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KTM 3CF6001F5EN Motorcycle User Manual

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1. STANDARD ADJUSTMENT FORK TIGHTENING TORQUES CHASSIS WP4860MXMA WP4357MXMA Collar nut front wheel spindle M 16 20x1 5 40 Nm 30ft Ib 1418W710 0518W712 Brake caliper front M8 Loctite 243 25 Nm 19ft Ib Compression adjuster 20 20 Brake disk front M6 Loctite 243 15 Nm 11ft Ib Rebound adjuster 16 12 Brake disk rear M6 Loctite 243 15 Nm 11ft Ib Spring 4 4 N mm 4 2 N mm Clamping screws upper fork bridge M8 20 Nm 15ft Ib Spring preload 5 mm 0 20in 5 mm 0 20in Clamping screws lower fork bridge M8 15 Nm 11ft Ib Air chamber length 100 mm 5 1in 130 mm 5 9in Clamping screws fork stubs M8 10 Nm 7ft Ib Fork oil SAE 5 SAE 5 Collar nut rear wheel spindle M 20x1 5 80 Nm 59ft Ib Hexagon nut swing arm bolt M 14x1 5 100 Nm 74 16 Hexagon collar screw handlebar clamp M8 20 Nm 15ft Ib Allan head screw handlebar support M10 Loctite 243 40 Nm 30ft Ib Shock absorber top M12 60 Nm 44ft Ib Shock absorber bottom M12 60 Nm 44ft Ib STANDARD ADJUSTMENT SHOCK ABSORBER Sprocket screws M8 Loctite 243 35 Nm 25ft Ib Ball joint for push rod M6 Loctite 243 10 Nm 7ft Ib WP OO1S FDS WE 5018 5 Engine mounting bolt M10 45 Nm 33ft Ib pee MCC Engine brace M8 33 Nm 24ft Ib 1218W738 1218733 Screw adjusting ring spring preload shock abs M6 8 Nm 6ft lb Compression adjuster 15 LS Low speed 13 Other screws on chassis M6 10 Nm 7ft lb 2 HS high speed M8 25 Nm
2. X Chain wear In order to check the chain wear regard the following indications Shift the gear into idling and pull the upper chain strand with approx 10 15 Kilogramm 33 Ib upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different pla ces on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets CAUTION SECURE THE SCREWS OF THE CHAIN WHEEL BY APPLYING LOCTITE AND FASTEN THEM IN A CROSSWISE ORDER TIGHTENING TORQUE FOR NUTS 35 25 FT LB TIGHTENING TORQUE FOR SCREWS 50 Nm 37 FT LB General information about KTM disc brakes BRAKE CALIPERS The brake calipers of this series use a floating mount This means that the brake calipers are not solidly attached to the caliper support which enables them to float for maximum braking contact Secure the screws of the caliper support with Loctite 243 and tighten to 25 Nm 19 ft Ib BRAKE PADS The brake pads are fitted with TOSHIBA TT 2701 sintered lining at the front and TOSHIBA H 38 sintered lining at the back These linings provide an optimal combination of dosing brake performance and lifecycle The lining type is stated on the back of the br
3. Draining of float chamber of the carburetor Following every wet cleaning procedure the float chamber of the carbure tor should be drained in order to remove any water that may have penetra ted into it Water in the float chamber causes malfunction Perform this task on a cold engine Close the fuel tap and place a cloth underneath the carburetor which is able to absorb any escaping fuel Unscrew the plug and clean it with compressed air Check the O ring and reinstall the plug Open the fuel tap and check the float chamber for leaks A WARNING A FUEL IS EASILY FLAMMABLE AND TOXIC WHEN HANDLING FUEL BE SURE TO EXERCISE THE UTMOST CAUTION NEVER PERFORM ANY WORK ON THE FUEL SYSTEM IN THE PROXIMITY OF OPEN FLAMES OR BURNING CIGARETTES ALWAYS ALLOW THE ENGINE TO COOL OFF FIRST IMMEDIATELY CLEAN UP ANY FUEL WHICH MAY HAVE BEEN SPILLED MATERIALS SATURATED WITH FUEL ARE ALSO EASILY FLAMMABLE IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES CONSULT A DOCTOR IMMEDIATELY DISPOSE THE FUEL PROPERLY Oil circuit Via the long oil screen the oil pump 6 draws engine oil from the oil sump of the transmission This engine oil flows through an oil line 6 into the cylinder head for camshaft lubrication the oil quantity is controlled by the jet screw An oil duct branches off to the long oil filter where the coarser particles contained in the engine oil are filtered away Then the engine oil arr
4. 19 Chain Weal i et pr gr ede ea aes 20 HEAD WORD INDEX 44 General informations about KTM disc brakes 20 Adjusting of free travel at the hand brake lever 21 WIRING DIAGRAMME Appendix HSITDONA SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube Write this number into the field on page no 1 Engine number engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket Please note this number down on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever is located on the left side of the handlebar The adju sting screw is used to change the original position of the clutch lever see maintenance work on chassis and engine Hand decompression lever The hand decompression lever is needed only if a fall on your motorcycle causes overflowing in the carburetor To pump the engine free pull the hand decompression lever during the starting procedure The outer end of the lever must at all times provide for a backlash of approx 10mm 0 4 in Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompression level encounters CAUTION NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE RATHER USE THE SHORT CIRCUIT
5. EU zm 1 Fuse The fuse is disposed in the starter relay of the E starter underneath the left side paneling Having removed the left side paneling the air box cover and the protection cover you will be able to see the fuse The following loads are connected to it E starter system horn flasher lights The starter relay also contains a 10 amp spare fuse Replace a blown fuse only with an equivalent one If a new fuse that has just been set in gets blown again you are strongly advised to have it inspected by a KTM dealer The fuse capacity is 10 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the par king light lamp with holder O carefully out of the reflector Pull connector off the headlamp and remove rubber Disengage retaining clip and take bulb out of reflector When changing the parking light lamp sim ply pull it out of the holder Insert new lamp such that the noses engage the recesses When doing so do not touch the glass body of the lamp so that it remains free from fat Engage retaining clip mount rubber cap and connector If the parking light lamp is to be replaced simply insert it into
6. L J U 2 UJ HSITONGA NN Checking the adjustment of the hand decompression release cable Start the engine and at idling speed slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever The backlash until said thumping should be approx 10mm measured at the lever s outer end If necessary correct this backlash To adjust move back the protective cover loosen the counter nut and correct the adjustment screw accordingly Tighten counter nut and push back protective cover CAUTION IF THERE IS NO PLAY IN THE DEKO LEVER THIS CAN RESULT IN ENGINE DAMAGE NOTE No adjustment need be made to the automatic decompressor Adjusting the throttle cables The throttle grip should always provide for a backlash of 3 5mm Besides with the engine running the idling speed must not change if you turn the handlebar all the way to the left or right To adjust the throttle cables dismount the seat and the tank together with spoilers Slide back the protection cover Loosen the counter nut and turn the adjusting screw accordingly Turning the adjusting screw coun terclockwise will reduce the backlash turning the adjusting screw clockwise will increase the backlash Tighten the counter nut and check whether the throttle grip can be actuated smoothly Mount tank and seat Checking the oil le
