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KTM 450 EXC USA User's Manual

Contents

1. Components A6 CDI controller B1 Throttle position sensor B3 Wheel speed sensor G1 Battery G2 Generator Hl Right rear flasher H2 Left front flasher H3 Left rear flasher H4 Right front flasher H5 Brake tail light H7 Parking light H11 Low high beam H13 Horn H15 Flasher indicator light H18 High beam indicator light K1 Starter relay with main fuse K2 Flasher relay L1 Pulse generator L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light switch S5 Tripmaster switch optional S6 Light switch S7 Horn button S8 Flasher switch S10 Electric starter button S11 Emergency OFF switch S12 Headlight flasher button S13 Ignition switch X1 Ignition curve plug connection X2 Radiator fan plug connection optional Cable colors bl Black bl wh Black white br Brown br bl Brown black bu Blue bu wh Blue white gn Green gr Gray or Orange pu Violet re Red re bl Red black re wh Red white wh White wh gn White green wh re White red WIRING DIAGRAM tng ye Yellow ye bl Yellow black ye re Yellow red 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 prope
2. Reconnect spring Checking rear brake fluid level Warning Danger of accidents Failure of the brake system Ifthe 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 accidents Reduced 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 gt If there is an air bubble in the sight glass O visible Add brake fluid to the rear brake circuit A p 61 Adding brake fluid to the rear brake circuit A Warning Danger of accidents Failure of the brake system Ifthe 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 irritation Brake 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 ____MAINTENANGE WORK ON CHASSI
3. Removing the oil filter A Warning Danger of scalding Engine 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 hazard Hazardous 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE gp 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 Lay the motorcycle on its side and fill the oil filter housing to about 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 Refit the oil filter cover 8 Mount and tighten screws O Guideline Screw oil filter cover M6 10 Nm 7 4 Ibf ft Stand the motorcycle upright Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the screw cap O on the generator cover and fill up with engine oil Engine oil 1st 0
4. Stand the motorcycle upright on a horizontal surface Remove radiator cap Check the anti freeze of the coolant 25 45 C 13 49 F Ifthe 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 Ifthe level of the coolant does not meet specifications ____MAINTENANGE WORK ON CHASSIS AND ENGINE zx Correct the coolant level Alternative 1 Coolant p 105 Alternative 2 Coolant mixed ready to use p 105 Refit the radiator cap Checking the coolant level Warning Danger of scalding During 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 poisoning Coolant 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
5. Shift lever Chain guide Fuel tap Air filter box lid Clutch lever Light switch headlight flasher button flasher switch horn button CO NI mH BR WI M F Hand brake lever __ VIEW OF VEHICLE 1 w View of the vehicle from the right rear example 300398 10 1 Level viewer for brake fluid rear 2 Fork compression adjustment 3 Foot brake pedal 4 Kickstarter 5 Horn 6 Ignition switch 7 Fork rebound adjustment 8 Filler cap 9 Shock absorber compression adjustment 10 Shock absorber rebound adjustment ____LOGATION OF SERIAL NUMBERS h nmn Chassis number The chassis number is stamped on the steering head on the right 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 REN 300403 10 The key number is provided on the KEYCODECARD e Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 300397 10 The engine number is stamped on the left side of the engine under the engine sprocket 500072 10 The fork part number is stamped on the inner side of the fork stub 100801 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side E L N b p lt 5001
6. 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 O 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 Ibf ft Mount and tighten the gear oil screen drain plug Guideline Plug gear oil screen M16x1 5 20 Nm 14 8 Ibf ft 500159 10 Filling up with gear oil 4 e Info Too little gear oil or poor quality oil results in premature wear to the transmission Remove the screw cap O and fill up with gear oil Gear oil 0 90 I 0 95 qt Engine oil SAE 10W 50 p 105 Mount and tighten screw cap O Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventila 200118 10 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 Check the gear oil
7. Remove screws and hang the CDI control unit to the side e 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 e Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines ____MAINTENANGE WORK ON CHASSIS AND ENGINE 1 1 a 500098 10 500099 11 29 500103 10 Remove o ring O Remove protector ring O Remove the lower triple clamp with the steering stem Remove the upper steering head bearing Clean the bearing and sealing elements check for damage and grease Long life grease p 107 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing e Info Check whether the top steering head seal is correctly positioned Push up protective ring and o ring O Position the upper triple clamp with the steering Mount and tighten screw O Guideline Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Position the clutch line wiring harness and CDI control unit Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Install the front fender p 49 Refit the headlight mask with the headlight p 50 Install the fork legs 9 p 46 Mount and tighten screw O Guideline Screw top steer
8. Warning Environmental hazard Battery 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 hazard Hazardous 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 Remove the seat p 71 Disconnect the minus negative cable of the battery to avoid damage to the motor cycle s electronics Connect the battery charger to the battery Swit
9. e 40 Setting the clock k GER sk Hie Red k r n e 17 Checking static sag of shock absorber 40 Adjusting the speedometer functions 17 Checking riding sag of shock absorber 41 Querying the lap time EEEEE n 18 Adjusting spring preload of the shock absorber amp 41 Display mode SPEED speed LEEEEEEEEHH 18 Adjusting riding sag VM 42 Display mode SPEED H service hours 18 Removing the shock absorber XM 42 Display mode SPEED CLK clock 19 Installing the shock absorber ccoo 42 Display mode SPEED LAP lap time 19 Checking basic setting of fork 43 Display mode SPEED ODO odometer ssse 19 Adjusting the compression damping of the fork 43 Display mode SPEED TR1 trip master 1 19 Adjusting rebound damping of fork 43 Display mode SPEED TR2 trip master 2 20 Adjusting spring preload of the fork 44 Display mode SPEED A1 average speed 20 Bleeding fork legs essen 44 Display mode SPEED A2 average speed 2 20 Cleaning the dust boots of the fork legs ooo 44 Display mode SPEED S1 stop watch 1 21 Loosening the fork protector
10. 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 hazard Hazardous 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 OQ Remove cover with membrane 6 1 Fill bleeding syringe O with the appropriate hydraulic fluid Bleed syringe 50329050000 Brake fluid DOT 4 DOT 5 1 p 105 D sd w 7 fa On the slave cylinder remove bleeder screw and mount bleeding syringe O Via t Bad Inject the liquid into the system until it escapes from bore hole O 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
11. E eee 45 Display mode SPEED S2 stop watch 2 21 Positioning the fork protector 45 Fuel ta Desi cci teet ee eeu ete be Vana na y WER NE kn vue naa oo xa aA dd 22 Checking steering head bearing play 45 Opening filler M EE 22 Adjusting play of steering head bearing 46 Closing filler cap merre 22 Removing the fork legs VM 46 Choke oir 23 Installing fork ON 46 Jens e PE E 23 Removing the fork protector v 47 Foot brake Tev xc ak idi d Ra eme dens 23 Installing the fork protector Wenn Nan OA NANA 47 Res oh H K e F Removing the lower triple clamp amp 47 e e E Ane ieoa 1 LR E E B rta EHD 24 Greasing the steering head bearing amp 49 Unlocking the steering LL 25 Remo Ue Ue E a De GENERAL TIPS AND HINTS ON PUTTING INTO Insta ling the front Tenders suites E etie uite 49 OPERATION uU dieit A nerada E iE 26 Removing headlight mask with headlight 43 Advice ON Tsun t oe Kan la a Rus 26 Refitting the headlight mask with the headlight 50 Running in the engine es 27 Handlebar position n 50 Preparing vehicle for arduous riding conditions 27 Adjusting the handlebar position 50 Preparing for riding on dry sand o on 27 Checking throttle cable ro
12. trip master 2 Display mode SPEED A1 No function No function The TR1 A1 and S1 dis Next display mode average speed 1 plays are reset to 0 0 Display mode SPEED A2 No function No function Next display mode average speed 2 Display mode SPEED S1 No function No function Displays of TR1 A1 and Next display mode stop watch 1 S1 are reset to 0 0 Display mode SPEED S2 Starts or stops S2 No function Displays of S2 and A2 Next display mode stop watch 2 are reset to O O Table of conditions and menu activation Display The motorcycle is Menu can be acti stationary vated Display mode SPEED H service hours e CONTROLS a Table of conditions and menu activation Display The motorcycle is Menu can be acti stationary vated Display mode SPEED CLK clock e Display mode SPEED LAP lap time e Display mode SPEED TR1 trip master 1 e Display mode SPEED TR2 trip master 2 e Display mode SPEED A1 average speed 1 e Display mode SPEED A2 average speed 2 e Display mode SPEED S1 stop watch 1 e Display mode SPEED S2 stop watch 2 e Fuel tap 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 e Fuel supply closed OFF No fuel flows from the tank to the carburetor e Fuel supply open ON Fuel flows from the tank to the carburetor The fuel tan
13. 2 m HH HH te ei used 75 Maintenance ANA h 4328 Motorcycle cleaning Dil filter CHANGING zo ee ee a tst 82 INStall tos tots gt alae pde dee WAL 4 83 FEMOVINGY DD wen kh reb du Se MEE 82 Overview of indicator lamps 15 Owner s manual ooccoccoo eee 8 Play in throttle cable AGIUSTING Ga 51 CHECKING e a dale ora cta dy e At dye OR al Rubr cts RR DR 51 Putting into operation adviceonfirstuse KR KK KIRR KIR KIRR 26 afterstorage Vta oss ates ker dul db t pente bee 90 checks before putting into operation 31 Rear sprocket engine sprocket checking for wear KK KK KI K KIRI KI KIRI KIRI KK KI 53 Rear wheel installing DD DH 66 removing cede reet e eee ET M ERA 65 Rebound damping fork adjusting o creari nh re wee 43 shock absorber adjusting o oooooooo o 39 Riding sag adjust zano et ee xr afl Cs xc Rte dem 42 Seat MOUNTING oux DEH NN 71 removillg ka senaya la e nb eee E a ray oe ky d aha JAZ an E Ran a 71 Service schedule o oo o ooo oo KK 35 37 Shift lever a ie 23 basic position adjusting o o ooooooooo 79 basic position checking o o ooooooooooo 79 Shock absorber installing ago corre etie cre Bee get ge sob la 42 reimoviftg aired a Aree dr epee hes 42 riding sag checking kK KK KK KI KIR eee eeae 41 st
14. 38 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 Position the fork protector on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf 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 Ibf ft Warning Danger of accidents Unstable 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 be damaged after time 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 Jack up the motorcycle p 38 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 A p 46 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 r
15. 4 e Check the crankshaft run out at the bearing M pin A Change the connecting rod conrod bearing and crank pin Change the crankshaft main bearing Check the transmission 4 e Check the shift mechanism A e Check the spring length of the oil pressure regu lator valve A Change glass fiber yarn filling of main silencer A Replace foot brake cylinder seals 4 e Check adjust the carburetor components 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 SERVICE SCHEDULE zx Important checks and maintenance work to be carried out by the rider NB1A Check the engine oil level p 81 e Check the brake fluid level of the front brake p 57 Check the rear brake fluid level p 61 e Check the front brake linings p 58 e Check the rear brake linings p 62 e Check and adjust the cables Bleed fork legs p 44 e Clean the dust boots of the fork legs p 44 Clean the chain p 52 e Check the chain tension p 52 e Check the chain wear p 53 e Check rear sprocket engine sprocket for wear p 53 e Clean the air filter A p 77 Check the ti
16. 5 eroe os et nn o e a 35 Forkpart lmbef a ow ula o ipee dee e e e eds 13 Important maintenance work to be carried out by an Shock absorber part number 13 authorized KTM workshop kk 35 CONTROL Saa 3 las Gell t a 14 Important maintenance work to be carried out by an Clutch ever td Melo tots rt Caec de 14 authorized KTM Workshop as additional order E 36 Hand brake lever esses eee 14 un U and maintenance work to be carried Sa n o ja MAINTENANCE WORK ON CHASSIS AND ENGINE 38 Electric starter BUEFOTIs ce eee C Lat NS IR 14 Jacking up the motorcycle l lLh li kk 38 Light SWItoI n ti ri a E bs 15 Removing the motorcycle Hon thg work stand MAPA EQ e Highlight flasher button jj Su khe tebe su bin n cet he Wit totdi Horn button Se SUERTE Se S N den ERR xeb OI Eee a edm PORT des Xa d 15 Compression damping of shock absorber 38 Flasher switch e siet Keneda yek peva d k idees zab 15 Adjusting the high speed compression damping of the Overview of indicator lamps 15 ee e esessessescescescccceevereesserseseeseesenteneeerees 38 Speedometer E A E LCS 16 Adjusting the low speed compression damping of the Speedometer activation and test E EE EE 16 Sock ASIF DSK doge yarar yeli Vista dece e i e 39 Tripmaster Witt 16 Adjusting rebound damping of the shock absorber 39 setting kilometers or mileS E ee 16 Measuring rear wheel sag unloaded
