headlight mask and swing it forwards.
600703-10
–
Pull out the electric plug connector and remove the headlight mask with the
headlight.
600702-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
50
9
.35
–
Connect the electric plug connector .
600702-11
–
Position the headlight mask and fix it with the rubber band .
Info
Ensure that the retaining lugs engage in the fender.
–
–
Position the brake line and wiring harness. Put the clamp on, mount and tighten
screw .
600703-11
9
.36
andlebar position
On the upper triple clamp, there are 2 holes at a distance of to each other.
Distance between holes 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of from the center.
Distance between holes 3.5 mm (0.138 in)
The handlebar supports can be mounted in 4 different positions.
0A
0B
400271-11
9
.37
djusting the handlebar position
x
Warning
Danger of accidentsꢀHandlebar breakage.
–
If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-
bar.
–
Remove the four screws . Remove the handlebar clamp. Remove the handlebar
and lay it to one side.
01
02
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
–
–
Remove the two screws . Remove the handlebar support.
Place the handlebar support in the required position. Mount and tighten the two
screws .
400271-10
Guideline
Screw, handlebar support
M10
40 Nm
Loctite® 243™
(29.5 lbf ft)
Info
Position evenly the left and right handlebar supports.
–
Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
51
–
Position the handlebar clamp. Mount and evenly tighten the four screws .
Guideline
Screw, handlebar clamp
M8
20 Nm
(14.8 lbf ft)
Info
Make sure the gap width is even.
9
.38
–
The two throttle cables must run parallel behind the handlebar down to the frame.
They must be routed directly to the right of the frame above the tank bracket
towards the carburetor.
500152-10
9
.39
hecking the play in the throttle cable
–
Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Play in throttle cable
3… 5 mm (0.12… 0.2 in)
»
If the throttle cable play does not meet sxpecifications:
–
Adjust the play in the throttle cable.
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
400192-10
–
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–
Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
»
If the idle speed changes:
–
Adjust the play in the throttle cable.
x
9
.40
djusting the play in the throttle cable
x
–
–
–
–
–
–
Remove the fuel tank.
x
Move the handlebar to the straight-ahead position.
Push back bellows .
Loosen nut . Turn adjusting screw in as far as possible.
Loosen nut . Turn adjusting screw so that there is play in the gas throttle
cable at the throttle grip.
Guideline
Play in throttle cable
3… 5 mm (0.12… 0.2 in)
–
–
Tighten nut .
500153-10
Press and hold the throttle grip in the closed setting. Turn adjusting screw out
until there is no play in the throttle cable .
–
–
–
–
Tighten nut .
Push bellows on. Check the throttle grip for smooth operation.
Install the fuel tank.
x
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MAINTENANCE WORK ON CHASSIS AND ENGINE
52
9
.41
hecking for chain dirt accumulation
–
Check the chain for coarse dirt accumulation.
If the chain is very dirty:
»
–
400678-01
9
.42
leaning the chain
Warning
Danger of accidentsꢀOil or grease on the tires reduces their grip.
Remove oil and grease with a suitable cleaning material.
–
Warning
Danger of accidentsꢀReduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
–
Clean the chain regularly and then treat with chain spray.
400725-01
9
.43
hecking the chain tension
Warning
Danger of accidentsꢀDanger caused by incorrect chain tension.
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
–
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–
–
Push the chain up at the rear edge of the chain guide to measure the chain ten-
sion .
Info
The upper chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
8… 10 mm (0.31… 0.39 in)
400213-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
53
»
If the chain tension does not meet specifications:
–
–
9
.44
hecking chain tension when fitting rear wheel
Warning
Danger of accidentsꢀDanger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–
–
Make sure that the chain adjusters are fitted correctly on the adjusting screws.
Push the chain up at the rear edge of the chain guide to measure the chain ten-
sion .
Info
The upper chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
If the chain tension does not meet specifications:
8… 10 mm (0.31… 0.39 in)
400213-10
»
–
9
.45
–
Check rear sprocket/engine sprocket for wear.
If the rear sprocket / engine sprocket are worn:
»
–
Replace the rear sprocket/engine sprocket.
Info
When fitting the split link, always make sure that the closed side of
the locking clip faces forward (riding direction).
The engine sprocket, rear sprocket and chain should always be
replaced together.
400227-01
–
Check the chain guide for tightness and wear.
9
.46
hecking chain wear
–
–
–
Shift transmission to neutral.
Pull on the upper part of the chain with the specified weight .
Guideline
Weight of chain wear measurement
10… 15 kg (22… 33 lb.)
0A
–
Measure the distance of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance at the longest
272 mm (10.71 in)
chain section
»
If the distance is greater than the specified measurement:
–
Replace the chain.
B
0
Info
When you replace the chain, you should also replace rear sprocket
and engine sprocket.
New chains wear out faster on old, worn sprockets.
1 2 3
16 1741008226-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
54
–
9
.47
djusting chain tension
Warning
Danger of accidentsꢀDanger caused by incorrect chain tension.
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
–
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–
–
Push the chain up at the rear edge of the chain guide to measure the chain ten-
sion .
Info
The upper chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
400213-10
–
–
–
Loosen nut .
Loosen nuts .
Adjust the chain tension by turning the adjusting screws left and right.
Guideline
Chain tension
8… 10 mm (0.31… 0.39 in)
Turn adjusting screws on the left and right so that the markings on the left
and right chain adjusters are in the same position relative to the reference
marks . The rear wheel is then correctly aligned.
–
–
–
Tighten nuts .
Make sure that chain adjusters are fitted correctly on adjusting screws .
Tighten nut .
Guideline
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
Chain adjusters can be turned by 180°.
400225-10
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
55
9
.48
djusting chain tension - after checking
–
–
–
Loosen nut .
Loosen nuts .
Adjust the chain tension by turning the adjusting screws left and right.
Guideline
Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.
–
–
Tighten nuts .
Make sure that the chain adjusters are fitted correctly on the adjusting
screws .
–
Tighten nut .
Guideline
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters can be turned by 180°.
400225-13
9
.49
djusting chain tension - fitting rear wheel
–
–
Loosen nuts .
Adjust the chain tension by turning the adjusting screws left and right.
Guideline
Chain tension
8… 10 mm (0.31… 0.39 in)
Turn the adjusting screws left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks .
The rear wheel is then correctly aligned.
–
Tighten nuts .
400225-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
56
9
.50
djusting chain guide
x
–
Remove screws and . Take off the chain guide.
Condition
Number of teeth: ≤ 44 teeth
–
–
Insert nut in hole . Position the chain guide.
Mount and tighten screws and .
Guideline
Remaining screws, chassis
M6
10 Nm
(7.4 lbf ft)
Condition
Number of teeth: ≥ 45 teeth
–
–
Insert nut in hole . Position the chain guide.
Mount and tighten screws and .
Guideline
Remaining screws, chassis
M6
10 Nm
(7.4 lbf ft)
400252-10
9
.51
hecking brake discs
Warning
Danger of accidentsꢀReduced braking efficiency due to worn brake disc(s).
Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
–
–
Check the thickness of the front and rear brake discs at several places on the disk
to see if it conforms to measurement .
Info
A
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit
Front
Rear
2.5 mm (0.098 in)
3.5 mm (0.138 in)
400257-10
»
If the brake disc thickness is less than the specified value:
Change the brake disc.
Check the front and rear brake discs for damage, cracking and deformation.
If the brake disc shows signs of damage, cracking or deformation:
Change the brake disc.
–
–
»
–
9
.52
hecking free travel of hand brake lever
Warning
Danger of accidentsꢀBrake system failure.