7. Length of bypass valve spring MAINTENANCE WORK ON CHASSIS AND ENGINE A WARNING A MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK REQUIRES EXPERT SKILLS AND TECHNICAL KNOW HOW FOR YOUR OWN SAFETY ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CAR BURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT THE FUEL TAP IS IN THE OFF POSITION IF THE MOTORCYCLE SHOULD FALL OVER NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK USING OTHER SCREWS OR LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED REMOVE OILS FATTY MATTERS FILTERS FUELS WASHING DETERGENTS ETC ORDERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE S
8. 33 Compression damping of shock absorber MXC EXC 10 Adjusting the mixture control screw 33 Rebound damping of shock absorber SX MXC EXC 10 Checking the float level 33 Steering lock o Wel fes 10 Draining of float chamber of the carburetor 34 uec EO ae 34 DRIVING INSTRUCTIONS 11 Checking pri gereon ot Erigine oll i hice eae SERE TERIS 35 PERIODIC LUBRICATION AND MAINTENANCE SCHEDULE 14 IO gea sess idc d i TROUBLE SHOOTING 37 MAINTENANCE WORK ON CHASSIS AND ENGINE 16 Changing the original position of the clutch lever 16 39 Checking and adjusting the steering head bearing 16 Breather Plug WORE TOM edited 17 CONSERVATION FOR WINTER OPERARION 39 Cleaning the dust sleeves of the telescopic fork 17 Adjusting the spring preload on the fork SX 17 STORAGE 39 Pono Manel Dab DOsUON 15 Re initiation after time of 39 Changing the spring preload of shock absorber 18 Pivot bearihg E 18 TECHNICAL SPECIFICATIONS ENGINE 40 Check chain tension 19 E OEGE ENAN FENSION ed TECHNICAL SPECIFICATIONS 515 43 Chain maintenance
9. Check antifreezer and amount of cooling liquid Warm up the engine once again close the fuel cock and wait until the engine dies Then open the drain plug of the float chamber to remove the remaining fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slowly operate the kickstarter until you can hear the automatic decompressor click release Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate pivot points of the control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see chapter BATTERY The storage place should be dry and not subject to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST RE INITIATION AFTER TIME OF STORAGE Mount the charged battery regard po
10. KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS COLORS MATERIALS SERVICES OFFERED AND RENDERED AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI TUTING THEM WITH OTHERS IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS ANNOUNCEMENT IN THE EVENT OF SUCH MODIFICATIONS PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION WE SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS 2 A E I 2 Introduction We would like to congratulate you on your purchase of a KTM motorcycle You are now the owner of a state of the art sports motorcycle that guarantees to bring you lots of fun and enjoyment provided that you clean and maintain it appropriately Before you go for your first ride be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics even if this means that you have to dedicate some of your valuable time to this task Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury Besides this manual contains important information on motorcycle maintenance At the time this manual was typeset it was up to date with the latest state of this production series It cannot be completely ruled out
11. 19ft lb Rebound adjuster 25 25 M10 45 Nm 33ft lb Spring PDS7 260 PDS6 260 Other collar nuts on chassis M6 15 Nm 11ft lb Spring preload 4 mm 0 24 in 5 mm 0 24 in M8 30 Nm Q2ft Ib M 10 50 Nm 37ft Ib HEAD WORD INDEX Page Adjust the throttle cables 32 Adjusting digital 26 Adjusting of free travel at the hand brake 21 Adjusting the mixture control 33 Adjusting the spring preload on the fork 17 Battery ssssssssseeeee emen 28 Bleeding of the hydraulic 32 Bleeding the cooling system 30 Breather plug front fork sss 17 Carburetor adjust idling 33 Chain maintenance sssini saisai 19 Chain Wear ie eoi dee Ted ess 20 Changing the basic position of the brake pedal 22 Changing the engine oil sss 35 Changing the original position of the clutch lever 16 Changing the spring preload of shock absorber 18 Charging battery 28 Chassis NUMB Cirian ee es is 4 Check chain tension en 19 Check set distance of magnetic 27 Checking adjustment of the hand decompression
12. 400 520 SX MXC EXC RACING MODELS MAKE NO COMPROMISES IN THEIR DESIGN AS SUCH THEY DO NOT INCLUDE ANY RADIATOR FAN AND THE SIZE OF THE RADIATOR IS DIMENSIONED FOR OPTIMUM ERGONOMICS IN NORMAL RACING THE COOLING SYSTEM IS SUFFICIENT IF YOU USE YOUR MOTORBIKE IN OTHER CONDITIONS PLEASE NOTE THAT THE E STARTER ALLOWS YOU TO START MXC EXC RACING MODELS AGAIN AT ANY TIME THEREFORE TURN OFF THE ENGINE IF YOU INTEND TO RUN YOUR MOTORCYCLE IN IDLE OR AT STANDSTILL FOR LONGER PERIODS OF TIME MORE THAN 2 MINUTES AVOID LETTING THE CLUTCH SLIP FREQUENTLY AND FOR EXTENDED PERIODS THIS WOULD CAUSE THE ENGINE OIL TO HEAT UP THEREBY HEATING UP THE ENGINE AND THE COOLING SYSTEM RATHER YOU SHOULD DRIVE AT LOW SPEEDS 4 STROKE STYLE LETTING THE ENGINE PULL YOU AND NOT AT HIGH SPEEDS NOT BY LETTING THE CLUTCH SLIP 2 STROKE STYLE A WARNING A OBSERVE THE TRAFFIC REGULATIONS DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE REPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR DAMAGED IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR LENS THE OPERATOR
13. THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature O 35 C 30 95 F Do not expose to direct sun radiation Charging the battery Remove the battery and check the charging level Use a voltmeter to measure the voltage between the battery poles off load voltage Accurate results can only be obtained if the battery has neither been char off load voltage charging level charging time charging voltage Volt 26 05A 212 7 100 12 5 75 4h 12 2 50 7h rh 12 0 25 11h 11 8 0 14h ged nor discharged during a period of 30 minutes preceding the measuring If the battery is empty it can be recharged for a maximum period of 10 hours at 0 5 A and a maximum of 14 4 V l CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTI LATION EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES AVOID QUICK CHARGING IF POSSIBLE
14. and needle jet are subjected to increased wear This wear may cause carburetor malfunction e g overly rich mixture Therefore these parts should be replaced after 200 hours Adjusting the mixture control screw Especially on the EXC models accessing the mixture control screw is diffi cult For this reasons we have created an appropriate special tool Introduce the special tool into the bore at the carburetor bottom Press the tool slightly upward and turn the adjusting wheel Guntil the tool enga ges the slot of the mixture control screw Now you can go about adjusting the screw Marks were provided on the adjusting wheel making it easier to keep track of the turns Checking the float level float height For this purpose dismount the carburetor and remove the float chamber Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it see photo Now use a sliding caliper to measure the distance between the casing edge and the float s upper edge The float height is to be 9mm If the float height does not correspond to the desired value check the float needle valve and if necessary replace it If the float needle valve is o k you can adjust the float height by bending of the float lever O Mount the float chamber install the carburetor and adjust the idle speed 3 A