17. 60 Checking rear brake fluid level E EEE 61 Adding brake fluid to the rear brake circuit 61 Checking rear brake linings i 62 Changing rear brake linings A ooo 62 Removing front wheel amp L eee 64 Installing the front wheel Aoc 65 Removing the rear wheel ieee 65 Installing the rear wheel amp E 66 Tire condition checking kek 67 Checking tire alr pressure siepe ettet i n 67 Checking spoke tens O kek 68 Removing the battery amp u eee 68 Installing the battery XM 69 Recharging the battery eee 69 Removing a Us ici edet ka deya W k bke kk ua seda voted 70 Installing the f se 4 xa delk ida da cu e do 70 Checking the headlight adjustment ss 70 Adjusting the beam width of the headlight 71 Removing tlie Seat eI IIR ES 71 Mounting the sats oot bee RSS 71 Removing the fuel tank u eee 71 Installing the fuel tank u e 72 Cooling SM a tien n ERES Z3 Checking the anti freeze and coolant level 73 Checking the coolant level EE 74 Draining coolant A u eke 74 Refilling coolant VM eee 75 Glass fiber yarn filling of main silencer 75 Removing main silencer LL 75 Installing the main silencer zU 76 Removing the air filter box lid 76 Installin
18. Check the brake system and do not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE ______________sa____ Warning _ Danger of accidents Reduced 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 hazard Hazardous 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 Brake fluid DOT 4 DOT 5 1
19. in as far as possible Loosen nut 6 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 O 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 amp p 72 Check the play in the throttle cable p 51 ____MAINTENANGE WORK ON CHASSIS AND ENGINE ge Checking for chain dirt accumulation Check the chain for coarse dirt accumulation Ifthe chain is very dirty Clean the chain p 52 400678 01 Cleaning the chain A A x Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced 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 hazard Hazardous 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
20. li convient de lire attentivement tout le manuel d utilisation avant la premi re mise en service ATENTION Leer atentamente todas las instucciones para el servicio antes de la primera puesta en marcha de la motocich 7002 10 01 MANUFACTURER KTM SPORTMOTORCYCLE AG Mattighofen Austria IMPORTER KTM NORTH AMERICA INC 1119 Millan Ave Amherst OH 44001 ENGINE DISPLACEMENT 448 cc ENGINE EXHAUST EMISSION CONTROL SYSTEM AKTXC 525EXC EM AKTXPP104RK1__ MODEL NAME 450 EXC THIS VEHICLE CONFORMS WITH US EPA AND CALIFORNIA REGULATIONS APPLICABLE TO 20XXMODEL YEAR NEW MOTORCYCLES AND IS CERTIFIED TO 0 8 G KM HC NOX 12 0 GKM CO EXHAUST EMISSION STANDARD IN CALIFORNIA 0 10 0 15 INTAKE amp EXHAUST NGK LKARSA S 0 9 mm UNLEADED GASOLINE ONLY 91 R M 2 OCTANE OR HIGHER 3 SAE 10 W 60 100840 01 Emission control information KTM SPORTMOTORCYCLE AG AUSTRIA THIS 20XXKTM0780449 MOTORCYCLE 780 05 082 100 MEETS U S EPA NOISE EMISSION REQUIREMENTS OF 80 dBA AT 6212 RPM BY THE U S FEDERAL TEST PROCEDURE MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXCEED FEDERAL NOISE STANDARDS ARE PROHIBITED BY U S FEDERAL LAW SEE OWNER S MANUAL Motorcycle Type 450 EXC Date manufactured XXXXXX VIN VBKOOOOX MXXXXXX 100839 01 Noise emission information Notes warnings Pay close attention to the notes warnings e Info Various information and warning labels are affixed to the vehicle Do not remove in
21. 35 I 0 37 qt Engine oil SAE 10W 50 p 105 partial quantity approx Mount and tighten the screw connection on the generator cover Danger gt Danger of poisoning Exhaust 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 let it run idle for 30 seconds Stop the engine and check that it is oil tight ____MAINTENANGE WORK ON CHASSIS AND ENGINE ea 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 0 60 0 63 qt Engine oil SAE 10W 50 p 105 filling capacity approx Mount and tighten the screw connection on the generator cover Topping up engine oil e info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the screw cap O on the generator cover and fill up with engine oil Engine oil SAE 10W 50 p 105 Mount and tighten screw cap O Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always
22. 6 Nm 4 4 Ibf ft Loctite 2437 Screw locking lever M5 6 Nm 4 4 Ibf ft Loctite 2437 Screw oil pump cover M5 6 Nm 4 4 Ibf ft Loctite 222 Bleeding connection transmission M6 4 Nm 3 Ibf ft Loctite 2437 Nut water pump impeller M6 8 Nm 5 9 Ibf ft Loctite 2437 Plug vacuum connection M6 5 Nm 3 7 Ibf ft Loctite 2437 Screw generator cover M6x25 10 Nm 7 4 Ibf ft Screw generator cover M6x40 10 Nm 7 4 Ibf ft Screw camshaft bearing support M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw clutch cover M6x25 10 Nm 7 4 Ibf ft Screw clutch cover M6x30 10 Nm 7 4 Ibf ft Screw clutch spring M6 10 Nm 7 4 Ibf ft Screw cylinder head M6 10 Nm 7 4 Ibf ft Screw engine housing M6x60 10 Nm 7 4 Ibf ft Screw engine housing M6x75 10 Nm 7 4 Ibf ft Screw exhaust flange M6 10 Nm 7 4 Ibf ft Screw gear oil level check M6 8 Nm 5 9 Ibf ft Screw idler M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw kickstarter spring hanger M6 10 Nm 7 4 Ibf ft Screw kickstarter stop M6 10 Nm 7 4 Ibf ft Loctite 2437 Screw oil filter cover M6 10 Nm 7 4 Ibf ft Screw shift drum locating M6 10 Nm 7 4 Ibf ft Loctite 243TM Screw shift lever M6 14 Nm 10 3 Ibf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 Ibf ft Screw stator bracket M6 10 Nm 7 4 Ibf ft Loctite 243TM Screw timing chain guide rail M6 8 Nm 5 9 Ibf ft Loctite 243TM Screw timing chain securing guide M6 8 Nm
23. 62 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings A p 62 Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help f Warning AX Skinirritation Brake 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 accidents Reduced 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE eg Warning Danger of accidents Reduced 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 accidents Reduced 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
24. Press the button Next display mode briefly Display 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 e Info The displayed value can differ from the actual average speed if 2 was not timed after the ride 400326 0 Press the button No function Press the button No function Press the button O for 3 5 seconds Press the button O Next display mode briefly CONTROLS i Display mode SPEED S1 stop watch 1 Press the button O 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 mn i c The calculation of this value starts with the first impulse of the wheel speed sensor and Lie UD 2 ends 3 seconds after the last impulse Press the button No function Press the button No function 400327 0 Press the button O Displays of TR1 A1 and S1 are reset to 0 0 for 3 5 seconds Press the button O briefly Next display mode Display mode SPEED S2 stop watch 2 Press the button O briefly and repeatedly until S2 app
25. and insert the wheel spindle Mount and tighten screw Guideline Screw front wheel spindle M24x1 5 45 Nm 33 2 Ibf ft Operate the hand brake lever several times until the brake linings are lying correctly on the brake disc Remove the motorcycle from the work stand p 38 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 Ibf ft N 400258 10 Jack up the motorcycle p 38 Press the brake caliper by hand on to the brake disc in order to press back the brake piston e 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 O 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 e 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE _______________se____ Remove spacers O Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs Always keep the brake
26. e e Check the exhaust system for leakage and looseness Check the cables for damage smooth operation and routing without sharp bends Check the fluid level of the hydraulic clutch p 78 e e Clean the air filter A p 77 Check cables for damage and routing without sharp bends Check that the electrical equipment is functioning properly e e Check the headlight adjustment p 70 e e Brakes Check the front brake linings p 58 e e Check the rear brake linings p 62 e e e Check the brake discs p 56 e e e Check the brake fluid level of the front brake p 57 e e Check the rear brake fluid level p 61 e e e Check brake lines for damage and leakage Check the free travel of the hand brake lever p 56 e e Check the free travel of the foot brake lever p 60 Check brake system function Check screws and guide bolts of brake system for tightness suspension Check shock absorber and fork for leakage and functioning 4 Clean the dust boots of the fork legs p 44 e e Bleed fork legs p 44 e e Check the frame and swingarm for damage Check the swingarm bearing A Check the steering head bearing play p 45 e e Check all screws to see if they are tight Wheels Check the spoke tension p 68 e e Check the wheel hubs for damage Check rim run out e e Check the tire condition p 67 e e e C
27. 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 Clean the chain p 52 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and preserving materials for metal rubber and plastic p 107 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 Contact spray p 107 Lubricate the steering lock Universal oil spray p 108 STORAGE _ gt t hsh auaua ________ ae____ Storage Warning Danger of poisoning Fuel 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 c
28. 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 Open the filler cap p 22 M 400382 10 Fill the fuel tank with fuel up to measurement Q Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx 9 2 1 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 106 Close the filler cap p 22 SERVICE SCHEDULE h 3 Important maintenance work to be carried out by an authorized KTM workshop S3N S15A S30A Engine Change the engine oil and oil filter and clean the engine oil screen p 82 e e Change the gear oil and clean the gear oil screen p 84 L Replace spark plug Check the valve clearance A e e Check engine mounting screws for tightness Clean spark plug connectors and check for tightness Check that the screws in the shift lever and the kickstarter are tight Carburetor Check carburetor connection boots for cracks and leakage Check vent hoses for damage and routing without sharp bends Check idle e Attachments Check the cooling system for leakage Check the anti freeze and coolant level p 73
29. 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 Check the engine oil level p 81 Checking the gear oil level e 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 f no gear oil flows out Add gear oil V p 86 Mount and tighten the gear oil level check screw Guideline Screw gear oil level check M6 8 Nm 5 9 Ibf ft Changing gear oil cleaning gear oil screen Drain the gear oil and clean the gear oil screen 4 p 85 Fill up with gear oil 4 p 85 an e 301490 10 Draining gear oil cleaning gear oil screen 4 Warning Danger of scalding Engine 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 hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations
30. mm 0 16 in Position the cover with the membrane Mount and tighten the screws 400340 10 e Info Clean up overflowed or spilt fluid immediately with water Checking the basic position of the shift lever Siton 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 Ifthe distance does not meet the specifications Q Adjust the basic position of the shift lever A p 79 400692 10 Adjusting the basic position of the shift lever J y C Remove screw and take off shift lever 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 e Info I 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 Screw shift lever M6 14 Nm Loctite 2437 10 3 Ibf ft ____MAINTENANGE WORK ON CHASSIS AND ENGINE sg Carburetor 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 wrong
31. only if lap times are measured Condition The motorcycle is stationary Press the button O briefly and repeatedly until LAP appears at the bottom right of the display Press the button O briefly LAP Y LAP 1 appears on the left side of the display 6 HA a toe bd Laps 1 10 can be displayed by pressing the button LAP The button has no function Press the button O briefly Y Next display mode 400321 0 e Info If an impulse is received from the wheel speed sensor the left side of the display changes back to the SPEED mode Display mode SPEED speed Press the button O briefly and repeatedly until SPEED appears on the left side of the display The current speed is displayed in the SPEED display mode ri The current speed can be displayed in Km h or Mph ci SPEED Km e 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 Display mode SPEED H service hours Condition e The motorcycle is stationary Press the button O briefly and repeatedly until H appears at the bottom right of the display MANE 2 In display mode H the service hours of the engine are displayed LILI LILI a ji The service hour counter stores the total traveling time Info The service hour counter is necessa
32. p 105 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water Warning _ Danger of accidents Reduced 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 gt 1 mm 20 04 in Ifthe minimum thickness is less than specified Change the front brake linings 4 p 59 Check the brake linings for damage and cracking If damage or cracking is visible Change the front brake linings 4 p 59 100394 10 ____MAINTENANGE WORK ON CHASSIS AND ENGINE sg Changing the front brake linings 4 A A Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Warning Skin irritation Brake 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 accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brakes according to the service sch