–
If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due
to overheating. Adjust free travel on hand brake lever according to specifications.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
57
–
Push the hand brake to the handlebar and check free travel .
Free travel of hand brake lever ≥ 3 mm (≥ 0.12 in)
If the free travel does not meet specifications:
»
–
400196-13
9
.53
–
–
Adjust the free travel of the hand brake lever with adjusting screw .
Info
Turn the adjustment screw clockwise to reduce free travel. The pressure
point moves away from the handlebar.
Turn the adjustment screw counterclockwise to increase free travel. The
pressure point moves towards the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
400196-12
9
.54
hecking the brake fluid level of the front brake
Warning
Danger of accidentsꢀFailure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidentsꢀReduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
–
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Check the brake fluid level in viewer .
»
If the brake fluid is below the MIN mark:
–
Top up the brake fluid of the front brake.
x
400231-10
9
.55
opping up the front brake fluid
x
Warning
Danger of accidentsꢀFailure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritationꢀBrake fluid can cause skin irritation on contact.
–
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
58
Warning
Danger of accidentsꢀReduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!
–
–
–
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws .
Remove cover with membrane .
Add brake fluid to level .
Guideline
Measurement of
5 mm (0.2 in)
–
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
100820-10
9
.56
Warning
Danger of accidentsꢀReduced braking efficiency caused by worn brake linings.
–
Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
–
–
Check the brake linings for minimum thickness .
Minimum thickness
≥ 1 mm (≥ 0.04 in)
»
–
Change the front brake linings.
If the minimum thickness is less thxan specified:
Check the brake linings for damage and cracking.
»
If damage or cracking is visible:
–
Change the front brake linings.
x
100394-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
59
9
.57
hanging the front brake linings
x
Warning
Danger of accidentꢀBrake system failure.
Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
–
Warning
Skin irritationꢀBrake fluid can cause skin irritation on contact.
–
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsꢀReduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Danger of accidentsꢀReduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsꢀReduced braking efficiency due to use of non-approved brake linings.
–
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!
–
–
–
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws .
Remove cover with membrane .
Press the brake caliper by hand on to the brake disc in order to press back the
brake pistons. Ensure that brake fluid does not overflow from the brake fluid reser-
voir, using suction to remove it if it does.
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
100395-10
–
–
Remove locking split pins , withdraw bolt , and take out the brake pads.
Clean brake caliper and brake caliper support.
100396-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
60
–
Check that anti-squeal shim in the brake caliper and anti-rattle shim in the
brake caliper support are seated correctly.
7
0
6
0
100397-01
100398-10
100399-10
–
–
Fit the brake pads, insert the bolt, and mount the locking split pins.
Operate the hand brake lever repeatedly until the brake pads rest on the brake disc
and there is a noticeable pressure point.
–
–
Correct the brake fluid reservoir level to the marking .
Guideline
Measurement of
5 mm (0.2 in)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
9
.58
hecking the free travel of the foot brake lever
Warning
Danger of accidentsꢀBrake system failure.
–
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
–
–
Disconnect spring .
Move the foot brake lever backwards and forwards between the end stop and the
foot brake cylinder piston bracket and check free travel .
Guideline
Free travel at foot brake lever
3… 5 mm (0.12… 0.2 in)
»
If the free travel does not meet specifications:
–
Adjust the basic position of the foot brake lever.
x
–
Reconnect spring .
500139-11
9
.59
djusting the basic position of the foot brake lever
x
Warning
Danger of accidentsꢀBrake system failure.
–
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
61
–
–
Disconnect spring .
Loosen nut , and with push rod , turn it back until you have maximum free
travel.
–
To adjust the basic position of the foot brake lever individually, loosen nut and
turn screw accordingly.
Info
The range of adjustment is limited.
–
–
–
–
Turn push rod accordingly until you have free travel . If necessary, adjust the
basic position of the foot brake lever.
500154-10
Guideline
Free travel at foot brake lever
3… 5 mm (0.12… 0.2 in)
Hold screw and tighten nut .
Guideline
Remaining nuts, chassis
M8
M6
30 Nm
(22.1 lbf ft)
Hold push rod and tighten nut .
Guideline
Remaining nuts, chassis
15 Nm
(11.1 lbf ft)
Reconnect spring .
9
.60
Warning
Danger of accidentsꢀFailure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidentsꢀReduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
–
–
Stand the vehicle upright.
Check the brake fluid level in the sight glass .
»
If there is an air bubble in the sight glass xvisible:
–
Add brake fluid to the rear brake circuit.
400234-10
9
.61
dding brake fluid to the rear brake circuit
x
Warning
Danger of accidentsꢀFailure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritationꢀBrake fluid can cause skin irritation on contact.
–
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
62
Warning
Danger of accidentsꢀReduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
–
–
–
Stand the vehicle upright.
Remove screw cap with membrane and the O-ring.
Add brake fluid to level .
–
Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400233-10
9
.62
hecking rear brake linings
Warning
Danger of accidentsꢀReduced braking efficiency caused by worn brake linings.
–
Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
–
Check the brake linings for minimum thickness .
Minimum thickness
≥ 1 mm (≥ 0.04 in)
»
If the minimum thickness is less than specified:
–
Change the rear brake linings.
x
–
Check the brake linings for damage and cracking.
»
If damage or cracking is visible:
–
Change the rear brake linings.
x
400238-10
9
.63
hanging rear brake linings
x
Warning
Danger of accidentꢀBrake system failure.
Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
–
Warning
Skin irritationꢀBrake fluid can cause skin irritation on contact.
–
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsꢀReduced braking effect caused by old brake fluid.
–
Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
63
Warning
Danger of accidentsꢀReduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsꢀReduced braking efficiency due to use of non-approved brake linings.
–
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!
–
–
–
Stand the vehicle upright.
Remove screw cap with membrane and the O-ring.
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
100807-10
100808-10
100407-10
100408-01
–
–
Remove locking split pins , withdraw bolt , and take out the brake pads.
Clean brake caliper and brake caliper support.
–
Check that anti-squeal shim in the brake caliper and anti-rattle shim in the
brake caliper support are seated correctly.
–
–
Fit the brake pads, insert the bolt, and mount the locking split pins.
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a noticeable pressure point.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
64
–
Correct the brake fluid reservoir level to the marking .
–
Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400233-10
9
.64
emoving front wheel
x
–
–
Press the brake caliper by hand on to the brake disc in order to press back the
brake pistons.
Info
Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.
100809-01
500084-10
500085-10
500086-10
–
–
Remove screw .
Loosen screw .
–
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Do not operate the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
–
Remove spacers .
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MAINTENANCE WORK ON CHASSIS AND ENGINE
65
9
.65
nstalling the front wheel
x
Warning
Danger of accidentsꢀReduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
–
–
Clean and grease shaft seal rings and bearing surface of the spacers.
Insert the spacers.
500086-11
–
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
Mount and tighten screw .
Guideline
Screw, front wheel spindle
M24x1.5
45 Nm
(33.2 lbf ft)
–
Operate the hand brake lever several times until the brake linings are lying correctly
on the brake disc.
–
–
500084-11
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
–
Fully tighten screw .
Guideline
Screw, fork stub
M8
15 Nm
(11.1 lbf ft)
9
.66
emoving the rear wheel
x
–
–
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
–
–
Remove nut .
Remove chain adjuster . Withdraw wheel spindle only enough to allow the rear
wheel to be pushed forward.
–
–
Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
400258-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
66
–
Remove spacers .