15. cde ER AR eel 18 Rebound damping of fork 9 Rebound damping of shock absorber SX MXC EXC 10 Refilling the front brake fluid 21 Refilling the rear brake fluid 22 Re initiation after time of storage 39 Replacing head light parking light lamp 29 Replacing the battery of the digital speedometer 25 Replacing the front brake pads 22 Replacing the glass fiber yarn packing of the silencer 31 Replacing the rear brake 23 Serial Number Locations 4 Shift lever teet eate eedem Eee tede 8 Short circuit button SX MXC uu eee cette eee 5 Side stand siet o REPE 8 Speedometer indicator lamps EXC Australia 5 Steering bae dante 10 StOrdg6 iii RR Te e Rs 39 Technical specifications 43 Technical specifications 40 Tires air preSSUEe ann Ies enero ete eps he Teide aT 25 Trouble shooting see 37 Wiring diagramme iisisti iis Appendix 321017 KTM SPORTMOTORCYCLE AG suspension 5230 Mattighofen Ae W ADVANCE PAIR Internet www ktm at
16. 8 ELECTRICAL SYSTEM Check correct functioning of headlamps tail lights brake lights indicators control lamps and horn while the engine is running 9 LUGGAGE If you are taking luggage with you check that this is securely fastened A WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLO RED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM For EXAMPLE FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE THE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR 1 PER SON ONLY NEVER TAKE ANOTHER RIDER ALONG A WARNING A THE SX MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS AND FREEWAYS WHEN RIDING YOUR MOTORCYCLE PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE Instructions for initial operation Verify that your KTM dealer performed the PREPARATION OF VEHICLE
17. BUTTON OR THE EMERGENCY OFF BUTTON THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED A LACK OF PLAY IN THE DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE Hand brake lever The hand brake lever is mounted on the handle bars on the right and actuates the front wheel brake The adjusting screw can be used to change the basic position of the hand brake lever see Maintenance A WARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Digital speedometer indicator lamps EXC The green control lamp flashes when the indicator is working in the same rhythm as the flashing indicator The blue control lamp lights up when the high beam is on Speedometer digital EXC Some models are equipped with a digital speedometer KMH Speed max 200 km h is always indicated Aside from speed indication the following indications can be selected Trip distance STP Stopwatch 10 h automatic start stop function DST Total distance up to 99 999 km Clock See maintenance work for change of battery and basic setting I ml U e 5 Odometer EXC USA The odometer is a mileage indicator and can be set to O by means of the adjustment wh
18. Engine oil has be changed with the engine being at operating temperature CAUTION AN ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE VERY HOT DO NOT BURN OR SCALD YOURSELF Place the motorcycle on a horizontal surface remove the plug and allow the oil to drain into a receptacle Clean plug with magnet thoroughly Once the entire oil has been drained clean the sealing surface mount the plug together with the sealing ring and tighten it to 20 Nm 15 ft Ib ENGLISH w ul CLEANING THE SHORT OIL SCREEN The short oil screen is accommodated in the hex socket plug at the engine bottom Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dis mount the oil screen clean the components thoroughly and blow compres sed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and tigh ten the plug to 10 Nm 7 ft Ib CLEANING THE LONG OIL SCREEN The long oil screen is accommodated in the hexagon plug O adjacent the engine number Dismount the plug together with the oil screen clean the components thoroughly and blow compressed air through them Check the O rings for damage and if necessary replace them To mount the long oil screen place it on an approx 300 mm 12 in long pin type key or a similar tool Insert the pin type key through the opening
19. IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop screw The free play at the foot brake pedal must then be adjusted by means of the piston rod O Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking rear brake fluid level The reservoir for the rear disc brake is disposed on the engine in the vicinity of the oil filters The brake fluid level must not drop below the MIN mar king when the vehicle is in an upright position A WARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS AR
20. Needle clip position 4 th from top 3 th from top 2 th from top 3 th from top 6 th from top 3 th from top Starting jet 85 85 85 85 85 85 Mixture control screw open 1 1 25 2 5 1 1 25 1 Throttle valve 15 15 15 15 15 15 Performance restrictor slide stop24 5mm 2 Stop pump membrane 055 055 055 055 055 055 TIGHTENING TORQUES Hexagon collar screw engine case clutch cover ignition cover M6 10 Nm 6 ft lb Oil drain plug M12x1 5 20 Nm 15 ft lb Allan head plug oil screen short M16x1 5 10 Nm 7 ft lb Hexagon plug oil screen long M20x1 5 15 Nm 11 ft lb Plug pressure valve M12x1 5 20 Nm 15 16 Jet screw and hollow screw oil line M8 10 Nm 7 ft Ib Screws oil pump cover M5 Loctite 243 6 Nm 5 16 Hexagon collar screw cylinderhead top section M6 10 Nm 7 ft Ib Hex collar screw cylinderhead top section water pump cover M6 8 Nm 6 ft lb Hexagon collar screw exhaust flange M6 Loctite 243 8 Nm 6 ft lb Cylinder head screw M10 40 50 Nm 30 35 ft lb Allan head screw camshaft gear M8 Loctite 243 28 Nm 21 ft lb Stop screw autodecopression M5 Loctite 243 6 Nm 5 ft Ib Allan head screw cap rocker arm M5 5 Nm 4 ft lb Counter nuts valve adjustment screw 6 0 75 11 Nm 10 ft Ib Allan head screw primary gear free wheel M6 Loctite 243 16 Nm 12 ft lb Hexagon nut primary gear M20x1 5 L
21. Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber Type White Power 1218W738 25 clicks 10 Type White Power 1218W739 25 clicks A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN ANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 15 Steering lock The handlebar can be locked by means of the lock located on the steering head To lock it turn handlebar all the way to the right insert key turn it to left press it in turn it to right and remove it CAUTION NEVER LEAVE THE KEY INSERTED IN THE STEERING LOCK IF YOU TURN THE HANDLEBAR TO THE LEFT THE KEY COULD GET DAMAGED DRIVING INSTRUCTIONS Check the following before each start When you start off the motorcycle must be in perfect mecha nical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of kinks 3 CHAIN A loose chain can fall from the