33. steering Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key Y You can now steer the bike again e Info Never leave the key in the steering lock 400731 01 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION se Advice on first use Danger Danger of accidents Danger 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 injury Missing 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 crashing Poor 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 accidents Critical riding behavior due to inappropriate riding Warning Danger of accidents Accident risk caused by presence of a passenger Your vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents Failure of brake system Adapt your riding speed to the road conditions and your riding ability Ifthe foot brake lever is not relea
34. then treat with chain spray Chain cleaner p 107 Off road chain spray p 107 400725 01 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension Ifthe 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 Jack up the motorcycle p 38 Push the chain up at the rear edge of the chain guide to measure the chain ten sion e Info l 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 y gt ____MAINTENANGE WORK ON CHASSIS AND ENGINE ______________sa____ Ifthe chain tension does not meet specifications Adjusting chain tension after checking p 55 Remove the motorcycle from the work stand p 38 Checking chain tension when fitting rear wheel Warning Danger of accidents Danger caused by incorrect chain tension Ifthe
35. 0 p 22 Refuel p 33 The intake system has an air leak Check rubber sleeves and carburetor for tight ness Engine overheats Coolant level low in cooling system Check the cooling system for leaks Check the coolant level p 74 Insufficient airflow Switch off engine when stationary Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant p 74 Refill the coolant p 75 Bent radiator hose Change the radiator hose A Thermostat defective Check the thermostat Guideline 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 Check the engine oil level p 81 Engine oil too thin low viscosity Change the engine oil and oil filter and clean the engine oil screen A p 82 Piston and or cylinder worn Piston cylinder determine the mounting clear ance A Battery discharged The battery does not charge Check the charging voltage A Check the charging current 4 Check the generator X Undesired power consumer Check the stall current 4 Speedometer values deleted time stop watch lap times The battery in the speedometer is empty Change the battery in the speedometer CLEANING ss Cleaning the motorcycle Note Ma
36. 27 01 Check the chain guide for tightness and wear Checking chain wear Jack up the motorcycle p 38 Shift transmission to neutral Pull on the upper part of the chain with the specified weight O Guideline Weight of chain wear measurement 10 15 kg 22 33 Ib Measure the distance of 18 chain links in the lower chain section e 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 Ifthe distance is greater than the specified measurement Replace the chain e Info l When you replace the chain you should also replace rear sprocket and engine sprocket New chains wear out faster on old worn sprockets 16 17 18 400226 10 Remove the motorcycle from the work stand p 38 Warning Danger of accidents Danger caused by incorrect chain tension Ifthe 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 cor
37. 29 10 CONTROLS gt 1 y Clutch lever The clutch lever is fitted on the left side of the handlebar The clutch is hydraulically operated and self adjusting 500133 10 Hand brake lever Hand brake lever is located on the right side of the handlebar The hand brake lever is used to activate the front brake 1400196 10 Emergency OFF switch 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 500144 10 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 300396 10 Electric starter button is fitted on the right side of the handlebar Possible states e Electric starter button is in home position e Electric starter button is pressed In this position the electric starter is actu ated 500144 12 ___ CONIROLS tg Light switch 500142 10 Highligh
38. 5 9 Ibf ft Loctite 243 Screw timing chain tensioning rail M6 8 Nm 5 9 Ibf ft Loctite 243TM Screw torque governor M6 10 Nm 7 4 Ibf ft Loctite 243TM Screw valve cover M6 10 Nm 7 4 Ibf ft Screw water pump cover M6x25 10 Nm 7 4 Ibf ft Screw water pump cover M6x55 10 Nm 7 4 Ibf ft Oil jet conrod lubrication M6x0 75 4 Nm 3 Ibf ft Plug oil channel M7 9 Nm 6 6 Ibf ft Loctite 243TM Screw rocker arm bearing M7x1 15 Nm 11 1 Ibf ft Plug crankshaft location M8 10 Nm 7 4 Ibf ft Screw kickstarter M8 25 Nm 18 4 Ibf ft Loctite 243TM Plug oil drilling M10 15 Nm 11 1 Ibf ft Loctite 2437 Screw engine sprocket M10 60 Nm 44 3 Ibf ft Loctite 2437 Balancer shaft nut M10x1 40 Nm 29 5 Ibf ft B Screw unlocking of timing chain ten M10x1 10 Nm 7 4 Ibf ft sioner ____ TECHNICAL DATA ENGINE TIGHTENING TORQUES 1 3 Screw cylinder head M10x1 25 Tightening sequence lubricated with engine oil Tighten diagonally begin ning with the rear screw on the chain shaft Step 1 10 Nm 7 4 Ibf ft Step 2 30 Nm 22 1 Ibf ft Step 3 50 Nm 36 9 Ibf ft Nut rotor M12x1 60 Nm 44 3 Ibf ft Spark plug M12x1 25 15 20 Nm 11 1 14 8 Ibf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 Ibf ft Oil pressure control valve plug M12x1 5 20 Nm 14 8 Ibf ft Plug SLS M12x1 5 20 Nm 14 8 Ibf ft Plug
39. 6 DAYS EXTREME Metzeler MCE 6 DAYS EXTREME Additional information is available in the Service section under http www ktm com Total fuel tank capacity 9 2 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 106 approx Fuel reserve approx 21 2 qt TECHNICAL DATA FORK gt _________ss____ Fork part number 14 18 7J 06 Fork WP Suspension Up Side Down 4860 MXMA PA Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks Rebound damping Comfort 24 clicks Standard 20 clicks Sport 20 clicks Spring length with preload spacer s 510 mm 20 08 in Spring rate Weight of rider 65 75 kg 143 165 Ib 4 4 N mm 25 1 Ib in Weight of rider 75 85 kg 165 187 Ib 4 6 N mm 26 3 Ib in Weight of rider 85 95 kg 187 209 Ib 4 8 N mm 27 4 Ib in Air chamber length 110556 mm 4 33723 in Spring preload Preload Adjuster Comfort 0 turn Standard 2 turns Sport 4 turns Fork length 940 mm 37 01 in Fork oil per fork leg 626 ml 21 17 fl oz Fork oil SAE 5 p 105 ____ TECHNICAL DATA SHOCK ABSORBER e Shock absorber part number 12 18 7J 06 Shock absorber WP Suspension PDS 5018 DCC Compression damping low speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks Compression damping hi
40. Brake system Disc brakes brake calipers on floating bearings Brake discs diameter Front 260 mm 10 24 in Rear 220 mm 8 66 in Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi 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 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 475 10 mm 58 07 0 39 in Seat height unloaded 985 mm 38 78 in Ground clearance unloaded 380 mm 14 96 in Weight without fuel approx 114 8 kg 253 1 Ib Maximum permissible front axle load 145 kg 320 Ib Maximum permissible rear axle load 190 kg 419 Ib Maximum permissible overall weight 335 kg 739 Ib Battery YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah Maintenance free Lighting equipment Headlight S2 socket BA20d 12V 35 35 W Parking light W5W socket W2 1x9 5d 12V 5W Indicator lights W2 3W socket W2x4 6d 12V 2 3W Turn signal RY10W socket BAU15s 12V 10W Brake tail light P21 5W socket BAY15d 12V 21 5 W TECHNICAL DATA CHASSIS ig Tires l lb 0 L OUWOJMA Front tire Rear tire 90 90 21 M C 54M M S TT 140 80 18 M C 70M M S TT Metzeler MCE
41. Ibf ft Remaining nuts chassis M8 30 Nm 22 1 Ibf ft Remaining screws chassis M8 25 Nm 18 4 Ibf ft Screw bottom triple clamp M8 12 Nm 8 9 Ibf ft Screw engine brace M8 33 Nm 24 3 Ibf ft Screw fork stub M8 15 Nm 11 1 Ibf ft Screw front brake caliper M8 25 Nm 18 4 Ibf ft Loctite 243TM Screw handlebar clamp M8 20 Nm 14 8 Ibf ft Screw side stand fixing M8 40 Nm 29 5 Ibf ft Loctite 2437 Screw subframe M8 35 Nm 25 8 Ibf ft Loctite 243TM Screw top steering stem M8 17 Nm 12 5 Ibf ft Loctite 243TM Screw top triple clamp M8 17 Nm 12 5 Ibf ft Engine attachment bolt M10 60 Nm 44 3 Ibf ft Remaining nuts chassis M10 50 Nm 36 9 Ibf ft Remaining screws chassis M10 45 Nm 33 2 Ibf ft Screw handlebar support M10 40 Nm 29 5 Ibf ft Loctite 2437 Screw bottom shock absorber M12 80 Nm 59 Ibf ft Loctite 243TM Screw top shock absorber M12 80 Nm 59 Ibf ft Loctite 243TM Nut seat fixing M12x1 20 Nm 14 8 Ibf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 Ibf ft Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft Screw top steering head M20x1 5 10 Nm 7 4 Ibf ft Screw in nozzles cooling system M20x1 5 12 Nm 8 9 Ibf ft Loctite 243 Screw front wheel spindle M24x1 5 45 Nm 33 2 Ibf ft Wiring diagram cws 2 CX3 2 TIR 500249 10 ___ WIRIG DIAGRAM tg
42. 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 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE ______________ a ____ Guideline Choke function deactivated The choke lever is pushed in to the stop p 23 Idle speed 1 550 1 650 rpm e Info Following extreme air temperature or altitude changes adjust the idle speed again Emptying the carburetor float chamber Danger Fire hazard Fuel 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
43. S AND ENGINE ge Warning Danger of accidents Reduced 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 hazard Hazardous 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 Q Brake fluid DOT 4 DOT 5 1 p 105 Mount the screw cap with the membrane and the O ring e Info Clean up overflowed or spilt brake fluid immediately with water Warning Danger of accidents Reduced 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 Q Minimum thickness gt 1 mm gt 0 04 in Ifthe minimum thickness is less than specified Change the rear brake linings A 7 p
44. aded p 40 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 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 O e Info The riding sag is the difference between measurements and Check the riding sag Riding sag 105 mm 4 13 in Ifthe riding sag differs from the specified measurement Adjust the riding sag A p 42 Adjusting spring preload of the shock absorber Danger Danger of accidents Disassembly 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 e Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring 400216 10 Remove shock absorber A p 42 After removing the shock absorber clean it thoroughly Unscrew screw Turn adjusting ring until the spring is no longer under tension Combination wrench 50329080000 Hook wrench T106S Measure the overall spring length when not under tension Tighten the spring by turning adjusting ring to measurem
45. arburetor jetting and settings e Info 600871501 Your authorized KTM workshop has the recommended carburetor tuning set tings Clean the chain Chain cleaner p 107 Fit the steel sprocket e Tip Do not grease the chain Clean radiator fins 600868 01 Straighten bent radiator fins carefully Preparing for riding on wet sand Check the radiator cap Value on radiator cap 1 8 bar 26 psi Ifthe displayed value does not correspond to specifications Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling 600872 10 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 Change the radiator cap Seal the air filter box A e Tip Seal the air filter box on the edges against dirt Clean the air filter amp p 77 e Info Check the air filter approx every 30 minutes 600870 01 600868 01 Fit a waterproofing device on the air filter Waterproofing device for air filter 59006021000 e Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and settings e Info Your authorized KTM workshop has the recommended carburetor tu
46. ard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 Ib 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 Compression 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 Adjusting the high speed compression damping of the shock absorber Danger Danger of accidents Disassembly 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 e Info The high speed setting can be seen during the fast compression of the shock absorber ____MAINTENANGE WORK ON CHASSIS AND ENGINE 1 3 Turn adjusting screw O clockwise with a socket wrench until it stops e Info Do not loosen nut Turn back counterclockwise by the number of turns correspondin
47. art is permitted only with the express written permission of the copyright owner ISO 9001 12 100 6061 HA 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 T V Management Service 150 9001 REG NO 12 100 6061 KTM Sportmotorcycle AG 5230 Mattighofen Austria __ TABLE OF CONTENTS 0 0 2 MEANS OF REPRESENTATION 4 eke 4 Preparing for rides at high temperature and slow speed 30 IMPORTANT INFORMATION eeeeerrn kkkk 5 Preparing for rides at low temperatures or in snow 30 Overview of labels 3 ada 6 RIDING INSTRUCTIONS Siy yi ud xaka ke L deka dripada 31 VIEW OF VEHICLE aces axak ya didene xerez lak tret ete cdas 10 Checks before putting into operation EUEUUUEUUU UUjUL E L Uj 31 View of the vehicle from the left front example 10 CI N De E EEE e 31 View of the vehicle from the right rear example 11 Starting UD lA ec eee it ls 32 LOCATION OF SERIAL NUMBERS 4K kk kk 12 Shifting idiN8 siecia enen Ala ay an XORA NR 32 Ghassisnumbehe ssnin esos cono orth Pr Potest lene 12 Braking sioe betur eiecit i aa a a ttt 32 Typelab l kusan a Ker Paya e dade Mes edet des Seya w na 12 Stopping parking emirato 33 KAMA 12 A eiut Lue ELE 33 Engine nurmiber s ee recte rir eb ere d ec p EE 12 SERVICE SCHEDULE