400260-11
9
.67
nstalling the rear wheel
x
Warning
Danger of accidentsꢀReduced braking efficiency due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
–
–
–
Clean and grease shaft seal rings and bearing surface of the spacers.
Insert the spacers.
400260-10
–
–
Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
Put the chain on.
400259-10
–
–
–
Position the chain adjuster . Mount nut , but do not tighten it yet.
Make sure that the chain adjusters are fitted correctly on the adjusting
screws .
–
Tighten nut .
Guideline
Nut, rear wheel spindle
M20x1.5
80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters can be turned by 180°.
–
–
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.
400225-12
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MAINTENANCE WORK ON CHASSIS AND ENGINE
67
9
.68
ire condition checking
Info
Only mount tires approved or recommended by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
–
–
Examine the front and rear tires for cuts, foreign bodies and other damage.
If you find cuts, foreign bodies or other damage on a tire:
Change the tires.
»
–
Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth
If the tread depth is less than the minimum allowable depth:
Change the tires.
≥ 2 mm (≥ 0.08 in)
400602-10
»
–
–
Check the age of the tires.
Info
The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits refer
to the week of manufacture and last two digits refer to the year of manufac-
ture.
KTM recommends that the tires be changed after five years at the latest,
regardless of the actual state of wear.
»
If a tire is more than 5 years old:
–
Change the tires.
9
.69
hecking tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
–
–
Remove the dust cap.
Check tire air pressure when tires are cold.
Tire air pressure off road
Front
Rear
1.0 bar (15 psi)
1.0 bar (15 psi)
Road tire pressure
Front
Rear
1.5 bar (22 psi)
2.0 bar (29 psi)
400695-01
»
If the tire pressure does not meet specifications:
Correct the tire air pressure.
Fit the dust cap.
–
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
68
9
.70
hecking spoke tension
Warning
Danger of accidentsꢀInstable handling due to incorrect spoke tension.
–
Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
Info
A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
–
Tap each spoke with a screwdriver.
Info
The sound frequency depends on the length and thickness of the spoke.
If there are different sound frequencies in spokes with the same length and
thickness, this indicates different spoke tensions.
You should hear a high note.
»
If the spoke tension varies:
400694-01
–
Correct the spoke tension.
x
–
Check the spoke torque.
Guideline
Spoke nipple, front wheel
M4.5
M5
5… 6 Nm (3.7…
4.4 lbf ft)
Spoke nipple, rear wheel
5… 6 Nm (3.7…
4.4 lbf ft)
Torque wrench with various accessories in set (58429094000)
9
.71
emoving the battery
x
Warning
Risk of injuryꢀBattery acid and battery gases cause serious cauterization.
–
–
–
–
–
Keep batteries out of the reach of children.
Wear suitable protective clothing and goggles.
Avoid contact with battery acid and battery gases.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
–
–
–
–
Switch off all power-consuming components and switch off the engine.
Disconnect the negative (minus) cable of the battery.
Pull back the plus pole cover and disconnect the positive (plus) cable of the bat-
tery.
–
–
Hang the rubber band out to the bottom.
Lift the battery up.
500069-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
69
9
.72
nstalling the battery
x
–
Place the battery in the battery holder.
–
–
–
–
Reconnect the rubber band .
Attach the plus cable and replace the plus pole cover .
Attach the minus cable .
500069-11
9
.73
echarging the battery
x
Warning
Risk of injuryꢀBattery acid and battery gases cause serious cauterization.
–
–
–
–
–
Keep batteries out of the reach of children.
Wear suitable protective clothing and goggles.
Avoid contact with battery acid and battery gases.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Warning
Environmental hazardꢀBattery parts and acid are harmful to the environment.
–
Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
–
–
–
Switch off all consumers and the engine.
Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.
–
Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and cranking
power of the battery, and to test the generator. With this device, you cannot over-
charge the battery.
Info
Never remove the lid .
Charge the battery with at most 10% of the capacity specified on the bat-
tery .
400240-10
–
Switch off the charger after charging. Disconnect the battery.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
70
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
–
9
.74
emoving a fuse
–
–
–
Switch off all consumers and the engine.
Remove protective cover .
Info
The fuse is located in the starter relay under the filter box cover.
–
Remove the fuse .
400270-10
9
.75
nstalling the fuse
Warning
Fire hazardꢀThe electrical system can be overloaded by the use of incorrect fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
–
–
Insert the fuse.
Fuse (58011109110)
Info
A reserve fuse is located in the starter relay.
Replace a blown fuse only by an equivalent fuse.
–
–
Replace the protection cover.
400273-10
9
.76
hecking the headlight adjustment
–
–
On a light-colored wall behind a horizontal area, make a mark as high as the center
of the headlight.
0A
Make a second mark at distance of under the first mark.
Guideline
Distance
5 cm (2 in)
0B
–
–
Stand the motorcycle upright in front of the wall at distance . The driver, in full
protective clothing, should now sit on the motorcycle in a normal sitting position
(feet on the footrests).
400726-10
Guideline
Distance
5 m (16 ft)
Switch on low beam. Check the headlight adjustment.
The border between light and dark must be exactly at the lower mark when the
motorcycle is operational and complete with rider.
»
If the boundary between light and dark does not meet specifications:
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
71
9
.77
djusting the beam width of the headlight
–
–
–
Loosen screw .
Adjust the light range by swiveling the headlight.
Guideline
The boundary between light and dark must be exactly on the lower mark for a
motorcycle with a rider (mark is applied under: Checking the headlight adjust-
ment).
Info
If you have a payload, you may have to correct the headlight beam width.
301251-10
–
Tighten screw .
9
.78
emoving the seat
–
Remove screw . Lift up the seat at the rear, pull it back and then remove from
above.
500080-10
9
.79
ounting the seat
–
Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear
and simultaneously push it forward.
–
–
Make sure that the seat is correctly locked in.
Mount and tighten the screw of the seat fixing.
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
500068-01
9
.80
emoving the fuel tank
x
Danger
Fire hazardꢀFuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoningꢀFuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
–
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MAINTENANCE WORK ON CHASSIS AND ENGINE
72
–
–
Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
–
–
Remove screws with the collar sleeve.
Hang the horn and horn bracket to one side.
500157-10
800019-10
500067-10
–
–
Remove screw with the collar sleeve.
Remove the tube from the fuel tank vent line.
–
Pull both spoilers to the side of the radiator bracket and take the fuel tank away
upward.
9
.81
nstalling the fuel tank
x
Danger
Fire hazardꢀFuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoningꢀFuel is poisonous and a health hazard.
–
Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
–
–
Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
Make sure that no cables are trapped or damaged.
500067-01
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MAINTENANCE WORK ON CHASSIS AND ENGINE
73
–
–
Mount the fuel tank vent hose.
Mount and tighten screw with the collar sleeve.
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
–
Position the horn with the horn bracket.
800019-11
Mount and tighten screws with the collar sleeve.
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
–
Connect the fuel hose.
500157-11
9
.82
The water pump in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve
in the radiator cap . This ensures that operating the vehicle at the specified coolant
temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-
ing effect.
400335-10
9
.83
hecking the anti-freeze and coolant level
Warning
Danger of scaldingꢀDuring motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoningꢀCoolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
Engine is cold.
–
–
–
Stand the motorcycle upright on a horizontal surface.
Remove radiator cap.
Check the anti-freeze of the coolant.
−25… −45 °C (−13… −49 °F)
»
If the anti-freeze of the coolant does not meet specifications:
Correct the anti-freeze of the coolant.
–
–
Check the coolant level in the radiator.
400243-10
Coolant level above radiator fins.