22. and filter box Check tyres for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation Check brake performance Treat blank metal parts with the exception of brake and exhaust system with wax based anti corrosion agent Treat ignition and steering locks and light switches with contact spray Check tightness of screws nuts and hose clamps regular Continued tests of the 400 520 racing motor for KTM s specialized workshop additional order for KTM s specialized workshop a 100 fuel consumption is equivalent to approx 15 operating hours 30 hours 2001 45 hours 3001 60 hours 4001 90 hours 600 120 hours 800 135 hours 900 Force fit of clutch drive shaftestsitz Clutch disk wear Cylinder and piston wear Groove piston pin retainer wear Camshaft wear Radial clearance of camshaft bearing Valve spring length Spring washer wear Valve disk slack Valve guide wear Radial clearance of rocker arm roller Elongation of timing chain Wear of toothing on chain tensioner Crankshaft journal crankshaft wear Radial clearance of conrod bearing Radial clearance of piston pin bearing Wear of balancing shaft bearing Wear of crankshaft bearing Transmission wear Flection of transmission shafts
23. change down to lower gears depending on your speed When driving down hill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will not need to brake so much and the brakes will not overheat A VVARNING A IN CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER RIDES THROUGH WATER AND IN CASE OF RIDES ON WET OFF ROAD TRACKS HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN RIDES ON SALT STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRA KING EFFECT THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEA KER THE BREAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL Stopping and parking Apply the brakes fully and put the engine into neutral To turn off the engine push the short circuit button or the emergency OFF button with the engine at idling speed until the engine stops Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle A WARNING A NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING THE ENGINE EXHAUST PIPE MUFFLER BRAKE ROTORS AND SHOCK A
24. into the bore of the opposite engine casing wall Then push the oil screen into the engine casing as far as possible Remove the pin type key mount the plug and tighten it to 15 Nm 11 ft Ib CAUTION THE OIL SCREEN IS MOUNTED SLIGHTLY DOWNWARDS INCORRECT FITTED THE SCREEN LOOSES ITS FUNCTION AND THIS CAN CAUSE INCREASED ENGINE WEAR HSITDONA 3 CHANGING THE OIL FILTERS Remove the screw and swing the brake fluid container sideward Place a receptacle underneath the engine to collect the drained oil Remove the 4 screws and dismount the two oil filter covers Using circlip pliers you may now pull the oil filter inserts out of the housing Clean the oil filter cover the sealing surfaces of the O rings and the engine casing Check the O rings of the oil filter covers for damage and if neces sary replace them Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil Insert the long oil filter at the front and the short oil filter at the back of the housing Grease the O rings of the oil filter covers and mount the covers Mount the screws and tighten them to 8 Nm 6 ft Ib Position the brake fluid container and tighten the screw to 8 Nm 6 ft Ib Return the motorcycle to its upright position Remove the oil dipstick at the clutch cover and fill in 1 2 liters of fully synthetic engine oil Shell Advance Ultra 4 Start the engine and check all screwed conn
25. jobs see Customer Service Manual Read these operating instructions carefully before your first ride Familiarize yourself with the operating elements Set the clutch lever the handbrake lever and the footbrake pedal to the positions that are most convenient for you Get used to handling the motorcycle on an empty parking lot or open space before starting on a longer drive Also try to drive as slowly as possible and in standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your abitily and experience Hold the handle bars with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake lever when you are not braking If the foot brake lever is not released the brake pads rub continuously and the braking system is over heated Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking luggage with you this should be secured as close as possible to the middle of the vehicle dis tribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for ope
26. push the button the back with a sharp object approx 1 second to termi by pushing the right but 4 repeat nos 2 3 until the previously nate the setting procedure ton you jump to the next noted total mileage is indicated the value is thus stored figure TIME make sure the time is 2 push the left button until the right 3 by pushing the right but indicated and push the figure is showed in the display ton you jump to the next button on the back figure approx 5 seconds time starts blinking 5 push the button on the back approx 1 second to terminate 4 repeat nos 2 3 until correct time is indicated the setting procedure WHEEL CIRCUMFERENCE Ws 1 make sure that the indication 2 use the right button to select the position TRP is active and push the but 5 sec to be changed ton on the back approx 5 seconds WS appears J gt gt ENGLISH N 5 push the button on 4 repeat nos 2 3 until the back for approx 1 3 push the left button until the right figure correct wheel circumfe second to terminate is showed in the display rence is indicated the setting procedure km h WS mm x 3 14 mm x 3 14 i mp h WS mm x 3 14 1 61 p i d uu 0 Wheel circumference with standard tires 2205 mm Check set distance of the magnetic sensor The distance between magnet and sensor m
27. release cable32 Checking and adjusting the steering head bearing 16 Checking engin oil level sees 34 Checking of brake fluid level front brake 21 Checking rear brake fluid 22 Checking spoke tension sssssssseee 25 Checking the coolant 30 Checking the float level oo eo eect etter eee 33 Checking the front brake 5 21 Checking the oil level of the hydraulic clutch 32 Checking the rear brake 23 Choke i ea taal Epid 8 Cleaning en Pt Terr tti die deve Pr P ds 39 Cleaning the air filter oo ctr treet 31 Cleaning the dust sleeves of the telescopic fork 17 Cleaning the spark arrestor MXC EXC USA 31 Clutch lever n te te Ee dts 4 Combination switch EXC ssssssssseeee 6 Compression damping of 9 Compression damping of shock absorber MXC EXC 10 Conservation for winter operarion 39 Cooling syst m he e tp E ees 30 Correct chain tension sss 19 Damping action during compression of shock absorber SX 9 Digital speedometer EXC s
28. the holder Reinsert parking light lamp together with holder Engage the bottom end of headlamp mask at the retaining pins and fix the mask by means of the rubber bands ENGLISH Cooling system Coolant is circulated by a water pump located in the engine When the engine is cold the coolant circulates only through the cylinder and the cylin der head After the engine has reached its operating temperature about 70 C 158 F the thermostat opens and the coolant is also pumped through both aluminum radiators Air blowing in through the radiators cools the coolant The slower the speed of the motorcycle the less the coolant is cooled down Dirty radiators also reduce the cooling efficiency Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap a water temperature rising up to 120 C 248 F is admissible without fear of problems A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE CAUTION SCALDING HAZARD DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS IN CASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN I