48. atic sag checking llle 40 Side stand i acean ota e RR RA n RE ESS 24 Sp re parts 52i apo oy ma ara n hae a V idus 5 Speedometer ACIUSTING ocios dee Dd desee ave kur Y xU dede 17 clock Setting xy nn Un nV esca e k Sk awa ean 17 function description o o o o o ooooooooo oo 16 kilometers or miles setting 16 Spoke tension CHECKING acostar dek a eur IUe a Ge eS 68 Spring preload fork adjusting x55 snm oes ERG RET 44 shock absorber adjusting o o oooo ooo 41 Starting iia A RA Ra a 31 INDEX J 42 Steering locking piene HEW Dk HW neces EE NE 24 Ted APPEL 25 Steering head bearing greasing eese Qe Yu dek do OE ER PCR OR GNE d 49 Steering head bearing play adi sting su s oett ego a A ed ERR el an T RERUM 46 Ghecking s siste Raves o ame ER la 45 Storage uis neo eb Shay PR lay ala 90 Technical data Carburetok 2 nous tes dar a ue eu Se 95 Chassis xe de Waa eeu ee e a vet 96 97 chassis tightening torques less 100 ENSINGS ks diva n oa nie dew n dra teeny a ee beb dayan 91 92 engine tightening torques 2 0000 93 94 TOM ke ors Streets uuo innen Me ca io 98 Shock absorber nois ose feng a an eee kela PR ea Wl 99 Throttle cable route checking 4 5 odere RF a Eres pun 51 Tire condition checking ue ber SHEER TARDA 67 Tire pressure CHECKING EC Tc read ya 67 Transport A di
49. attery away from sparks or open fire Charge only in well ventilated rooms Inthe 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 Remove the seat p 71 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE eg Installing the battery us Place the battery in the battery holder Battery YTX5L BS p 96 Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat p 71 500069 11 Recharging the battery 4 A Warning Risk of injury Battery 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 Inthe 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
50. before trying again Motorcycle has been out of use for more than 1 week Empty the carburetor float chamber 4 p 81 Turn handle O of the fuel tap to the ON position Figure 500137 10 p 22 Y 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 O Turn the emergency OFF switch to the position O The engine is cold Pull choke lever out as far as possible Press the electric starter button or press the kickstarter robustly through its full range e Info Do not rev up 400733 01 Starting up e 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 Shifting riding Warning Danger of accidents If 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
51. 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 hazard Hazardous 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 e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove locking split pins withdraw bolt and take out the brake pads Clean brake caliper and brake caliper support 100808 10 Check that anti squeal shim in the brake caliper and anti rattle shim in the brake caliper support are seated correctly 100407 10 Fit the brake pads insert the bolt and mount the locking split pins Operate the foot brake lever r
52. can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel 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 hazard Improper 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 e Info Carry out this work with a cold engine Turn handle of the fuel tap to the OFF position Figure 500137 10 p 22 Y No more fuel flows from the tank to the carburetor Direct the hose of the float chamber into a suitable container e Info Water in the float chamber results in malfunctioning Undo the screw turn it counterclockwise a few turns and drain the fuel from EN the float chamber DNS o Tighten screw O i M A 500256 10 Checking engine oil level e 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 l
53. ce 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 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 You should use the fuels oils and greases according to specifications as listed in the owner s manual 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 OU lt You will find the current KTM PowerParts for your vehicle on the KTM website International KTM Website http www ktm com 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 b9029019000 During assembly non reusable parts e g self locking screws and nuts seals and seal rings O rings
54. ch on the battery charger Battery charger 58429074000 You can also use the battery charger to test the open circuit voltage and cranking pu power of the battery and to test the generator With this device you cannot over Ay AW charge the battery e info Never remove the lid 400240 10 Charge the battery with at most 10 of the capacity specified on the bat tery O Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Mount the seat p 71 Removing a fuse Switch off all consumers and the engine Remove the air filter box lid p 76 Remove protective cover e Info The fuse is located in the starter relay under the filter box cover Remove the fuse O 400270 10 Installing the fuse Warning Fire hazard The 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 e Info A reserve fuse O is located in the starter relay Replace a blown fuse only by an equivalent fuse Replace the protection cover Install the air filter box lid p 76 Ona light colored wall behind a horizontal a
55. 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 e Info I 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 Chain tension 8 10 mm 0 31 0 39 in Ifthe chain tension does not meet specifications Adjust the chain tension when fitting rear wheel p 55 Checking the rear sprocket engine sprocket for wear Check rear sprocket engine sprocket for wear lt ji Ifthe rear sprocket engine sprocket are worn e2990600999 Replace the rear sprocket engine sprocket e Info l 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 4002
56. ct the tire air pressure Fit the dust cap ____MAINTENANGE WORK ON CHASSIS AND ENGINE gg Checking spoke tension Warning Danger of accidents Instable 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 e Info I 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 Ifthe spoke tension varies 400694 01 Correct the spoke tension 4 Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 Ibf ft Spoke nipple rear wheel M5 5 6 Nm 3 7 4 4 Ibf ft Torque wrench with various accessories in set 58429094000 Removing the battery A Warning Risk of injury Battery 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 b
57. 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 Long life grease p 107 Insert the spacers Lift the rear wheel into the swing arm position it and insert the wheel spindle 6 Put the chain on Position the chain adjuster Mount nut O but do not tighten it yet Check chain tension when fitting rear wheel p 53 Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut O Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft e 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 Remove the motorcycle from the work stand p 38 ____MAINTENANGE WORK ON CHASSIS AND ENGINE eg Tire condition checking Info I 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 espec
58. e 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 A AGCESSOMIES lt lt e a an n ka GOZ IE aa aa 5 Air filter cleaning ous t a aus x Re tee s UP mns 77 installing iu ise Lace e a ye Y Yn Rut 77 FEMOVING cd uuo ars sq rbd ad pedes Eod 76 Air filter box lid installing c users ouch de Ee do RS 76 KOMOVING x 4e ed gam dut on gr oar HER dh ra dee eae A 76 Anti freeze GlieekIhg utor as ait Saws atados ien ee sins 73 Arduous riding conditions 27 diy sarid E a m EM E 27 high temperature KK KI K KI KI KIRI KI K K K K K K 30 low temperature isso 0a A 30 muddy surfaces z sa du a ku e Leg A 29 Slow speeds 4 vs tees dd e sS bda aka s 30 SNOW Tas ug A 30 Wet sand inicia re ES 28 WeLSHITdCeS i ek Wa quedo AREE KAW SA 29 B Basic suspension setting checking with rider s weight o o o ooo o 38 Battery INSTA a A aran k n an n RE da Ae trt Eo REA 69 recharging a cs Rene xa refe BOR RERUM G z alan A 69 removing c ho a Raed e E Na 68 Brake discs checking i cd Re ee ls dne 56 Brake fluid front brake adding llle 57 rear brake adding aos kK KK K e RAE DEM 61 Brake fluid level front brake checking KK KIRI 57 rear brake checking cee eee eae 61 Brak
59. e linings front brake changing llle 59 front brake checking llle 58 rear brake changing 0 00 KIR KI KII KII 62 rear brake checking KRI KII ee KII 62 C Carburetor adjusting idle 24 ecu ve ama eR SNC leeks 80 float chamber emptying llle 81 dlen isset rey eae HHHH 80 Chain cleaning zz mu bere SET X WEAR eus 52 Chain guide adjusting 4 s oua esset bio tae e ieu 56 Chain tension adjusting 4 lt 2 eeu beu dead a S NE ad i 54 CHECKING to Ke N DAY YEY eee me dite a e Es 52 Chain wear checking tit teta e atio en fa a ECT 53 Chassis number LL LL LL VL A KK KI KK KK KIR K K KI KIRI o 12 Choke b un an kw neces E EEG Mame kien 23 ANA tt Cleaning lt 4 e Senay o kde READ 89 Clutch fluid level checking KI KI KI KIRI KI KI KIRI eee 78 fluid CHANGING s 2 J t ue dik sla Wr le bal d RA 78 Clutch lever 2 2 m be Re ARE RIDES 14 adjusting basic position o ooooooooooooo 77 Compression damping fork adjUsblng ss sna Lu ex SRSA Slee kara d LU aaa 43 Compression damping high speed shock absorber adjusting llle 38 Compression damping low speed shock absorber adjusting llle 39 Coolant rrr 74 refilling 22 3 dhe SN 75 Coolant level CHECKING a d oue ua ara 73 74 Cooling system llli 73 E Electric starter button o o o 14 Emergency OFF s
60. e 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 Jack up the motorcycle p 38 Remove bleeder screws briefly Y Any excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the work stand p 38 Jack up the motorcycle p 38 Loosen the fork protector p 45 Push dust boots of both fork legs downwards e info I 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 accidents Reduced 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 oil the dust boots and inner fork tube of both fork legs Universal oil spray p 108 Press the dust boots back into their normal position ____MAINTENANGE WORK ON CHASSIS AND ENGINE as Loosening the fork protector 7 600875 10 Checking steering head bearing play Remove excess oil Position the fork protector p 45 Remove the motorcycle from the work stand p
61. e the limit specified in the service schedule is reached Arduous riding conditions are Riding on dry sand p 27 Riding on wet sand p 28 Riding on wet and muddy surfaces p 29 Rides at high temperature and slow speed p 30 Rides at low temperatures or in snow p 30 Preparing for riding on dry sand Check the radiator cap Value on radiator cap 1 8 bar 26 psi Ifthe displayed value does not correspond to specifications Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling 600872 10 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 Change the radiator cap Seal the air filter box X e Tip I Seal the air filter box on the edges against dirt Clean the air filter A p 77 e Info Check the air filter approx every 30 minutes Fita dust protection device on the air filter Dust protection device for air filter 59006019000 e Info I See the KTM PowerParts fitting instructions 7 Fita sand screen device on the air filter Sand protection device for air filter 59006022000 e Info See the KTM PowerParts fitting instructions Adjust the c
62. e 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 Press the button Starts or stops the clock Press the button Stops the current lap time and saves it and the stop watch starts the next lap Press the button O for 3 5 seconds The stop watch and the lap time are reset Press the button O briefly Next display mode the display Press the button O briefly and repeatedly until ODO appears at the bottom right of In ODO display mode the total number of kilometers ridden is displayed Press the button No function Press the button No function Press the button O for 3 5 seconds Press the button O briefly Next display mode display Press the button O briefly and repeatedly until TR1 appears at the top right of the 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 e Info If 999 9 is exceeded the values of TR1 A1 and S1 are automatically reset to 0 0 Press the button No function Press the button No function Press the button O for 3 5 seconds The TR1 A1 and S1 displays are reset to O O CONTROLS ag Press the but
63. ears at the top right of the display S2 stop watch 2 is a manual stop watch g If S2 is running in the background the S2 display flashes in the speedometer display NC 1 LIS LIC 44 Press the button Starts or stops S2 Press the button No function Press the button O Displays of S2 and A2 are reset to O O for 3 5 seconds 400328 0 Press the button O Next display mode briefly Table of functions Display Press the button Press the button Press the button O for 3 Press the button O 5 seconds briefly Display mode SPEED H No function No function The display changes to Next display mode service hours the Setup menu of the speedometer functions Display mode SPEED CLK No function No function The display changes to Next display mode clock the Setup menu of the clock Display mode SPEED LAP Starts or stops the Stops the current lap The stop watch and the Next display mode lap time clock time and saves it and lap time are reset the stop watch starts the next lap Display mode No function No function Next display mode SPEED ODO odometer Display mode SPEED TR1 No function No function The TR1 A1 and S1 dis Next display mode trip master 1 plays are reset to O O Display mode SPEED TR2 Increases value of TR2 Reduces value of TR2 Deletes value of TR2 Next display mode
64. edule Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced 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 accidents Reduced 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 hazard Hazardous 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 co
65. em and do not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently ___RIDING INSTRUCTIONS sr 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 Stopping parking Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Warning Danger of burns Some 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 damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from bei