10 mm (0.39 in)
»
If the level of the coolant does not meet specifications:
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MAINTENANCE WORK ON CHASSIS AND ENGINE
74
–
Correct the coolant level.
Alternative 1
Alternative 2
–
Refit the radiator cap.
9
.84
hecking the coolant level
Warning
Danger of scaldingꢀDuring motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoningꢀCoolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
–
–
–
Stand the motorcycle upright on a horizontal surface.
Remove radiator cap.
Check the coolant level in the radiator.
Coolant level above the radiator fins. 10 mm (0.39 in)
»
If the coolant level does not meet specifications:
–
Correct the coolant level.
Alternative 1
400243-10
Alternative 2
–
Mount the radiator cap.
9
.85
raining coolant
x
Warning
Danger of scaldingꢀDuring motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoningꢀCoolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
Engine is cold.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
75
–
–
–
–
–
Stand the motorcycle upright.
Place a suitable container under the water pump cover.
Remove screw . Remove the radiator cap .
Completely drain the coolant.
Fit screw with a new seal and tighten it.
Guideline
Screw, water pump cover
M6x25
10 Nm (7.4 lbf ft)
400335-11
9
.86
efilling coolant
x
Warning
Danger of poisoningꢀCoolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
–
–
–
Make sure that the screw is tightened.
Stand the vehicle upright.
Pour coolant in up to measurement above the radiator fins.
Guideline
10 mm (0.39 in)
Coolant
0.95 l (1 qt.)
Coolant (mixed ready to use)
400244-10
–
–
–
Refit the radiator cap.
Make a short test ride.
9
.87
The main silencer is filled with glass fiber yarn.
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.
9
.88
emoving main silencer
Warning
Danger of burnsꢀThe exhaust system gets very hot when the vehicle is driven.
–
Allow the exhaust system to cool down. Do not touch hot components.
–
–
Disconnect spring .
Remove screws and take off main silencer.
800020-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
76
9
.89
–
–
Mount the main silencer. Mount and tighten screws .
Guideline
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
Reconnect spring .
800020-11
9
.90
–
Pull off the air filter box lid in area to the side and remove to the front.
800021-10
9
.91
–
Insert the air filter box lid into the rear area and clip it into the front area .
800021-11
9
.92
emoving the air filter
x
Note
Engine failureꢀUnfiltered intake air has a negative effect on the service life of the engine.
–
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
–
–
Detach air filter holder at the bottom and swing it to one side. Remove the air
filter with the air filter support.
–
Remove the air filter from the air filter support.
500107-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
77
9
.93
nstalling the air filter
x
–
–
Mount the clean air filter onto the air filter support.
Apply grease to the section of the air filter.
301262-10
–
–
Put in both parts together, position them and fix them with air filter holder .
Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
500107-10
9
.94
leaning air filter
x
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Do not clean the air filter with fuel or gasoline since these substances attack the foam.
–
–
x
Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Info
Only squeeze the air filter when drying it out, never wring it out.
–
Oil the dry air filter with a high/quality filter oil.
–
–
–
Clean the air filter box.
Check carburetor connection boot for damage and tightness.
Install the air filter.
x
9
.95
djusting basic position of clutch lever
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
Info
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
500133-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
78
9
.96
hecking the fluid level of hydraulic clutch
Warning
Skin irritationꢀBrake fluid can cause skin irritation on contact.
–
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Info
The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!
–
–
–
–
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws .
Remove cover with membrane .
Check the fluid level.
Fluid level under top level of container 4 mm (0.16 in)
»
If the level of the fluid does not meet specifications:
–
Correct the fluid level of the hydraulic clutch.
400339-10
–
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt fluid immediately with water.
9
.97
hanging the hydraulic clutch fluid
x
Warning
Skin irritationꢀBrake fluid can cause skin irritation on contact.
–
–
–
Avoid contact with skin and eyes, and keep out of the reach of children.
Wear suitable protective clothing and goggles.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The fluid level rises with increasing wear of the clutch lining disc.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!
–
–
–
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws .
Remove cover with membrane .
400339-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
79
–
Fill bleeding syringe with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
–
On the slave cylinder, remove bleeder screw and mount bleeding syringe .
500158-10
–
Inject the liquid into the system until it escapes from bore hole of the master
cylinder without bubbles.
–
–
–
To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
Remove the bleeding syringe. Mount and tighten screws bleeder screw.
Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level under top level of container 4 mm (0.16 in)
–
Position the cover with the membrane. Mount and tighten the screws.
400340-10
Info
Clean up overflowed or spilt fluid immediately with water.
9
.98
hecking the basic position of the shift lever
–
Sit on the vehicle (facing the direction of travel) and measure the gap between the
top of the boot and shift lever .
Gap between the shift lever and the top 10… 20 mm (0.39… 0.79 in)
of the boot
»
If the distance does not meet the specifications:
–
Adjust the basic position of the shift lever.
x
0A
400692-10
9
.99
djusting the basic position of the shift lever
x
–
Remove screw and take off shift lever .
100805-10
–
–
Clean gear teeth of the shift lever and shift shaft.
Mount the shift lever on the shift shaft in the required position and engage the
gearing.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle compo-
nents during the shift procedure.
–
Mount and tighten screw.
Guideline
100806-10
Screw, shift lever
M6
14 Nm
Loctite® 243™
(10.3 lbf ft)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
80
9
.100
arburetor - idle
The idle setting of the carburetor has a big influence on the starting behavior, stable
idling and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.
Info
The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.
The idle speed is adjusted with the adjustment screw .
The idle mixture is adjusted with the idle mixture adjustment screw .
400341-10
9
.101
arburetor - adjusting idle
x
–
Screw in the idle adjusting screw until it stops and then to the prescribed basic
setting.
Guideline
Idle mixture adjusting screw (450 EXC USA)
Open
1.75 turns
Idle mixture adjusting screw (530 EXC USA)
Open
2.0 turns
Adjustment tool for mixture control screw (77329034000)
400341-10
–
Run the engine until warm.
Guideline
Warm-up time
≥ 5 min
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–
Adjust the idle speed with adjusting screw .
Guideline
Idle speed
1,550… 1,650 rpm
–
–
Turn the idle adjusting screw slowly until the idle speed begins to fall.
Note the position and turn the idle adjusting screw slowly counterclockwise until
the idle speed falls.
–
Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extreme sport motorcyclist will set the mixture about ¼ of a turn back
from this ideal value (leaner, in a clockwise direction) since the engine
becomes hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to mount a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
–
Adjust the idle speed with adjusting screw .
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MAINTENANCE WORK ON CHASSIS AND ENGINE
81
Guideline
Idle speed
1,550… 1,650 rpm
Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.
9
.102
mptying the carburetor float chamber
x
Danger
Fire hazardꢀFuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoningꢀFuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazardꢀImproper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
Carry out this work with a cold engine.
–
–
No more fuel flows from the tank to the carburetor.
Direct the hose of the float chamber into a suitable container.
Info
Water in the float chamber results in malfunctioning.
–
–
Undo the screw (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.
Tighten screw .
500256-10
9
.103
hecking engine oil level
Info
The engine oil level must be checked when the engine is cold.
–
Stand the motorcycle upright on a horizontal surface.
Condition
Engine is cold.
–
Check the engine oil level.
The engine oil must be between the halfway mark and the top of the oil level
viewer .
»
If the engine oil level is below the specified level:
–
200119-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
82
9
.104
hanging engine oil and oil filter, cleaning engine oil screen
x
–
Drain the engine oil and clean the engine oil screen.
x
–
–
–
x
Install the oil filter.
x
Fill up with engine oil.
x p. 83)
301489-10
9
.105
raining engine oil, cleaning engine oil screen
x
Warning
Danger of scaldingꢀEngine oil and gear oil get very hot when the motorcycle is ridden.