29. this case consult an authorized KTM dealer immediately BRAKE FLUID KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5 1 brake fluid one of the best brake fluids that is currently available We recommend that you continue to use it DOT 5 1 brake fluid is based on glycol ether and of an amber color If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible by DOT 5 1 Never use brake fluid DOT 5 The color of this silicon oil based product is purple red The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid A WARNING A HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY IF YOU WASH YOUR MOTORCYCLE OFTEN THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY BRAKE FLUID TENDS TO ABSORB WATER THEREFORE VAPOR POCKETS MAY FORM IN OLD BRAKE FLUIDS EVEN AT LOW TEMPERATURES CAUSING THE BRAKE SYSTEM TO FAIL min 3 mm Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw In this way the position of the point of pressure i e the resi stance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 3 MM 0 1 IN ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MO
30. turn it back by as many clicks as are specified for the relevant type of fork WP 1418W710 16 clicks SX WP 0518W712 12 clicks MXC EXC I d ml 2 9 Damping action during compression of shock absorber SX The shock absorber on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber com pression rates The high speed setting is effective at fast compression rates Turning in a clockwise direction will increase the damping turning counter clockwise will decrease the damping Standard low speed setting Turn the adjusting screw to the limit in a clockwise direction using a screwdriver Unscrew the respective number of clicks for the specific type of shock absorber in a counterclockwise direction Type White Power 1218W738 15 clicks Standard high speed setting Turn the adjusting screw to the limit in a counterclockwise direction using a box wrench Unscrew the respective number of turns for the specific type of shock absorber clockwise direction Type White Power 1218W738 2 turns A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HI
31. 0 238 in spring washer min 0 4 mm 0 016 in new 0 5 mm 0 019 in valve spring Interior min 36 5 mm 1 423 in new 37 45 mm 1 46in Exterior min 39 7 mm 1 548 in new 40 2 mm 1 567 in balancer shaft Journal runout max 0 06 mm 0 0024 in Oil pumps clearance outer rotor max 0 20 mm 0 0078 in housing clearance outer rotor max 0 20 mm 0 0078 in inner rotor axial clearance 0 15 mm 0 0059 in valve minimum spring length 25 00 mm 0 98 in Clutch Length of springs min 41 5 mm 1 63 in new 43 mm 1 693 in min 1 70 mm 0 067 in new 1 8 mm 0 070 in 18 3 mm 0 713 in neu 20 2 mm 0 788 in wear limit organic hight disk package Transmission shafts axial clearance 0 10 0 40 mm 0 004 0 016 in Transmission shaft runout max 0 06 mm 0 0024 in rocker arm axial clearance 0 02 0 10 mm 0 007 0 04 in rocker arm axle radial clearance max 0 08 mm 0 003 in timing chain max 770 mm 30 03 in new 768 mm 29 952in TECHNICAL DATA CHASSIS 400 520 SX MXC EXC RACING 2002 400 520 SX RACING 400 520 EXC RACING 400 520 MXC EXC USA Frame Central tube chrom moly steel frame Fork WP USD 4860 MXMA WP Up Side Down 4357 MXMA Wheel travel front rear 295 320 mm Rear suspension WP Progressive Damping System shock absorber aluminium swingarm Front brake Disk brake with carbon steel brake disc 260 mm 10 2 in brake ca
32. BSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED CAUTION NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE RATHER USE THE SHORT CIRCUIT BUTTON OR THE EMER GENCY OFF BUTTON CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE OTHERWISE THE CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS NOTE REGARDING THE SIDE STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground is solid and that your motorcycle is standing securely Just in case you can shift into first gear CAUTION THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE THE SIDE STAND AND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR CYCLE THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND PERIODIC MAINTENANCE SCHEDULE 2001 SPORTMOTORCYCLES 400 520 SX MXC EXC RACING 1 service after after every A washed motorcycle can be checked more quickly which saves money 3 ju 13 hot 20 fuel 100 fuel Change engine oil short and long oi Ifilters Clean
33. E COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the rear brake fluid reservoir When the brake fluid level has dropped to the MIN mark you need to refill the brake fluid reservoir This is done by first unscrewing the cap and rubber bellows Add brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 until it reaches the MAX mark then screw rubber bellows and cap back on Rinse off spilled or overflowing brake fluid with water A WARNING A NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the rear brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in A WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED l CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN T
34. ES WHILE THE ENGINE IS HOT THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS ee N CASE YOU GET BURNT HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING when engine is cold COLD WATER RIGHT AWAY COOLANT IS TOXIC KEEP THE COOLANT OUT OF THE REACH OF CHILDREN N CASE COOLANT IS INGESTED GO SEE A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR CAUTION IF THE COOLANT HAS BEEN DRAINED IT WILL BE ABSOLUTELY NECESSARY TO BLEED THE COOLING SYSTEM DURING FILLING SEE BELOW Bleeding the cooling system By removing the screw at the front end of the cylinder you can drain the coolant To bleed the cooling system fill in approx 0 8 liters 0 2 US Gallons of coolant and remove the bleeder screw Do not reinstall the bleeder screw until coolant escapes at the bore without any bubbles Then fill in the coolant until it reaches a level about 10mm above the radiator fins After a short ride check the coolant level once more Cleaning the air filter A dirty air filter impairs the air flow rate reduces the engine performance and increases the fuel consumption In extreme cases dirt may even get into the engine and cause damage Therefore change the air filter in regular intervals For this purpose rotate the two qui
35. EWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE 1 LITER USED OIL CONTAMINATES 1 000 000 LITERS WATER Changing the original position of the clutch lever The adjusting screw can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclock wise increases the distance between the clutch lever and the handlebar CAUTION ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE Checking and adjusting the steering head bearing Check steering head bearing for play periodically For check put motorcycle on stand so that the front wheel is off the ground Now try to move the fork forward and backward For readjusting loosen the five pinch bolts of the top triple clamp and turn steering stem bolt clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly rap on the triple clamp to release tension Retighten the five pinch bolts to 20 Nm 15 ft Ib A WARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTORCY CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL CAUTIO