66. ent O Guideline Spring preload 9 mm 0 35 in e 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 Ibf ft Install the shock absorber 4 p 42 ____MAINTENANGE WORK ON CHASSIS AND ENGINE 1 Adjusting riding sag A Remove shock absorber p 42 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 Ib 69 N mm 394 Ib in Weight of rider 75 85 kg 165 187 Ib 72 N mm 411 Ib in Weight of rider 85 95 kg 187 209 Ib 76 N mm 434 Ib in e Info The spring rate is shown on the outside of the spring Smaller weight differences can be compensated by changing the spring preload Install the shock absorber A p 42 Check the static sag of the shock absorber p 40 Check the riding sag of the shock absorber p 41 Adjust the rebound damping of the shock absorber p 39 Removing the shock absorber Jack up the motorcycle p 38 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 6 push splash protector to the side and remo
67. epeatedly until the brake linings lie on the brake disc and there is a noticeable pressure point Correct the brake fluid reservoir level to the marking Brake fluid DOT 4 DOT 5 1 p 105 Mount the screw cap with the membrane and the O ring e Info Clean up overflowed or spilt brake fluid immediately with water Jack up the motorcycle p 38 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove screw Loosen screw Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e 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 MAINTENANCE WORK ON CHASSIS AND ENGINE gs Installing the front wheel amp Warning A Danger of accidents Reduced 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 500084 11 Clean and grease shaft seal rings and bearing surface of the spacers Long life grease p 107 Insert the spacers Lift the front wheel into the fork position it
68. esting locations should be noticeable If click positions are noticeable Adjust play of the steering head bearing A p 46 Check the steering head bearing and replace if required Remove the motorcycle from the work stand p 38 ____MAINTENANGE WORK ON CHASSIS AND ENGINE ag Adjusting play of steering head bearing A Removing the fork legs bus gt mw Lia hw f 100803 10 Jack up the motorcycle p 38 Loosen screw Remove screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 Ibf 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 12 5 Ibf ft Mount and tighten screw Guideline Screw top steering stem M8 17 Nm Loctite 2437 12 5 Ibf ft Check the steering head bearing play p 45 Remove front wheel p 64 Remove screws 6 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 Unscrew screws Take out the left fork leg Unscrew screws O Take out the right fork leg Position the fork legs e Info l 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 fr
69. et ne Rer ay A kO Eee d 5 Troubleshooting Ss RR KK KK KK 87 88 Type label urbe pepe oy ine teas 12 Use definiti n uh sped ot Ava xS 5 View of vehicle lel TO ca ayar stu HC qoa RANTE Ses Bes 10 righE Tear s suus woe acr Ros efe UR RUE ees 11 Warranty 5 nore eet b 5 Wiring diagram oooo 102 104 Work TUl s 2 a Ka a wo REESE 5 3211468en IenlW o ud 6007 60 N KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com
70. ete made tune ferto aste d Veo De dert ERE A 90 SIOLagG iie ceret ok A ia eie eral 90 Putting into operation after storage l UU 90 TECHNICAL DATA ENGINE eeeeeeenn me 91 Capacity engine olle lx cellad ka anek hei xad nosed enatis 91 Capacity gear oil 91 Gapacity coolant us esteri eiue tina 92 TECHNICAL DATA ENGINE TIGHTENING TORQUES 93 TECHNICAL DATA CARBURETOR 4 J kk 95 450 EXG USA aliados oui cocina ties 95 b3O4EXCUSRA nitido pb UE e RD RI TR 95 TECHNICAL DATA CHASSIS Jll kk 96 Lighting equipment iii 96 I c 97 Capacity fuels cierre in c o eV EATON 97 TECHNICAL DATA FORK sess 98 TECHNICAL DATA SHOCK ABSORBER eee 99 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 100 WIRING DIAGR AN 5 5 kisandin kk e dak len h k ben l a ad nnne 102 Wiring diagramie san ena k ya dan Kak Kura Ee e e Ee vete ese vd 102 SUBSTANGES rs ne pne e Ee s uetus AR 105 AUXILIARY SUBSTANCES St 5 4440 stakaks by l nnn 107 STANDARDS Zin set connie ee ke EU d E PEE Mer CR 109 Lj DI EO RR AW DA 110 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 worksh
71. evel The engine oil must be between the halfway mark and the top of the oil level viewer O Ifthe engine oil level is below the specified level Top up the engine oil p 84 Changing engine oil and oil filter cleaning engine oil screen A Drain the engine oil and clean the engine oil screen p 82 Remove the oil filter A p 82 Install the oil filter A p 83 Fill up with engine oil A p 83 301489 10 Draining engine oil cleaning engine oil screen Warning Danger of scalding Engine 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 hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations e 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 O Guideline Plug engine oil screen M17x1 5 20 Nm 14 8 Ibf ft 200112 10
72. f 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 Ibf ft 500068 01 Removing the fuel tank Danger Fire hazard Fuel 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 poisoning Fuel 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 Remove the seat p 71 Turn handle O of the fuel tap to the OFF position Figure 500137 10 p 22 Pull off the fuel hose e Info Remaining fuel may flow out of the fuel hose Remove screws with the collar sleeve Hang
73. fork legs Turn back counterclockwise by the number of clicks corresponding to the fork type Guideline Compression damping Comfort 26 clicks Standard 22 clicks Sport 18 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Mount protection covers Adjusting rebound damping of fork e Info The hydraulic rebound damping determines the fork suspension behavior Turn adjusting screws clockwise until they stop e 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 24 clicks Standard 20 clicks Sport 20 clicks Adjusting spring preload of the fork Bleeding fork legs Cleaning the dust boots of the fork legs 500088 10 e info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Turn adjusting screws counterclockwise until they stop e 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 O turn Standard 2 turns Sport 4 turns Info Turn clockwise to increas
74. formation warning labels If they are miss ing you or others may not recognize potential hazards and may therefore be injured Grades of risks Danger Al Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken Warning A 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 xt Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual Itis 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 additio
75. g the air filter box lid ooonccccccnncoccncconnnccncnnnon 76 Removing the air filter 76 Installing the air filter V ee 77 Cleaning air filter kek 77 Adjusting basic position of clutch lever 77 Checking the fluid level of hydraulic clutch 78 Changing the hydraulic clutch fluid j 78 Checking the basic position of the shift lever 79 Adjusting the basic position of the shift lever 79 Carb retor dle nc acte lbs kin av e ak Sib nadi k A e lak 80 Carburetor adjusting idle V 80 Emptying the carburetor float chamber A 81 __ TABLE OF CONTENTS gt a Checking engine oil level 81 Changing engine oil and oil filter cleaning engine oil Core qe ET 82 Draining engine oil cleaning engine oil screen A 82 Removing the oil filter Acciona 82 Installing the oil filter M ccoo 83 Filling up with engine oil EE 83 TOPPING up engine oil M h A KhK E kek Checking the gear oil level Changing gear oil cleaning gear oil screen A 84 Draining gear oil cleaning gear oil screen A 85 Filling up with gear oil X ue 85 Adding gear oil ssesssse 86 TROUBLESHOOTING 3 2 4 02044 ie ee kele fee ee de es ea 87 GEEANING noce o 89 Cleaning the motorcycle kek 89 STORAGE
76. g to the shock absorber type Guideline Compression damping high speed 400208 10 Comfort 2 turns Standard 1 5 turns Sport 1 25 turns e Info Turn clockwise to increase damping turn counterclockwise to reduce damp ing Adjusting the low speed compression damping of the shock absorber Danger Danger of accidents Disassembly 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 e Info I The low speed setting can be seen during the slow to normal compression of the shock absorber Turn adjusting screw O clockwise with a screwdriver up to the last perceptible click e Info Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 22 clicks Standard 20 clicks Sport 15 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Adjusting rebound damping of the shock absorber Danger Danger of accidents Disassembly 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE gy Mea
77. gh speed Comfort 2 turns Standard 1 5 turns Sport 1 25 turns 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 Ib 69 N mm 394 Ib in Weight of rider 75 85 kg 165 187 Ib 72 N mm 411 Ib in Weight of rider 85 95 kg 187 209 Ib 76 N mm 434 Ib in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 105 mm 4 13 in Fitted length 411 mm 16 18 in Damper oil Shock absorber oil SAE 2 5 5018034281 p 105 _____TEGHNIGAL DATA CHASSIS TIGHTENING TORQUES tm Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 Ibf ft Screw spoiler on fuel tank M5x12 1 5 Nm 1 11 Ibf ft Spoke nipple rear wheel M5 5 6 Nm 3 7 4 4 Ibf ft Remaining nuts chassis M6 15 Nm 11 1 Ibf ft Remaining screws chassis M6 10 Nm 7 4 Ibf ft Screw ball joint of push rod on foot M6 10 Nm 7 4 Ibf ft brake cylinder Screw front brake disc M6 14 Nm 10 3 Ibf ft Screw rear brake disc M6 14 Nm 10 3 Ibf ft Screw shock absorber adjusting ring M6 5 Nm 3 7 Ibf ft Nut rear sprocket screw M8 35 Nm 25 8 Ibf ft Loctite 2437 Nut rim lock M8 10 Nm 7 4
78. heck the tire air pressure p 67 e e e Check the chain wear p 53 e e e Check the chain tension p 52 e e e Clean the chain p 52 e e e Check the wheel bearing for play A 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 ___SERVIGE SCHEDULE ______ e____ Important maintenance work to be carried out by an authorized KTM workshop as additional order Competition use Hobby use S15N S45A J1A S15A S30A S45A S30A S60A S90A Perform a fork service X Perform a shock absorber service 4 Grease the steering head bearing p 49 e Treat electric contacts with contact spray Change the hydraulic clutch fluid 4 7 p 78 Change the front brake fluid 4 Change the rear brake fluid 4 Clean the spark arrestor X e Check wear of clutch discs A e Check the clutch 4 e e Check measure the cylinder 4 Change the piston 4 Check the camshaft 4 e Change the camshaft bearing A Check the valve spring seat X Check the cylinder head 4 Check the valves A e Check the valve springs Check the radial clearance of the rocker arm rollers A Check the timing chain tensioner function 4 Check the balancer shaft
79. hildren 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 Clean the motorcycle p 89 Change the engine oil and oil filter and clean the engine oil screen p 82 Change the gear oil and clean the gear oil screen p 84 Check the anti freeze and coolant level p 73 Drain the fuel from the tanks into a suitable container Empty the carburetor float chamber p 81 Check the tire air pressure p 67 Remove the battery p 68 Recharge the battery A p 69 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 e Info KTM recommends jacking up the motorcycle Jack up the motorcycle p 38 Cover the vehicle with an air permeable cover or blanket e Info I 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 combustio
80. ially on wet surfaces AO 400602 10 Checking tire air pressure Info Examine the front and rear tires for cuts foreign bodies and other damage f you find cuts foreign bodies or other damage on a tire Change the tires Check the depth of the tread e Info Note local national regulations concerning the minimum tread depth Minimum tread depth 2 2 mm gt 0 08 in Ifthe tread depth is less than the minimum allowable depth Change the tires Check the age of the tires e Info I 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 o I 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 400695 01 Remove the dust cap Check tire air pressure when tires are cold Tire air pressure off road Front 1 0 bar 15 psi Rear 1 0 bar 15 psi Road tire pressure Front 1 5 bar 22 psi Rear 2 0 bar 29 psi Ifthe tire pressure does not meet specifications Corre
81. 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 Ifthe 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 34 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 22min 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 Braking Warning Danger of accidents If you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake syst
82. ing stem M8 17 Nm Loctite 2437M 12 5 Ibf ft Check the cable harness cable brake and clutch line for free movement and free laying Check the steering head bearing play p 45 MAINTENANCE WORK ON CHASSIS AND ENGINE gy Greasing the steering head bearing A e Remove the lower triple clamp p 47 Install the lower triple clamp A p 48 Ga 800010 10 Remove screws Remove the front fender Make sure the spacers remain in place 600692 10 Ensure that the spacers are mounted in the fender Position the front fender Mount and tighten screws d Guideline 4 Remaining screws chassis M6 10 Nm 7 4 Ibf ft N e Info Make sure the holding lugs engage in the start number plate or headlight mask 600692 TO Switch off all electrical equipment Remove screw and take off clamp Loosen the rubber band Push up the headlight mask and swing it forwards Pull out the electric plug connector and remove the headlight mask with the headlight ENS 7 N 600702 10 600702 10 ____MAINTENANGE WORK ON CHASSIS AND ENGINE ______________so____ Refitting the headlight mask with the headlight lm AS SPP a Connect the electric plug connector Position the headlight mask and fix it with the rubber band e Info Ensure that the retaining lugs engage in the fender Position the bra