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
–
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the engine oil only when the engine is warm.
–
–
–
–
–
–
–
Stand the motorcycle on its side stand on a horizontal surface.
Place a suitable container under the engine.
Remove engine oil plug screen .
Completely drain the engine oil.
Thoroughly clean the plug and engine oil screen.
Clean the sealing surface on the engine.
Mount and tighten the engine oil screen drain plug .
Guideline
Plug, engine oil screen
M17x1.5
20 Nm
(14.8 lbf ft)
200112-10
9
.106
emoving the oil filter
x
Warning
Danger of scaldingꢀEngine oil and gear oil get very hot when the motorcycle is ridden.
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
–
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
–
–
Place a suitable container under the engine.
Remove screws . Remove oil filter cover with the O-ring.
200113-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
83
–
Pull the oil filter insert out of the oil filter casing.
Circlip pliers reverse (51012011000)
–
–
Completely drain the engine oil.
Thoroughly clean parts and sealing surface.
200114-10
9
.107
nstalling the oil filter
x
–
Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with
engine oil.
–
–
Fill the oil filter with engine oil and place it in the oil filter container.
Lubricate the O/ring of the oil filter cover.
200114-11
–
–
Refit the oil filter cover .
Mount and tighten screws .
Guideline
Screw, oil filter cover
M6
10 Nm (7.4 lbf ft)
–
Stand the motorcycle upright.
200113-11
9
.108
illing up with engine oil
x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
–
Remove the screw cap on the generator cover and fill up with engine oil.
Engine oil (1st
partial quantity
approx.)
0.35 l (0.37 qt.)
–
Mount and tighten the screw connection on the generator cover.
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
200115-10
–
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–
–
Start the engine and let it run idle for 30 seconds.
Stop the engine and check that it is oil-tight.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
84
–
–
–
Stand the motorcycle upright on a horizontal surface.
Remove the screw connection on the generator cover.
Fill in engine oil to the upper half of level viewer .
Engine oil (total
filling capacity
approx.)
0.60 l (0.63 qt.)
–
Mount and tighten the screw connection on the generator cover.
301454-10
9
.109
opping up engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
–
–
Remove the screw cap on the generator cover and fill up with engine oil.
Mount and tighten screw cap .
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
200115-10
–
–
Start the engine and check that it is oil-tight.
9
.110
hecking the gear oil level
Info
The gear oil level should only be checked when the engine is cold.
–
Stand the motorcycle upright on a horizontal surface.
Condition
Engine is cold.
–
–
Remove gear oil level check screw . Stand the motorcycle upright.
Check the gear oil level.
A small amount of gear oil should flow out.
»
Add gear oil.
If no gear oil flowxs out:
–
–
Mount and tighten the gear oil level check screw.
Guideline
200116-10
Screw, gear oil level check
M6
8 Nm (5.9 lbf ft)
9
.111
hanging gear oil, cleaning gear oil screen
x
–
–
Drain the gear oil and clean the gear oil screen.
x
x
301490-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
85
9
.112
raining gear oil, cleaning gear oil screen
x
Warning
Danger of scaldingꢀEngine oil and gear oil get very hot when the motorcycle is ridden.
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
–
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the gear oil only when the engine is warm.
–
–
–
–
–
–
–
–
–
Stand the motorcycle on its side stand on a horizontal surface.
Place a suitable container under the engine.
Remove the gear oil drain plug .
Remove the gear oil screen plug .
Completely drain the gear oil.
Thoroughly clean the gear oil drain plug with a magnet.
Thoroughly clean the drain plug and gear oil screen with a magnet.
Clean the sealing surface on the engine.
Refit gear oil drain plug with seal ring and tighten it.
Guideline
Gear oil drain plug with magnet
M12x1.5
20 Nm
(14.8 lbf ft)
–
Mount and tighten the gear oil screen drain plug .
Guideline
Plug, gear oil screen
M16x1.5
20 Nm
(14.8 lbf ft)
500159-10
9
.113
illing up with gear oil
x
Info
Too little gear oil or poor-quality oil results in premature wear to the transmission.
–
–
Remove the screw cap and fill up with gear oil.
Mount and tighten screw cap .
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
200118-10
–
–
Start the engine and check that it is oil-tight.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
86
9
.114
dding gear oil
x
Info
Too little gear oil or poor-quality oil results in premature wear to the transmission.
–
Remove gear oil level check screw .
200116-10
–
–
Remove screw cap . Stand the vehicle upright.
Top up with gear oil until it flows out of the bore of the gear oil level screw.
–
–
Mount and tighten the gear oil level check screw.
Guideline
Screw, gear oil level check
M6
8 Nm (5.9 lbf ft)
Mount and tighten screw cap .
200118-11
Danger
Danger of poisoningꢀExhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–
Start the engine and check that it is oil-tight.
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TROUBLESHOOTING
87
Faults
Possible cause
Action
The engine cannot be cranked (elec-
tric starter).
Operating error
–
Go through the steps of starting the engine.
Battery discharged
–
–
–
–
–
–
–
–
–
Recharge the battery.
Check the charging voltage.
Check the stall current.
Check the generator.
x
x
x
x
Fuse blown
Starter relay defective
Starter motor defective
Operating error
Check the starter relay.
Check the starter motor.
Go through the steps of starting the engine.
Empty the carburetor float chamber.
x
x
Engine turns but does not start
Motorcycle was out of use for a long
time and there is old fuel in the float
chamber
–
x
Fuel supply interrupted
–
–
–
–
Check the fuel tank breather.
Clean the fuel tap.
Check/adjust the carburetor components.
x
Engine flooded
Clean and dry the spark plug or replace if nec-
essary.
Spark plug oily or wet
–
–
Clean and dry the spark plug or replace if nec-
essary.
Electrode distance (plug gap) of spark
plug too wide
Adjust the plug gap.
Guideline
Spark plug electrode gap
0.9 mm (0.035 in)
Defect in ignition system
–
–
–
Check the ignition system.
x
Short-circuit cable in wiring harness
frayed, short-circuit button or emer-
gency OFF switch defective
Check the wiring harness. (visual check)
Check the electrical system.
Plug connector of CDI control device,
pulse generator or ignition coil oxi-
dized.
–
Clean the plug connector and treat it with con-
tact spray.
Water in carburetor or jets blocked
Idling jet blocked
–
–
–
x
Check/adjust the carburetor components. x
Engine has no idle
Carburetor - adjust the idle speed.
Check/adjust the carburetor compoxnents.
Adjusting screws on carburetor dis-
torted
Spark plug defective
–
–
–
–
–
–
–
Change spark plug.
Ignition system defective
Check the ignition coil.
x
x
Check the CDI controller.
Check the spark plug connector.
x
x
Check the generator.
Check the ignition puxlse generator.
Engine does not speed up
Carburetor running over because float
needle dirty or worn
Check/adjust the carburetor components.
x
x
Loose carburetor jets
–
–
–
–
–
–
–
–
–
Check/adjust the carburetor components.
Ignition system defective
Check the ignition coil.
Check the CDI controller.
Check the spark plug connector.
x
x
x
x
Check the generator.
Check the ignition puxlse generator.
Engine has a lack of power
Fuel supply interrupted
Check the fuel tank breather.
Clean the fuel tap.
Check/adjust the carburetor components.
x
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TROUBLESHOOTING
88
Faults
Possible cause
Action
Engine has a lack of power
Air filter heavily contaminated
–
Clean the air filter.
x
Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer
–
–
Check exhaust system for damage.
silencer.