36. GH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN ANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 24MM Compression damping of shock absorber MXC EXC The compression damping during compression can be adjusted for the MXC and EXC shock absorbers Mono Compression Control The degree of damping be adjusted by turning adjusting screw with a screwdriver Turning in a clockwise direction will increase the damping turning in a counterclockwise direction will decrease the damping STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respective type of shock absorber Type White Power 1218W739 15 clicks A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSION NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN ANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT NEVER UNSCREW THE BLACK SCREW CONNECTION 24mm Rebound damping of shock absorber SX MXC EXC By using the adjusting screw the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop
37. HE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Replacing the rear brake pads Push the brake caliper toward the chain wheel in order to move the brake piston into its basic position Remove clips pull out the bolt 6 and remove the brake pads Thoroughly clean the brake caliper with com pressed air and check the sleeves of the guide bolts for damage Insert the left brake pad into the brake caliper and secure it with the bolt Insert the right brake pad and push the bolt into the brake caliper up to the stop Reattach clips 8 A WARNING A IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED AFTER ASSEMBLY CHECK IF CLIPS HAVE BEEN FITTED CORRECTLY HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws on the left side of the fork fists Loosen and remove the collar nut loosen the clamping screews on the right side of the fork fist Hold the front wheel pull out the wheel
38. K AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM AND AN OPENED THROTTLE GRIP INCREASE THE KICK BACK HAZARD DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING CAUTION MAXIMAL PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER IT CAN CAUSE ENGINE DAMAGE AWUN 12 Starting when the engine is warm 1 Open the fuel tap 2 Swing up the side stand 3 Putthe gear in neutral 4 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter What to do when the engine is flooded In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decompression lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it NOTE The carburetor has an accelerator pump Every time you open the
39. L00c 90 ZL OLCE IN HV COOC SANOIDINAULSNI IG WANVW 28401 OWL 404 osna JIVANVW SYANMO ONNLIFINVSONNNAIGIE ONIDVY 2X3 DXW XS OCS OO0P IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY IN YOUR OWN INTEREST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS A WARNING A IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE CAUTION IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR CYCLE IS NOT ROAD SAFE ANYMORE Please insert the series numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person
40. MOVE FORWARD Emergency OFF switch EXC Australia The red emergency OFF switch is arranged adjacent to the throttle grip m In this position the E starter is operational and the engine can be started In this position the E starter and ignition circuits are interrup e ted The E starter cannot be actuated and the engine will not start not even if you attempt to start it with the kickstarter 9 Pushing of the black starter button actuates the E starter A WARNING A ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE WILL MOVE FORWARD SX MXC EXC Filler cap To open filler cap Turn the filler cap counter clockwise To close filler cap ut filler cap on and tighten it by turning it clockwise Install tank breather hose without kinks Fuel The racing engine needs premium gasoline with an octane number of 95 or higher CAUTION USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE 95 OCTANES NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE A WARNING A GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING BE CAREFUL NOT TO SPILL GAS
41. N IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS THE BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED The steering head bearings should be regreased at least once a year i e Shell Advance Grease Breather plug front fork After every 5 hours of use for competitive racing slacken the breather plugs a few turns in order to relieve excess pressure from the inside of the fork To do this place the motorcycle on a stand with the front wheel lifted off the ground When riding the motorcycle mainly on street it will be enough to have this job performed in the course of the periodical mainten ance service CAUTION EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK IF YOUR FORK IS LEAKING IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE SEALS REPLACED Cleaning the dust sleeves of the telescopic fork The dust protection bellows are to remove dust and coarse dirt particles from the fork tube However after some time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push d
42. N CASE COOLANT IS INGESTED GO SEE A DOCTOR IMMEDIATELY IF COOLANT GETS INTO YOUR EYES RINSE THEM OUT WITH WATER IMMEDIATELY AND GO SEE A DOCTOR m 2 A z n A mixture of 40 anti freeze liquid and 60 water is used as coolant However the anti freeze protection must be at least 25 C 13 F This mixture offers anti freeze protection but also good corrosion protection and should therefore not be replaced by pure water CAUTION IF THE COOLANT HAS BEEN DRAINED IT WILL BE ABSOLUTELY NECESSARY TO BLEED THE COOLING SYSTEM DURING FILLING SEE BELOW FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE I E SHELL ADVANCE COOLANT USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING EXTREM CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVERHEATING PROBLEMS TO AVOID THIS AN ELECTRIC BLOWER is OFFERED FOR MODELLS WITH ELECTRIC STARTERS ASK YOUR KTM DEALER ABOUT IT UJ Checking the coolant level The coolant should be 10 mm 0 4 in above the radiator fins when the engine is cold cf diagram In the event of the coolant being drained always fill and bleed the system A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR WHEN THE ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE CAUTION SCALDING HAZARD 10 mm DO NOT DETACH ANY RADIATOR HOS
43. OLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in this position the tank will be emptied until only the reserve is left RES The reserve tank cannot be tapped until the rotating handle is turned to the RES position Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time too Reserve 3 01 0 8 US gallons Reserve 1 01 0 3 US gallons CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE d ml U e 7 Choke If you pull the choke button 6 out as far as possible a bore in the carbure tor will be unblocked through which the engine may take in additional fuel The result is a fat fuel air mixture of the type needed for cold starts To deactivate the choke push the choke button back into its basic position Sh