83. ion The motorcycle is stationary Press the button O briefly and repeatedly until H appears at the bottom right of the display Press the button O for 3 5 seconds TR TR2 AL MSS X The setup menu is displayed and the active functions shown M MZ gt kmh Mhz 0D0 LAP CLK H AN 400329 0 Press the button O repeatedly until the Km h Mph display flashes Km h adjusting Press the button Mph adjusting Press the button CONTROLS gg Setting the clock 400330 0 Adjusting the speedometer functions Press the button O for 3 5 seconds Y The settings are stored and the setup menu is closed e Info I 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 Condition The motorcycle is stationary Press the button O briefly and repeatedly until CLK appears at the bottom right of the display Press the button O for 3 5 seconds Y The hour display flashes Set the hour display with the button and or button Press the button O briefly Y 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 the button and the button e Info The seconds can only be set to zero Press the button O for 3 5 seconds Y The set
84. ive to the reference marks The rear wheel is then correctly aligned Tighten nuts Make sure that the chain adjusters O are fitted correctly on the adjusting screws Tighten nut O Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft Info e 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 Loosen nuts O 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 O Remove screws and Take off the chain guide Condition Number of teeth lt 44 teeth Insert nut O in hole O Position the chain guide Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Condition Number of teeth 2 45 teeth Insert nut O in hole O Position the chain guide Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Km Warning 4X Danger of accidents Reduced braking efficiency due to worn brake disc s Change the w
85. k empties down to the reserve e Reserve fuel supply open RES Fuel flows from the tank to the carburetor The fuel tank empties completely 500137 10 Press release button turn filler cap counterclockwise and lift it upwards and remove Replace the filler cap and turn clockwise until the release button locks in place e Info Route the fuel tank breather hose without kinking 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 mL i Info If the engine is warm the choke function must be deactivated mM Possible states q e e Choke function activated The choke lever is pulled out to the stop E e Choke function deactivated The choke lever is pushed in to the stop 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 Foot brake lever is located in front of the right footrest The foot brake lever is used to activate the rear brake 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 e Info Before riding swing
86. ke line and wiring harness Put the clamp on mount and tighten screw Check the headlight adjustment p 70 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 6 from the center Distance between holes 3 5 mm 0 138 in The handlebar supports can be mounted in 4 different positions 400271 11 Adjusting the handlebar position amp Warning Danger of accidents Handlebar breakage Ifthe 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 e 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 400271 10 screws Guideline Screw handlebar support M10 40 Nm Loctite 2437 29 5 Ibf ft e Info Position evenly the left and right handlebar supports Position the handlebar e Info Make sure cables and wiring are positioned correctly Checking throttle cable route 400192 10 Adjusting the play in the
87. leaded ROZ95 RON95 PON91 00 According to DIN EN 228 ROZ 95 RON 95 PON 91 Guideline KTM recommends Motorex products Supplier Motorex Twin Air Dirt Bio Remover KTM recommends Motorex products Chain Clean 611 Guideline KTM recommends Motorex products Protect amp Shine 645 KTM recommends Motorex products Accu Contact Guideline KTM recommends Motorex products KTM recommends Motorex products Moto Clean 900 Guideline KTM recommends Motorex products Chain Lube 622 KTM recommends Motorex products Twin Air Liquid Bio Power Guideline KTM recommends Motorex products Supplier Motorex Clean amp Polish Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal STANDARDS tog JASO T903 MA 7II 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 The SAE viscosity classes wer
88. level p 84 ____MAINTENANGE WORK ON CHASSIS AND ENGINE ______________se____ Adding gear oil A e info Too little gear oil or poor quality oil results in premature wear to the transmission Remove gear oil level check screw 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 Engine oil SAE 10W 50 p 105 Mount and tighten the gear oil level check screw Guideline Screw gear oil level check M6 8 Nm 5 9 Ibf ft Mount and tighten screw cap 200118 11 Danger Danger of poisoning Exhaust 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 TROUBLESHOOTING a Faults The engine cannot be cranked elec tric starter Possible cause Operating error Action Go through the steps of starting the engine p 31 Battery discharged Recharge the battery A p 69 Check the charging voltage A Check the stall current Check the generator X Fuse blown Remove the fuse p 70 Install the fuse p 70 Starter relay defective Check the starter relay X Star
89. ly e 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 Screw in the idle adjusting screw 6 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 N Open 2 0 turns aM Ve Adjustment tool for mixture control screw 77329034000 Run the engine until warm Guideline Warm up time gt 5 min Danger Danger of poisoning Exhaust 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 Choke function deactivated The choke lever is pushed in to the stop p 23 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 e Info I
90. ly dis play environmental consciousness and respect the rights of others Type label for Canada Type label for the USA Fuel evaporative system information Chain tension information Information on putting into operation Emission control information NI S mo Bl QI NI Noise emission information 500250 01 Type label for Canada MFD BY KTM SPORTMOTORCYCLE AG AUSTRIA SPORTNETSRCYCLES MOTORCYCLE DATE OOO Sd LE ELT GAWR FRONT 320 lbs 145 kg WITH 90 90 21 TIRE 54M TYPE 1 60 21 RIM AT 22 psi 1 5 bar COLD GAWR REAR 419 Ibs 190 kg WITH 140 80 18 TIRE 65M TYPE eee ee eee rete rere eee rere eee ert eer ere eee ee eee THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE Type label for the USA Fuel evaporative system information VACUUM HOSE ROUTING DIAGRAM ENGNE FAMILY AKTXCSTOEXC EVAPORATIVE FAMILY AKTXE0010EXC 100841 01 Chain tension information 0 4in ys 500255 01 ACHTUNG Information on putting into operation Lesen Sie vor der ersten Inbetriebnahme des Motorrades die gesamte Bedienungsanieitung aufmerksam durch IMPORTANT Before you go for the first ride on your motorbike read the entire User s Guide carefully ATTENZIONE Prima della prima messa in servizio del motociclo leggere attentamente L intero manuale d uso ATTENTION
91. n a RN 71 Fueltap suis dan n CER UE E ER 22 Fuel oilS ele usce one ee aus RUE EOS 5 Fuse installing ix crue mem eR Ry e 70 nnam 70 Gear oil adding 2 ia ee teen RED 86 changing 4 Lost sid dt d bt se EE 84 draining t aate unam REUS qam orte 85 refilling s sus caet acuden ox Ate Fo UR ORE Ea 85 Gear oil level checking usse a a reg ARA e ee ene 84 Gear oil screen cleanifig esa dece Reden que Dos E ee onus gie 84 85 Hand brake lever llli 14 free travel adjusting o o o ooooooooo ooo 57 free travel checking kk KK K KK KIRR KK KIRI KIIR 56 Handlebar position o o RR 50 adjusting ia A ENT ERR ADAE 50 Headlight beam width adjusting KK KK KK KK KIRI 71 Headlight adjustment checking o 4 see eq aru oa ate es ROO E Reo eer 70 Headlight flasher button 15 Headlight mask with headlight installing duce e d e Eu e UNS Eae A 50 removing 44 a bd dt RR enn 49 Horn button acc ca ERR RAE Rete s 15 Ignition switch LV VS KK KK KIRR KI KK eee 14 Key number kk kK KK KK KI KK i 12 Kick Starter na n Seaan did dur se ka nae sd 23 Light SWIEtG N l lt lt lt Ay okay a haw dd tme e W RE RES 15 Lower triple clamp TIEITIE Ay lt estere K aa re ean AA bac digas 48 PEMMOVING lt u yan layan a T dl d a dia K Tae ra E ne a 47 Main silencer installing a gine RUBRI S AT BUR 76 l emovilg
92. n condenses and causes parts of the engine and exhaust system to rust Putting into operation after storage Remove the motorcycle from the work stand p 38 Install the battery A p 69 Refuel p 33 Check before putting into operation p 31 Take a test ride TECHNICAL DATA ENGINE m Design 1 cylinder 4 stroke engine water cooled Displacement 450 EXC USA 449 3 cm 27 418 cu in Displacement 530 EXC USA 510 4 cm 31 147 cu in Stroke 450 EXC USA 63 4 mm 2 496 in Stroke 530 EXC USA 72 mm 2 83 in Bore 95 mm 3 74 in Compression ratio 11 9 Idle speed 1 550 1 650 rpm Control OHC 4 valves controlled via rocker arm drive via tooth wheel chain Valve diameter intake 39 5 mm 1 555 in Valve diameter exhaust 31 7 mm 1 248 in Valve clearance Exhaust at 20 C 68 F 0 12 0 17 mm 0 0047 0 0067 in Intake at 20 C 68 F 0 10 0 15 mm 0 0039 0 0059 in Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing No bearing bushes DLC plated piston pins Pistons 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 tran
93. n 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 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 a
94. ng run Always let the vehicle cool first Note Material damage Damage 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 amp while the engine is idling Turn handle O of the fuel tap to the OFF position Figure 500137 10 p 22 Park the motorcycle on firm ground Refueling Danger Fire hazard Fuel 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 poisoning Fuel 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 hazard Improper handling of
95. ning set tings Clean the chain Chain cleaner p 107 Fit the steel sprocket e Tip Do not grease the chain Clean radiator fins Straighten bent radiator fins carefully Preparing for riding on wet and muddy surfaces 600870 01 600868 01 Seal the air filter box e Tip Seal the air filter box along the edges to prevent the ingress of dirt Clean the air filter A p 77 e Info Check the air filter approx every 30 minutes Fit a waterproofing device on the air filter Waterproofing device for air filter 59006021000 e Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and settings e Info Your authorized KTM workshop has the recommended carburetor tuning set tings Fit the steel sprocket Clean the motorcycle p 89 Straighten bent radiator fins carefully Preparing for rides at high temperature and slow speed Check the radiator cap Value on radiator cap 1 8 bar 26 psi Ifthe displayed value does not correspond to specifications Warning Danger of scalding During motorcycle operation the coolant gets very hot and is under pressure Do not remove the radiator cap radiator hoses or other cooling 600872 10 system components when the engine is hot Allow the engine and cooling system to cool down In case of scalding rinse immediately with l
96. ny 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 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 B WN eB 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 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 View of the vehicle from the left front example 300399 10 Side stand
97. o OWNER S MANUAL 2010 _ 450 EXC USA 930 EXC USA Art no 3211468en DEAR KTM CUSTOMER a 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 Chassis number p 12 Dealer s stamp Engine number p 12 Key number p 12 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 p
98. ont MAINTENANCE WORK ON CHASSIS AND ENGINE gy O 39 a m j 100803 11 100802 11 Removing the fork protector 4 600878 10 Installing the fork protector 600878 10 Removing the lower triple clamp 4 500099 10 Fully tighten screw O Guideline Screw top triple clamp M8 17 Nm 12 5 Ibf ft Tighten screws O Guideline Screw bottom triple clamp M8 12 Nm 8 9 Ibf ft Position brake caliper mount and tighten screws 9 Guideline Screw front brake caliper M8 25 Nm Loctite 2437 18 4 Ibf ft Mount cable clip O Position the brake line and wiring harness Put the clamp on mount and tighten screws Install the front wheel p 65 Remove the fork legs p 46 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 Position the fork protection on the left fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the fork protection on the right fork leg Mount and tighten the screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Install the fork legs A p 46 Remove the fork legs A p 46 Remove the headlight mask with the headlight p 49 Remove the front fender p 49
99. op There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required EXS Identifies a page reference more information is provided on the specified page The typographical and other formats used are explained below Proprietary name Denotes a proprietary name Denotes a protected name BrandTM Denotes a brand available on the open market 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 e Info I 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 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 servi
100. orn 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 e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Brake discs wear limit Front 2 5 mm 0 098 in 400257 10 Rear 3 5 mm 0 138 in Ifthe 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 Ifthe brake disc shows signs of damage cracking or deformation Change the brake disc A Warning ZJ Danger of accidents Brake 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE sg Push the hand brake to the handlebar and check free travel Free travel of hand brake lever gt 3 mm 20 12 in Ifthe free travel does not meet specifications Adjust the free travel of the hand brake lever p 57 400196 13 Adjusting free travel of hand brake lever Check the free travel of the hand brake lever p 56 Adjust the free travel of the hand brake lever