Adjust the valve clearance.
Check the ignition coil.
Check the CDI controller.
Check the spark plug connector.
Change gxlass fiber yarn filling of main
Valve clearance too little
Ignition system defective
–
–
–
–
–
–
–
x
x
x
x
x
Check the generator.
Check the ignition puxlse generator.
Engine stalls or pops back into the
carburetor
Lack of fuel
Turn handle of the fuel tap to the ON posi-
–
–
The intake system has an air leak
Coolant level low in cooling system
Check rubber sleeves and carburetor for tight-
ness.
Engine overheats
–
–
–
–
–
–
–
–
Check the cooling system for leaks.
Switch off engine when stationary.
Clean radiator fins.
Insufficient airflow
Radiator fins very dirty
Foam formation in cooling system
x
x
Refill the coolant.
Bent radiator hose
Change the radiator hose.
Thermostat defective
Check the thermostat.
Guideline
x
Opening temperature: 70 °C (158 °F)
High oil consumption
Engine vent hose bent
–
Route the vent hose without bends or replace it
if necessary.
Engine oil level too high
–
–
Engine oil too thin (low viscosity)
the engine oil screen.
Piston/cylinder - determine the mounting clear-
ance
Change the engine oil xand oil filter and clean
Piston and/or cylinder worn
The battery does not charge
–
x
Battery discharged
–
–
–
–
–
x
Check the charging current.
Check the generator.
Check the stall current.
Change the battery in the speedometer.
Check the charging voltage. x
x
Undesired power consumer
x
Speedometer values deleted (time,
stop watch, lap times)
The battery in the speedometer is
empty.
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CLEANING
89
1
1.1
Note
Material damageꢀDamage and destruction of components by high-pressure cleaning equipment.
–
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-
cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
Environmental hazardꢀHazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
–
–
–
Seal the exhaust system to keep water out.
First remove coarse dirt particles with a gentle water spray.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
–
–
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
Empty the carburetor float chamber.
x
Warning
Danger of accidentsꢀReduced braking efficiency due to wet or dirty brakes.
–
Clean or dry dirty or wet brakes by riding and braking gently.
–
After cleaning, ride a short distance until the engine reaches operating termperature.
Info
The heat generated, causes water to evaporate from the engine and brakes, even in inaccessible areas.
–
–
–
–
Push back the protection covers of the handlebar grips to allow any water that has penetrated to evaporate.
After the motorcycle has cooled off, oil or grease all moving parts and bearings.
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 108)
To prevent electrical problems, treat electric contacts and switches with contact spray.
–
–
–
Lubricate the steering lock.
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STORAGE
90
1
2.1
Warning
Danger of poisoningꢀFuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
–
–
–
–
–
–
–
–
–
Change the engine oil and oil filter and clean the engine oil screen.
x
x
Empty the carburetor float chamber.
Drain the fuel from the tanks into a sxuitable container.
Remove the battery.
x
x
Recharge the battery.
Guideline
Storage temperature of battery (not placed in direct sunshine)
0… 35 °C (32… 95 °F)
–
Place the vehicle on a dry storage place that is not subject to large temperature variations.
Info
KTM recommends jacking up the motorcycle.
–
–
Cover the vehicle with an air-permeable cover or blanket.
Info
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes parts of the engine and exhaust system to rust.
1
2.2
utting into operation after storage
–
–
–
–
–
Install the battery.
Take a test ride.
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TECHNICAL DATA - ENGINE
91
Design
1-cylinder 4-stroke engine, water-cooled
449.3 cm³ (27.418 cu in)
510.4 cm³ (31.147 cu in)
63.4 mm (2.496 in)
72 mm (2.83 in)
Displacement (450 EXC USA)
Displacement (530 EXC USA)
Stroke (450 EXC USA)
Stroke (530 EXC USA)
Bore
95 mm (3.74 in)
Compression ratio
Idle speed
11.9:1
1,550… 1,650 rpm
Control
OHC, 4 valves controlled via rocker arm, drive via tooth/wheel
chain
Valve diameter, intake
Valve diameter, exhaust
Valve clearance
39.5 mm (1.555 in)
31.7 mm (1.248 in)
Exhaust at: 20 °C (68 °F)
Intake at: 20 °C (68 °F)
Crankshaft bearing
Conrod bearing
0.12… 0.17 mm (0.0047… 0.0067 in)
0.10… 0.15 mm (0.0039… 0.0059 in)
2 grooved ball bearings
Needle bearing
Piston pin bearing
Pistons
No bearing bushes - DLC-plated piston pins
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Engine lubrication
Pressure circulation lubrication with 2 rotor pumps (engine) / 1
rotor pump (transmission)
Primary transmission
Clutch
33:76
Multidisc clutch in oil bath / hydraulically activated
Transmission ratio
1st gear
14:36
2nd gear
17:32
3rd gear
19:28
4th gear
22:26
5th gear
24:23
6th gear
26:21
Generator
Ignition
12 V, 150 W
Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Spark plug
NGK LKAR 8AI - 9
Spark plug electrode gap
Cooling
0.9 mm (0.035 in)
Water, permanent circulation of coolant by water pump
Electric starter/kick starter
Starter
1
3.1
Engine oil
0.60 l (0.63 qt.)
0.90 l (0.95 qt.)
C
3.2
apacity - gear oil
Gear oil
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
93
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 222
Loctite® 243™
Screw, cable holder in generator cover
Locking screw for bearing
Oil jet, piston cooling
M4
4 Nm (3 lbf ft)
M5
6 Nm (4.4 lbf ft)
2 Nm (1.5 lbf ft)
2 Nm (1.5 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
4 Nm (3 lbf ft)
M5
Oil jet, rocker arm lubrication
Screw, ignition pulse generator
Screw, locking lever
M5
M5
M5
Screw, oil pump cover
Bleeding connection, transmission
Nut, water pump impeller
Plug, vacuum connection
Screw generator cover
Screw generator cover
Screw, camshaft bearing support
Screw, clutch cover
M5
M6
Loctite® 243™
Loctite® 243™
M6
8 Nm (5.9 lbf ft)
5 Nm (3.7 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
14 Nm (10.3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
4 Nm (3 lbf ft)
M6
M6x25
M6x40
M6
–
–
Loctite® 243™
M6x25
M6x30
M6
–
Screw, clutch cover
–
Screw, clutch spring
–
Screw, cylinder head
M6
–
Screw, engine housing
Screw, engine housing
Screw, exhaust flange
Screw, gear oil level check
Screw, idler
M6x60
M6x75
M6
–
–
–
M6
–
Loctite® 243™
M6
Screw, kickstarter spring hanger
Screw, kickstarter stop
Screw, oil filter cover
M6
–
Loctite® 243™
M6
M6
–
Loctite® 243™
Screw, shift drum locating
Screw, shift lever
M6
Loctite® 243™
M6
Screw, starter motor
M6
–
Loctite® 243™
Screw, stator bracket
M6
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Screw, timing chain guide rail
Screw, timing chain securing guide
Screw, timing chain tensioning rail
Screw, torque governor
Screw, valve cover
M6
M6
M6
M6
M6
–
Screw, water pump cover
Screw, water pump cover
Oil jet, conrod lubrication
Plug, oil channel
M6x25
M6x55
M6x0.75
M7
–
–
–
Loctite® 243™
9 Nm (6.6 lbf ft)
15 Nm (11.1 lbf ft)
10 Nm (7.4 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
60 Nm (44.3 lbf ft)
40 Nm (29.5 lbf ft)
10 Nm (7.4 lbf ft)
Screw, rocker arm bearing
Plug, crankshaft location
Screw, kickstarter
M7x1
M8
–
–
Loctite® 243™
M8
Loctite® 243™
Loctite® 243™
Plug, oil drilling
M10
M10
M10x1
M10x1
Screw, engine sprocket
Balancer shaft nut
–
–
Screw, unlocking of timing chain ten-
sioner
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
94
Screw, cylinder head
M10x1.25
Tightening sequence:
Tighten diagonally, begin-
ning with the rear screw on
the chain shaft.