44. ON DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REMOVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the front brake pads The brake pads can be inspected from below The linings nust be at least 1 mm 0 04 in thick A WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC gt ENGLISH 2 N Replacing front brake pads Press the brake caliper toward the brake disk to put the brake piston in its basic position Remove clips and pull out bolt Remove brake pads from the brake caliper Clean the brake caliper and the brake caliper support with compressed air Check the sleeves of the guide bolts for damage and grease guide bolts if necessary Mount the right brake pad and fix it with the bolt Mount the left brake pad and insert the bolt until it stops Mount the clips When mounting the brake pads be sure to check for correct fit of the sliding metal sheet in the caliper support and of the leaf spring A WARNING A IT
45. POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE NOTE The large adjusting range of the chain adjusters 32mm allows you to use different secondary ratios in combination with the same chain length The chain adjusters O can be rotated around 180 Chain maintenance For long chain life good maintenance is very important Chains without O rings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray i e Shell Advance Bio Chain O ring chains on the other hand are very simple to clean The best way is to use lots of water but never use brushes or cleaning liquids After letting the chain dry you can use a special O ring chain spray i e Shell Advance Bio Chain A WARNING A LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS EITHER WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRON GLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL CAUTION WHEN MOUNTING THE CHAIN MASTERLINK CLIP THE CLOSED SIDE OF THE MASTERLINK CLIP MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary max 272 mm a gt 5 123 16 17 18
46. S MAY RUPTURE DUE TO LOCAL OVERLOADING THE SPOKES MUST BE TENSIONED TO 5 7 NM Replacing the battery of the digital speedometer After approx 2 years the battery of the digital speedometer will be empty and must be replaced For this purpose the speedometer must be dismounted Remove headlight mask and pull speedometer illumination system 6 out of the speedometer housing Use a screwdriver to lever the blue speedometer glass downward and out of the speedometer housing The two noses must be disengaged from the speedometer housing Remove screws O and take speedometer out of housing Before you remove the battery do not forget to write down the following data total kilometer reading DST wheel circumference WS KTM standard tires 2205 mm Remove the battery cover on the back of the speedometer and detach the batteries The new batteries must be inserted with the plus pole on top Make sure that the seal ring has the right position on the cover when mounting the battery cover Now total mileage wheel circumference and time have to be entered To mount the speedometer proceed by following the reverse order of the above procedure a5 J U 2 T N TOTAL MILEAGE DST 1 use the right button to 2 push the left button until select the position to be the right figure is showed changed in the display AFTER CHANGING BATTERY N 01000 gt DST 0 0 5
47. TIONS TO DESIGN AND MODEL by KTM SPORTMOTORCYCLE AG AUSTRIA All rights reserved INDEX Page Page SERIAL NUMBER LOCATIONS 4 Checking of brake fluid level front brake 21 Chassis number 2202222000 0222s e eee 4 Refilling the front brake fluid reservoir 21 Engine number engine type 4 Checking the front brake pads 21 Replacing the front brake 22 OPERATION INSTRUMENTS 4 Changing the basic position of the brake pedal 22 4 Checking rear brake fluid level 22 Hand decompression 4 Refilling the rear brake fluid reservoir 22 MM PERCENT 4 Checking the rear brake 23 Digital speedometer indicator lamps EXC 5 hraka pads pP ML A 23 ul Dismounting and mounting the front wheel 23 Digital speedometer EXC 5 Dismounting and mounting the rear wheel 24 Odometer EXC USA te iot cdi qae Tires air pressure i i Ree 25 Speedometer indicator lamps EXC Australia 5 Checking spoke tension 25 Short circuit button SX MXC 5 Replacing the battery of the digital speedometer 25 Combination switch 6 Adjusting digital speedom
48. VED TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PRO VIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING Checking of brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the hand lebar and the reservoir is provided with an inspection glass With the reser voir in a horizontal position the brake fluid level should not drop below the middle of the glass A VVARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY Refilling the front brake fluid reservoir Loosen screws and remove lid and membrane O Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 i e Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING A Never USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTI
49. WILL BE BLINDED AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN A TWISTED HANDLEBAR MUST ALWAYS BE REPLACED DO NOT ADJUST THE HANDLEBAR IT WILL LOSE STA BILITY CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WWE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN THE ENGINE HAS REACHED ITS OPERA TING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVER REV DAMAGING THE VALVES IN ADDITION THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER NEVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN TED OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also
50. ake pad and also recorded in the homo logation papers Other brake pads are available for competition sports FRONT TOSHIBA 38 SINTERED harder to dose good brake per formance long life for wet slippery terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price REAR FERRIT 222 ORGANIC can be dosed better short life cycle for dry terrain FERODO ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face of the brake pads decreases At their thinnest point the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location outside the contact face Check wear in several locations A WARNING A BRAKE DISCS SUFFERING FROM WEAR GREATER THAN O 4 MM 0 016 IN CONSTI TUTE A SAFETY RISK HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS THEY REACH THE WEAR LIMIT HAVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER BRAKE FLUID RESERVOIRS The brake fluid reservoirs on front and rear wheel brakes have been desi gned in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn In
51. anging the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring For this purpose you should dismount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired Turning it counter clockwise will reduce the preload turning it clockwise will increase the preload After readjusting the clamping screw tighten it to 8 Nm 6 ft Ib ADJUSTMENT VALUES SPRING PRELOAD minimum preload 4 mm 0 15 in STANDARD PRELOAD 6 mm 0 24 in maximum 10 mm 0 4 in Pivot bearing The pivot bearing for PDS suspension struts at the swinging fork is Teflon coated and must not be lubricated with either grease or other lubri cants Grease and other lubricants cause the Teflon coat to dissolve whereby the bearing s lifecycle will be reduced dramatically When cleaning your bike with a high pressure cleaner do not aim the high pressure spray directly at the pivot bearing Check chain tension To check the chain tension park the motorcycle Press chain upw