101. pins lock washers must be replaced by new parts If thread lock e g Loctite9 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 Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Fire hazard Some vehicle components become very hot when the vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first Switch off engine IMPORTANT INFORMATION s Turn handle of the fuel tap to the OFF position Figure 500137 10 p 22 Use straps or other suitable devices to secure the motorcycle against accidents or falling over 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 legal
102. re air pressure p 67 e Check the tire condition p 67 e Check the coolant level p 74 e Empty the carburetor float chamber 4 p 81 ha Check all controls for smooth operation Check braking Check all screws nuts and hose clamps regularly for tightness NB1A Depending on conditions of use according to requirements ____MAINTENANGE WORK ON CHASSIS AND ENGINE gp Jacking up the motorcycle Note Danger of damage The 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 500074 01 Secure the motorcycle against falling over Removing the motorcycle from the work stand Note Danger of damage The 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 Checking the basic suspension setting with the rider s weight e 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 stand
103. rea make a mark as high as the center of the headlight Make a second mark at distance of 6 under the first mark Guideline Distance 5 cm 2 in 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 Adjust the beam width of the headlight p 71 MAINTENANCE WORK ON CHASSIS AND ENGINE ________ a Adjusting the beam width of the headlight Check the headlight adjustment p 70 Loosen screw Q 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 e Info If you have a payload you may have to correct the headlight beam width 301251 10 Tighten screw Remove screw Lift up the seat at the rear pull it back and then remove from above 500080 10 Mounting the seat Hook in the front o
104. rect if neces sary Jack up the motorcycle p 38 Push the chain up at the rear edge of the chain guide to measure the chain ten sion Q Info The upper chain section 9 must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws O left and right Guideline Chain tension 8 10 mm 0 31 0 39 in Turn adjusting screws O 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 G The rear wheel is then correctly aligned Tighten nuts Make sure that chain adjusters O are fitted correctly on adjusting screws O Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 Ibf ft e Info I The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length Chain adjusters O can be turned by 180 Remove the motorcycle from the work stand p 38 Loosen nut O 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 relat
105. rience 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 e Info Motorcycles react sensitively to any changes of weight distribution GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION ________z___ Do not exceed the overall maximum permitted weight and the axle loads Guideline Maximum permissible overall weight 335 kg 739 Ib Maximum permissible front axle load 145 kg 320 Ib Maximum permissible rear axle load 190 kg 419 Ib Check the spoke tension p 68 e Info The spoke tension must be checked after half an hour of operation Run in the engine Running 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 7 000 rpm Maximum engine performance During the first 3 service hours lt 50 During the next 12 service hours lt 75 96 Avoid fully opening the throttle Preparing 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 befor
106. rocker arm M14x1 25 20 Nm 14 8 Ibf ft Plug gear oil screen M16x1 5 20 Nm 14 8 Ibf ft Plug engine oil screen M17x1 5 20 Nm 14 8 Ibf ft Nut inner clutch hub M18x1 5 80 Nm 59 Ibf ft B Nut primary gear M20LHx1 5 100 Nm 73 8 Ibf ft Loctite 243TM Plug timing chain tensioner M24x1 5 30 Nm 22 1 Ibf ft 450 EXC USA ____TEGHNIGAL DATA CARBURETOR lg Carburetor type KEIHIN FCR MX 39 Carburetor identification number 3900Z Needle position 4th position from top Idle mixture adjusting screw Open 1 75 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 180 Jet needle OBDYU Idling jet 48 Idle air jet 100 Cold start jet 85 Leakage nozzle 40 530 EXC USA Carburetor type KEIHIN FCR MX 39 Carburetor identification number 3900Y Needle position 3rd position from top Idle mixture adjusting screw Open 2 0 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 180 Jet needle OBDZT Idling jet 48 Idle air jet 100 Cold start jet 85 Leakage nozzle 40 ____TEGHNIGAL DATA CHASSIS gg _ 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
107. rties KTM recommends Castrol and Motorex products RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 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 Antifreeze 40 C 40 F Supplier Motorex Anti Freeze According to JASO T903 MA p 109 SAE p 109 SAE 10W 50 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 According to SAE p 109 SAE 5 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 According to SAE p 109 SAE 2 5 Guideline Use only oils that comply with the specified standards see specifications on the container and that possesses the corresponding properties ___SUBSTANGES gt SV V LEEIEL qoe Super un
108. ry for ensuring that maintenance work is car ried out at the right intervals 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 400316 0 Press the button No function Press the button No function Press the button O The display changes to the Setup menu of the speedometer for 3 5 seconds functions Press the button O Next display mode briefly CONTROLS gt ___ Display mode SPEED CLK clock Display mode SPEED LAP lap time LAP 400320 0 Display mode SPEED ODO odometer 400317 0 Display mode SPEED TR1 trip master 1 lu Ln LN L NT 400323 0 923 47 u Press the button No function IC Un 21 Press the button No functi CK ress the button o function Press the button O The display changes to the Setup menu of the clock for 3 5 seconds 400319 0 Press the button O Next display mode Press the button O briefly and repeatedly until CLK appears at the bottom right of the display The time is displayed in CLK display mode briefly Press the button O briefly and repeatedly until LAP appears at the bottom right of the display In the LAP display mode up to 10 lap times can b
109. sed 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 accidents Unstable riding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage 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 Adjust the basic position of clutch lever p 77 Adjust the free travel of the hand brake lever p 57 Adjust the basic position of the foot brake lever A p 60 Adjust the basic position of the shift lever 4 p 79 Get used to handling the motorcycle on a suitable piece of land before making a longer trip e 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 expe
110. smission 33 76 Clutch 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 12V 150 W Ignition Contactless controlled fully electronic ignition with digital igni tion adjustment type Kokusan Spark plug NGK LKAR 8AI 9 Spark plug electrode gap 0 9 mm 0 035 in Cooling Water permanent circulation of coolant by water pump Starter Electric starter kick starter Capacity engine oil Engine oil 0 60 I 0 63 qt Engine oil SAE 10W 50 p 105 Capacity gear oil Gear oil 0 90 I 0 95 qt Engine oil SAE 10W 50 p 105 TECHNICAL DATA ENGINE 1 1 1 o Capacity A Coolant 0 95 1 at Coolant p 105 Coolant mixed ready to use p 105 ____ TECHNICAL DATA ENGINE TIGHTENING TORQUES 1 15 __ Screw cable holder in generator cover M4 4 Nm 3 Ibf ft Loctite 2437 Locking screw for bearing M5 6 Nm 4 4 Ibf ft Loctite 2437 Oil jet piston cooling M5 2 Nm 1 5 Ibf ft Loctite 243TM Oil jet rocker arm lubrication M5 2 Nm 1 5 Ibf ft Loctite 2437 Screw ignition pulse generator M5
111. suring rear wheel sag unloaded 400221 10 Turn adjusting screw clockwise up to the last perceptible click e Info Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Jack up the motorcycle p 38 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 O Remove the motorcycle from the work stand p 38 Measure distance of rear wheel unloaded p 40 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 e Info The static sag is the difference between measurements and Check the static sag Static sag 35 mm 1 38 in Ifthe static sag is less or more than the specified value Adjust the spring preload of the shock absorber A p 41 ____MAINTENANGE WORK ON CHASSIS AND ENGINE 1 1 4 Checking riding sag of shock absorber 400222 10 Measure distance O of rear wheel unlo
112. t components Disconnect spring O Remove screws and take off main silencer ____MAINTENANCGE WORK ON CHASSIS AND ENGINE yx Installing the main silencer Mount the main silencer Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Reconnect spring Pull off the air filter box lid in area to the side and remove to the front 800021 10 Insert the air filter box lid into the rear area and clip it into the front area O 800021 11 Note Engine failure Unfiltered 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 hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Remove the air filter box lid p 76 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 Installing the air filter A Mount the clean air filter onto the air filter support Apply grease to the section of the air filter Long life grease p 107 301262 10 Put in both parts together posi
113. t flasher button Horn button 500142 11 Flasher switch 500142 12 Overview of indicator lamps Light switch is fitted on the left side of the handlebar Possible states z Low beam on Light switch is turned downward In this position the Z low beam and tail light are switched on High beam on Light switch is turned upward In this position the D high beam and tail light are switched on Headlight flasher button is fitted on the left side of the handlebar Possible states e Headlight flasher button is in home position e Headlight flasher button is pressed The headlight flasher is activated in this position Horn button is fitted on the left side of the handlebar Possible states e Horn button t is in home position e Horn button is pressed The horn is sounded in this position Flasher switch O 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 gt 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 Possible states High beam indicator lamp lights up blue High beam is switched on T
114. ter motor defective Check the starter motor 4 Engine turns but does not start Operating error Go through the steps of starting the engine p 31 Motorcycle was out of use for a long time and there is old fuel in the float chamber Empty the carburetor float chamber A p 81 Fuel supply interrupted Check the fuel tank breather Clean the fuel tap Check adjust the carburetor components 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 Check adjust the carburetor components Engine has no idle Idling jet blocked Check adjust the carburetor components Adjusting screws on carburetor dis torted Carburetor adjust the idle speed p 80 Spark plug defective Change spark plug Ignition s
115. terial damage Damage 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 hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations e 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 Motorcycle cleaner p 107 e 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 4 p 81 Warning Danger of accidents Reduced 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 e Info The heat generated causes water to
116. the horn and horn bracket to one side 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 500067 10 Installing the fuel tank 4 Danger Fire hazard Fuel 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 poisoning Fuel 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 y 500067 01 Mount the fuel tank vent hose Mount and tighten screw with the collar sleeve Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Position the horn with the horn bracket Mount and tighten scre
117. 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 Ifthe coolant level does not meet specifications Correct the coolant level Alternative 1 400243 10 Coolant p 105 Alternative 2 Coolant mixed ready to use p 105 Mount the radiator cap Draining coolant amp Warning Danger of scalding During 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 poisoning Coolant 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 _____MAINTENANGE WORK ON CHASSIS AND ENGINE gt Stand the motorcycle upright Place a suitable container under the water pump cover Remo
118. the upper part of the kick starter inwards towards the engine H 500148 10 ___ CONIROLS CCA Side stand VER Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Note Material damage Damage 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 500140 10 frame could be damaged and the motorcycle could fall over To park the motorcycle press side stand O 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 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 Vi Y 500126 10 Locking the steering Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface M 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 Y Steering is no longer possible e Info Never leave the key in the steering lock 400732 01 Unlocking the