Step 1
lubricated with engine oil
10 Nm (7.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
50 Nm (36.9 lbf ft)
Nut, rotor
M12x1
60 Nm (44.3 lbf ft)
–
–
Spark plug
M12x1.25
15… 20 Nm (11.1…
14.8 lbf ft)
Gear oil drain plug with magnet
Oil pressure control valve plug
Plug, SLS
M12x1.5
M12x1.5
M12x1.5
M14x1.25
M16x1.5
M17x1.5
M18x1.5
M20LHx1.5
M24x1.5
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
80 Nm (59 lbf ft)
–
–
–
Plug, rocker arm
–
Plug, gear oil screen
Plug, engine oil screen
Nut, inner clutch hub
Nut, primary gear
–
–
–
Loctite® 243™
100 Nm (73.8 lbf ft)
30 Nm (22.1 lbf ft)
Plug, timing chain tensioner
–
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TECHNICAL DATA - CARBURETOR
95
1
5.1
Carburetor type
Carburetor identification number
Needle position
Idle mixture adjusting screw
Open
KEIHIN FCR-MX 39
3900Z
4th position from top
1.75 turns
Pump membrane stop
Main jet
2.15 mm (0.0846 in)
180
OBDYU
48
Jet needle
Idling jet
Idle air jet
100
85
Cold start jet
Leakage nozzle
40
1
5.2
30 EXC USA
Carburetor type
Carburetor identification number
Needle position
Idle mixture adjusting screw
Open
KEIHIN FCR-MX 39
3900Y
3rd position from top
2.0 turns
Pump membrane stop
Main jet
2.15 mm (0.0846 in)
180
OBDZT
48
Jet needle
Idling jet
Idle air jet
100
85
Cold start jet
Leakage nozzle
40
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TECHNICAL DATA - CHASSIS
96
Frame
Central tube frame made of chrome molybdenum steel tubing
Fork
WP Suspension Up Side Down 4860 MXMA PA
Suspension travel
Front
300 mm (11.81 in)
Rear
335 mm (13.19 in)
Fork offset
19 mm (0.75 in)
Shock absorber
WP Suspension PDS 5018 DCC
Disc brakes, brake calipers on floating bearings
Brake system
Brake discs - diameter
Front
260 mm (10.24 in)
220 mm (8.66 in)
Rear
Brake discs - wear limit
Front
2.5 mm (0.098 in)
3.5 mm (0.138 in)
Rear
Tire air pressure off road
Front
1.0 bar (15 psi)
1.0 bar (15 psi)
Rear
Road tire pressure
Front
1.5 bar (22 psi)
Rear
2.0 bar (29 psi)
Final drive
15:45
Chain
5/8 x 1/4"
Rear sprockets available
Steering head angle
Wheelbase
38, 40, 42, 45, 48, 49, 50, 51, 52
63.5°
1,475±10 mm (58.07±0.39 in)
985 mm (38.78 in)
380 mm (14.96 in)
114.8 kg (253.1 lb.)
145 kg (320 lb.)
190 kg (419 lb.)
335 kg (739 lb.)
Seat height unloaded
Ground clearance unloaded
Weight without fuel, approx.
Maximum permissible front axle load
Maximum permissible rear axle load
Maximum permissible overall weight
Battery
YTX5L-BS
Battery voltage: 12 V
Nominal capacity: 4 Ah
Maintenance-free
1
6.1
ighting equipment
Headlight
S2/socket BA20d
12 V
35/35 W
Parking light
Indicator lights
Turn signal
W5W/socket W2.1x9.5d
W2.3W / socket W2x4.6d
RY10W/socket BAU15s
P21/5W/socket BAY15d
12 V
5 W
12 V
2.3 W
12 V
10 W
Brake/tail light
12 V
21/5 W
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TECHNICAL DATA - CHASSIS
97
1
6.2
Front tire
Rear tire
90/90 - 21 M/C 54M M+S TT
140/80 - 18 M/C 70M M+S TT
Metzeler MCE 6 DAYS EXTREME
Metzeler MCE 6 DAYS EXTREME
Additional information is available in the Service section under:
http://www.ktm.com
1
6.3
apacity - fuel
Total fuel tank capacity,
approx.
9.2 l (2.43 US gal)
2 l (2 qt.)
Fuel reserve, approx.
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TECHNICAL DATA - FORK
98
Fork part number
14.18.7J.06
Fork
WP Suspension Up Side Down 4860 MXMA PA
Compression damping
Comfort
26 clicks
22 clicks
18 clicks
Standard
Sport
Rebound damping
Comfort
24 clicks
Standard
20 clicks
Sport
20 clicks
Spring length with preload spacer(s)
Spring rate
510 mm (20.08 in)
Weight of rider: 65… 75 kg (143… 165 lb.)
Weight of rider: 75… 85 kg (165… 187 lb.)
Weight of rider: 85… 95 kg (187… 209 lb.)
Air chamber length
4.4 N/mm (25.1 lb/in)
4.6 N/mm (26.3 lb/in)
4.8 N/mm (27.4 lb/in)
+20
+0.79
110 mm (4.33
in)
−30
−1.18
Spring preload - Preload Adjuster
Comfort
0 turn
Standard
2 turns
4 turns
Sport
Fork length
940 mm (37.01 in)
Fork oil per fork leg
626 ml (21.17 fl. oz.)
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TECHNICAL DATA - SHOCK ABSORBER
99
Shock absorber part number
12.18.7J.06
Shock absorber
WP Suspension PDS 5018 DCC
Compression damping, low-speed
Comfort
22 clicks
20 clicks
15 clicks
Standard
Sport
Compression damping, high-speed
Comfort
2 turns
Standard
1.5 turns
1.25 turns
Sport
Rebound damping
Comfort
26 clicks
Standard
24 clicks
Sport
22 clicks
Spring preload
9 mm (0.35 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.)
69 N/mm (394 lb/in)
72 N/mm (411 lb/in)
76 N/mm (434 lb/in)
250 mm (9.84 in)
10 bar (145 psi)
Weight of rider: 75… 85 kg (165… 187 lb.)
Weight of rider: 85… 95 kg (187… 209 lb.)