119. throttle cable amp Position the handlebar clamp Mount and evenly tighten the four screws Guideline Screw handlebar clamp M8 20 Nm 14 8 Ibf ft e Info Make sure the gap width is even 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 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 specifications Adjust the play in the throttle cable A p 51 Danger Danger of poisoning Exhaust 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 let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change Ifthe idle speed changes Adjust the play in the throttle cable A p 51 Remove the fuel tank 4 p 71 Check throttle cable route p 51 Move the handlebar to the straight ahead position Push back bellows Loosen nut Turn adjusting screw
120. tings are stored and the setup menu is closed e Info I 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 Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated mr ZIMZIR AM A2 St 2 AN Km h Mph 000 LAP CLK H 400318 0 Condition The motorcycle is stationary Press the button O briefly and repeatedly until H appears at the bottom right of the display Press the button O for 3 5 seconds Y The Setup menu is displayed and the activated functions are shown Change to the desired function by pressing the button briefly Y The selected function flashes Activating a function Press the button Y The symbol remains on the screen and the display changes to the next function Deactivating the function Press the button Y 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 O for 3 5 seconds Y The settings are stored and the Setup menu is closed CONTROLS as 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 Querying the lap time e Info This function can be called
121. tion them and fix them with air filter holder Q9 e Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Install the air filter box lid p 76 Cleaning air filter A Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations e info Do not clean the air filter with fuel or gasoline since these substances attack the foam Remove the air filter A p 76 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 107 e 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 Oil for foam air filter p 107 Clean the air filter box Check carburetor connection boot for damage and tightness Install the air filter p 77 Adjusting 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 T
122. ton Next display mode briefly Display mode SPEED TR2 trip master 2 Press the button O 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 TR2 a oO N 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 O O 400324 0 Press the button Increases value of TR2 Press the button Reduces value of TR2 Press the button O Deletes value of TR2 for 3 5 seconds Press the button O Next display mode briefly Display mode SPEED A1 average speed 1 Press the button O 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 1 120 The calculation of this value is activated by the first impulse of the wheel speed sensor lt i and ends 3 seconds after the last impulse Press the button No function Press the button No function 4003730 Press the button The TR1 A1 and S1 displays are reset to 0 0 for 3 5 seconds
123. ukewarm water Change the radiator cap Seal the air filter box A e Tip Seal the air filter box on the edges against dirt Clean the air filter amp p 77 e Info Check the air filter approx every 30 minutes Adjust the secondary drive to the road conditions e 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 Chain cleaner p 107 Clean radiator fins 600868 01 Straighten bent radiator fins carefully Check the coolant level p 74 Preparing for rides at low temperatures or in snow Seal the air filter box e Tip Seal the air filter box on the edges against dirt Clean the air filter A 9 p 77 e Info Check the air filter approx every 30 minutes Fit a waterproofing device on the air filter Waterproofing device for air filter 59006021000 e Info See the KTM PowerParts fitting instructions Adjust the carburetor jetting and settings e Info 600870 01 Your authorized KTM workshop has the recommended carburetor tuning set tings ___RIDING INSTRUCTIONS gt a Checks before putting into operation e info l 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
124. urn signal indicator lamp flashes green Turn signal light is switched on CONTROLS tg Speedometer Press the key O 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 e Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated 400312 01 Speedometer activation and test 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 0 WS wheel size After the display function test the wheel size WS is displayed briefly 3 m C e Info i i i 2205 mm corresponds to the size of the 21 front wheel with a series produc n Xan a tion tire WS The display then changes to the last selected mode 400314 0 Tripmaster switch Option Tripmaster switch You can use the trip master switch to control the functions of the speedometer from the handlebar e Info The trip master is an optional accessory setting kilometers or miles e 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 Condit
125. urn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 500133 11 ____MAINTENANGE WORK ON CHASSIS AND ENGINE 1 gt gt Checking the fluid level of hydraulic clutch A Warning Skin irritation Brake 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 Ifthe level of the fluid does not meet specifications Correct the fluid level of the hydraulic clutch Brake fluid DOT 4 DOT 5 1 p 105 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt fluid immediately with water Changing the hydraulic clutch fluid A A Warning Skin irritation Brake fluid can cause skin irritation on contact
126. ute h d 51 Preparing for riding on wet sand 28 Checking the play in the throttle cable 51 Preparing for riding on wet and muddy surfaces 29 Adjusting the play in the throttle cable A 51 Checking for chain dirt accumulation 52 Cleaning the ehal io ette bee e ete deeds os 52 Checking the chain tension hhw L kk 52 Checking chain tension when fitting rear wheel 53 Checking the rear sprocket engine sprocket for wear 53 Checking chain wear 53 Adjusting chain tension essseesseeeeeenene 54 Adjusting chain tension after checking 55 Adjusting chain tension fitting rear wheel 55 Adjusting chain guide A seeeenn 56 Checking brake diScs 4 3 us nece rh lan Perth DA dented hs 56 Checking free travel of hand brake lever 56 Adjusting free travel of hand brake lever 57 Checking the brake fluid level of the front brake 57 Topping up the front brake fluid J amp 57 Checking the front brake liningS E UU 58 Changing the front brake linings amp 59 Checking the free travel of the foot brake lever 60 Adjusting the basic position of the foot brake lever
127. ve screw Remove the radiator cap O Completely drain the coolant Fit screw with a new seal and tighten it Guideline Screw water pump cover M6x25 10 Nm 7 4 Ibf ft a Warning Danger of poisoning Coolant 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 o Guideline 10 mm 0 39 in Coolant 0 95 1 qt Coolant p 105 Coolant mixed ready to use 400244 10 p 105 Refit the radiator cap Make a short test ride Check the coolant level p 74 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 Warning b Danger of burns The exhaust system gets very hot when the vehicle is driven EN ww t Allow the exhaust system to cool down Do not touch ho
128. ve the shock absorber Push splash protector to the side and position the shock absorber Mount and tighten screw Guideline Screw top shock absorber M12 80 Nm Loctite 2437 59 Ibf ft Mount and tighten screw Guideline Screw bottom shock M12 80 Nm Loctite 243 800023 11 absorber 59 Ibf ft Info e l 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 Remove the motorcycle from the work stand p 38 ____MAINTENANGE WORK ON CHASSIS AND ENGINE 1 a Checking basic setting of fork e 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 Adjusting the compression damping of the fork e info The hydraulic compression damping determines the fork suspension behavior Remove protection covers Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the bottom end of the fork legs Make sure the setting is identical on both
129. ver 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 e Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes Remove locking split pins withdraw bolt and take out the brake pads Clean brake caliper and brake caliper support _____MAINTENANGE WORK ON CHASSIS AND ENGINE ______________ a____ 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 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 Q Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 105 Position the cover with the membrane Mount and tighten the screws e Info Clean up overflowed or spilt brake fluid immediately with water Warning Danger of accidents Brake 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 le
130. ver according to specifications Disconnect spring O 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 4 p 60 Reconnect spring O Warning Danger of accidents Brake 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 ____MAINTENANGE WORK ON CHASSIS AND ENGINE gy Disconnect spring O 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 6 accordingly e Info The range of adjustment is limited 500154 10 Turn push rod accordingly until you have free travel If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw and tighten nut O Guideline Remaining nuts chassis M8 30 Nm 22 1 Ibf ft Hold push rod O and tighten nut O Guideline Remaining nuts chassis M6 15 Nm 11 1 Ibf ft
131. witch 14 Engine FUN Din GEL e dr ta 27 Engine number LL LL A LL LA A VS KK KK KI KK KI KK KI KK 12 Engine oil Changing zx be eeu obe e re 82 ol qetla SN aset tse t ada et RUD Oe Ae 82 refilling xoc S kalan to tr KAN Sank pam eds fo a oe 83 TOPPING D ck evum KED a A E enan EET 84 Engine oil level CHECKING uo xe he a ras 81 Engine oil screen cleaning Like xA ber A a etr t 82 Environment vix oot eA M EVA ede 6 F Filler cap CLOSING a ern wat ed etel s drei ec ea Re es 22 OPINAS zz aeos ener ac Suen es US RO ea a Dat e 22 Filling up fael pe Seated dele ib eee Et EE dl daa 33 Flasher switch oooooooooooooooooo ooo 15 Foot brake lever oooooooooooooooooo 23 basic position adjusting ooooooooooo 60 free travel checking o o oo oooooooooooo 60 Fork basic setting checking kK KK KK KK KK KIIR 43 Fork legs bleeding 1 23 o h ka be eer OR wata d poe ie oA d 44 dust boots cleaning eee eee eee 44 O ur KAN an Eu etr Reden yd 46 removing A5 3 2 j x lt eR wi i k P bd ul T EE 46 Fork protector installing zia ET eel QE UIT P 47 KemoVvIlg ded sa ec rut s ete Yd tg A RR 47 Front fender installing cruce Rede EAR me 49 Fe mOVI O A Pr m 49 Front wheel installing eck zer avec pe e eMe ERU qa 65 remoVlDEg aaa HHHH anta ED EE A 64 Fuel tank installing adu Be cad m P RR a 72 removing xi i ERO Ga RARE Sea l di
132. with adjusting screw O 2d Info e 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 A00196 12 Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Checking the brake fluid level of the front brake Warning Danger of accidents Failure of the brake system Ifthe 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 accidents Reduced 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 Ifthe brake fluid is below the MIN mark Top up the brake fluid of the front brake 4 p 57 400231 10 Topping up the front brake fluid Warning Danger of accidents Failure of the brake system Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings
133. ws with the collar sleeve Guideline Remaining screws chassis M6 10 Nm 7 4 Ibf ft Connect the fuel hose Mount the seat p 71 The water pump O 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 Checking the anti freeze and coolant level Warning Danger of scalding During 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 poisoning Coolant 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
134. you ride Check the engine oil level p 81 Check the chain tension p 52 Check for chain dirt accumulation p 52 Check the tire condition p 67 Check the tire air pressure p 67 Check the brake fluid level of the front brake p 57 Check the rear brake fluid level p 61 Check the front brake linings p 58 Check the rear brake linings p 62 Check the brake system function Check the coolant level p 74 Check the settings of all controls and ensure that they can be operated smoothly Check the functioning of the electrical equipment Starting Danger Al Danger of poisoning Exhaust 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 failure High 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
135. ystem defective Check the ignition coil A Check the CDI controller Check the spark plug connector Check the ignition pulse generator Check the generator X Engine does not speed up Carburetor running over because float needle dirty or worn Check adjust the carburetor components Loose carburetor jets Check adjust the carburetor components 4 Ignition system defective Check the ignition coil A Check the CDI controller Check the spark plug connector Check the ignition pulse generator Check the generator X Engine has a lack of power Fuel supply interrupted Check the fuel tank breather Clean the fuel tap Check adjust the carburetor components TROUBLESHOOTING sa Faults Engine has a lack of power Possible cause Air filter heavily contaminated Action Clean the air filter V p 77 Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Change glass fiber yarn filling of main silencer A Valve clearance too little Adjust the valve clearance A Ignition system defective Check the ignition coil A Check the CDI controller Check the spark plug connector 4 Check the ignition pulse generator 4 Check the generator X Engine stalls or pops back into the carburetor Lack of fuel Turn handle O of the fuel tap to the ON posi tion Figure 500137 1

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