Spring length
Gas pressure
Static sag
35 mm (1.38 in)
Riding sag
105 mm (4.13 in)
411 mm (16.18 in)
Fitted length
Damper oil
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TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
100
Spoke nipple, front wheel
Screw, spoiler on fuel tank
Spoke nipple, rear wheel
Remaining nuts, chassis
Remaining screws, chassis
M4.5
M5x12
M5
5… 6 Nm (3.7… 4.4 lbf ft)
1.5 Nm (1.11 lbf ft)
5… 6 Nm (3.7… 4.4 lbf ft)
15 Nm (11.1 lbf ft)
–
–
–
–
–
–
M6
M6
10 Nm (7.4 lbf ft)
Screw, ball joint of push rod on foot
brake cylinder
M6
10 Nm (7.4 lbf ft)
Screw, front brake disc
Screw, rear brake disc
Screw, shock absorber adjusting ring
Nut, rear sprocket screw
Nut, rim lock
M6
14 Nm (10.3 lbf ft)
14 Nm (10.3 lbf ft)
5 Nm (3.7 lbf ft)
–
M6
–
M6
–
Loctite® 243™
M8
35 Nm (25.8 lbf ft)
10 Nm (7.4 lbf ft)
30 Nm (22.1 lbf ft)
25 Nm (18.4 lbf ft)
12 Nm (8.9 lbf ft)
33 Nm (24.3 lbf ft)
15 Nm (11.1 lbf ft)
25 Nm (18.4 lbf ft)
20 Nm (14.8 lbf ft)
40 Nm (29.5 lbf ft)
35 Nm (25.8 lbf ft)
17 Nm (12.5 lbf ft)
17 Nm (12.5 lbf ft)
60 Nm (44.3 lbf ft)
50 Nm (36.9 lbf ft)
45 Nm (33.2 lbf ft)
40 Nm (29.5 lbf ft)
80 Nm (59 lbf ft)
80 Nm (59 lbf ft)
20 Nm (14.8 lbf ft)
100 Nm (73.8 lbf ft)
80 Nm (59 lbf ft)
10 Nm (7.4 lbf ft)
12 Nm (8.9 lbf ft)
45 Nm (33.2 lbf ft)
M8
–
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom triple clamp
Screw, engine brace
M8
–
M8
–
M8
–
M8
–
Screw, fork stub
M8
–
Loctite® 243™
Screw, front brake caliper
Screw, handlebar clamp
Screw, side stand fixing
Screw, subframe
M8
M8
–
Loctite® 243™
M8
Loctite® 243™
Loctite® 243™
M8
Screw, top steering stem
Screw, top triple clamp
Engine attachment bolt
Remaining nuts, chassis
Remaining screws, chassis
Screw, handlebar support
Screw, bottom shock absorber
Screw, top shock absorber
Nut, seat fixing
M8
M8
–
M10
M10
M10
M10
M12
M12
M12x1
M16x1.5
M20x1.5
M20x1.5
M20x1.5
M24x1.5
–
–
–
Loctite® 243™
Loctite® 243™
Loctite® 243™
–
Nut, swingarm pivot
–
Nut, rear wheel spindle
Screw, top steering head
Screw-in nozzles, cooling system
Screw, front wheel spindle
–
–
Loctite® 243™
–
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101
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WIRING DIAGRAM
102
2
0.1
iring diagram
H18
P1
H2
H4
H15
H11
H7
CX/2
CZ/3
CY/3
DB/4
DA/4
CW/2
S2
AK1/2
AH1/2
CW2/2
CX2/2
DG/4
BP/4
CW3/2
CX3/2
B3
wh
bu
gn
ye
re
br
or
pu
bl
bl-wh
br
gr
bu-wh
bu-wh
ye-re
br
ye-re
br
ye-re
or
br
gr
ye-bl
re-wh
re-bl
gn
ye-re
or
re
bu
br
bl
ye
black
bl
OFF
ON
BF/1
bl
ye-re
ye-re
ye-bl
br
ye
bu
BA/1
br
re
ye-bl
gn
bl
re-bl
wh-re
re-wh
ye-re
CR/1
ye
wh
CR1/1
ye
wh-gn
BG1/3
AJ1/3
CA/4
CE/4
CX/2
CX1/2
AJ/3
BG/3
CW/2
CW1/2
N2
H3
H1
500249-10
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WIRING DIAGRAM
103
Components
A6
CDI controller
B1
Throttle position sensor
Wheel speed sensor
Battery
B3
G1
G2
Generator
H1
H2
H3
H4
H5
H7
H11
H13
H15
H18
K1
Right rear flasher
Left front flasher
Left rear flasher
Right front flasher
Brake/tail light
Parking light
Low/high beam
Horn
Flasher indicator light
High beam indicator light
Starter relay with main fuse
Flasher relay
K2
L1
Pulse generator
L2
Ignition coil
M1
N2
P1
Starter motor
Voltage regulator/rectifier
Speedometer
S1
Rear brake light switch
Front brake light switch
Tripmaster switch (optional)
Light switch
S2
S5
S6
S7
Horn button
S8
Flasher switch
S10
S11
S12
S13
X1
Electric starter button
Emergency OFF switch
Headlight flasher button
Ignition switch
Ignition curve plug connection
Radiator fan plug connection (optional)
X2
Cable colors
bl
Black
bl-wh
br
Black-white
Brown
br-bl
bu
Brown-black
Blue
bu-wh
gn
Blue-white
Green
gr
Gray
or
Orange
pu
Violet
re
Red
re-bl
re-wh
wh
Red-black
Red-white
White
wh-gn
wh-re
White-green
White-red
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SUBSTANCES
105
Brake fluid DOT 4 / DOT 5.1
According to
–
DOT
Guideline
–
Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
–
RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
–
Brake Fluid DOT 5.1
Coolant
Guideline
Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex® products.
–
Mixture ratio
Antifreeze protection: −25… −45 °C (−13… 50 % corrosion inhibitor/antifreeze
−49 °F)
50 % distilled water
Coolant (mixed ready to use)
Antifreeze
−40 °C (−40 °F)
Supplier
Motorex®
–
Anti Freeze
Engine oil (SAE 10W/50)
According to
–
–
Guideline
–
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
–
Cross Power 4T
Fork oil (SAE 5)
According to
–
Guideline
–
Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Supplier
Motorex®
–
Racing Fork Oil
Shock absorber oil (SAE 2,5) (50180342S1)
According to
–
Guideline
–
Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding
properties.
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AUXILIARY SUBSTANCES
107
Air filter cleaner
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Twin Air Dirt Bio Remover
Chain cleaner
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Chain Clean 611
Cleaning and preserving materials for metal, rubber and plastic
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Protect & Shine 645
Contact spray
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Accu Contact
Long-life grease
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Fett 2000
Motorcycle cleaner
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Moto Clean 900
Off-road chain spray
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Chain Lube 622
Oil for foam air filter
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Twin Air Liquid Bio Power
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AUXILIARY SUBSTANCES
108
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Clean & Polish
Universal oil spray
Guideline
KTM recommends Motorex® products.
–
Supplier
Motorex®
–
Joker 440 Universal
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STANDARDS
109
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
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INDEX
110
INDEX
A
Clutch
Air filter
Compression damping
Air filter box lid
Compression damping, high-speed
Anti-freeze
Compression damping, low-speed
Coolant
Coolant level
E
B
Basic suspension setting
Engine
Battery
Engine oil
Brake discs
Brake fluid
Engine oil level
Engine oil screen
Brake fluid level
Brake linings
F
Filler cap
Filling up
C
Carburetor
Chain
Fork
Chain guide
Fork legs
Chain tension
Chain wear
Fork protector
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INDEX
111
Front fender
Motorcycle
Front wheel
O
Oil filter
Fuel tank
P
Play in throttle cable
Fuse
Putting into operation
G
Gear oil
R
Rear sprocket / engine sprocket
Gear oil level
Rear wheel
Gear oil screen
Rebound damping
H
Riding sag
S
Seat
Headlight
Headlight adjustment
Headlight mask with headlight
Shock absorber
I
K
Speedometer
L
Lower triple clamp
Spoke tension
M
Spring preload
Main silencer
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INDEX
112
Steering
Steering head bearing
Steering head bearing play
T
Technical data
Throttle cable route
Tire condition
Tire pressure
U
V
View of vehicle
W
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*3211468en*
3211468en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
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