52. ard at the end of the chain sliding component The distance between chain and swing arm should be approx 15 mm 0 6 in In the course of this procedure the upper chain portion must be taut see illustration If necessary correct chain tension A WARNING A EXCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE COMPO NENTS OF THE SECONDARY DRIVETRAIN CHAIN BEARINGS OF TRANSMISSION AND REAR WHEEL ASIDE FROM RESULTING PREMATURE WEAR IF WORST COMES TO WORST THE CHAIN MAY RUPTURE OR THE COUNTERSHAFT OF THE TRANSMISSION MAY BREAK TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE 9X6 9X8 9b fr d U 2 Correct chain tension Loosen collar nut loosen lock nuts and turn right and left adjusting screws equally far Tighten lock nuts To ensure the correct alignment of the rear wheel the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks Tighten the counter nut of the adjusting screws Tighten collar nut to 80 Nm 60 ft Ib A VVARNING A F YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS
53. bounce the fork hard a few times to align the fork legs Then tighten clamping screws and to a max torque of 10 Nm 7 ft Ib A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED Dismounting and mounting the rear wheel Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground Loosen the collar nut 9 remove chain tensioner hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED IF THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM JAMMING The rear wheel is remounted in reverse o
54. chain wheels an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear to the chain and chain wheels Excessive tensioning of the chain will put additional load on the com ponents of the secondary drivetrain chain bearings of transmission and rear wheel Aside from resulting prema ture wear if worst comes to worst the chain may rupture or the countershaft of the transmission may break 4 TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure deteriorate the driving performance 5 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indi cates a leak in the braking system or completely worn out brake pads Arrange for the braking system to be checked by a KTM specialist as complete failure of the braking system can be avoided Also check the state of the brake hose and the thickness of the brake linings Check free travel at hand brake lever and foot brake lever 6 CABLES Check correct setting and easy running of all control cables 7 COOLING FLUID Check the level of cooling fluid when the engine is cold
55. chamber The engine will immediately start off when the float chamber is filled with new fuel Fuel supply interrupted Close fuel tap loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out the carburetor might need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap Flooded engine In order to pump the engine free pull the hand decompres sion lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark plug and dry it Sooty or wet spark plug Clean and dry the spark plug or exchange it respectively Electrode gap too large Adjust spark plug elektrode gap to 0 6 mm Spark plug connector or spark plug Dismount spark plug connect ignition cable hold to ground faulty blank place on engine and actuate starter a strong spark must be produced at the spark plug If no spark is created exchange the spark plug If the new spark plug doesn t produce a spark either dis connect the spark plug connector from the ignition cable hold it a distance of approx 5 mm from ground and start If a spark now occurs replace spark plug cap If no spark is produced control ignition system Short circuit cable scored in wiring Dismount the fuel tank disconnect the black yellow cable from harness emergency OFF switch or the cab
56. ck release fasteners counter clock wise and pull them outward up to the stop pull the filter box cover forward and remove it Unhook the filter holding brackets at the bottom swing them sideways and take the air filter together with the filter support out of the filter box CAUTION DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM KTM RECOMMENDS THE PRODUCTS MADE BY TWINAIR FOR AIR FIL TER MAINTENANCE FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS OTHERWISE DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR Thoroughly wash the air filter in special cleaning fluid and allow it to dry well Only press out the filter do not wring it out under any circumstances Oil the dry air filter with a high grade filter oil Also clean the air filter box Check carburetor collar for damage and that it is filled correctly Mount the air filter on the filter support Mount the filter together with the filter support in the filter box making sure to properly center them and fix them with the filter holding bracket Replacing the glass fiber yarn packing of the silencer Aluminum silencers are filled with glass fiber yarn to muffle noise The effect of heat causes the glass fiber yarn to become loose This may lead to a loss of performance and reduce the silencer s muffling power By experi ence the front glass fiber yarn packin
57. e speed 1400 1500 rpm 4 Turn mixture control screw slowly clockwise until idling speed starts to decrease Memorize this position and turn mixture control screw slowly counterclockwise until the idling speed will decrease again Adjust the point of the highest idling speed between these two positions If in the course of this procedure the speed undergoes a relatively high increase reduce the idle speed to a normal level and repeat the procedure speci fied in 4 Serious competitive racers will choose a setting approx 1 4 turn clockwise leaner than this ideal value because their engine will heat up more when used in competitions NOTE If you fail to obtain a satisfying result by following the procedure described above an incorrectly dimensioned idling nozzle may be the cause In case a the mixture control screw has been screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to be selected Naturally in cases of jet changes you have to start your adjusting work from the beginning 5 Then use the adjusting wheel to set the desired idle speed 6 In cases of greater changes in outside temperature and extremely different altitudes the idling speed should be readjusted Basic information on carburetor wear As a result of engine vibrations throttle valve jet needle
58. ection and oil filter cover for leaks Finally check the engine oil level and if necessary correct it TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the trouble shooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by oneself In case of uncertainty please contact a KTM dealer TROUBLE CAUSE REMEDY Engine doesn t crank Operating errror Turn on the emergency OFF switch Australia only E starter Blown fuse Dismount the left paneling and the filter box cover and replace the fuse in the starter relay Discharged battery Recharge the battery and investigate the causes for dischar ging contact a KTM dealer Low outside temperatur Start engine with kickstarter Engine cranks but doesn t Operating error Open fuel tap tank fuel actuate choke Pay attention to star start E starter ting information see driving instructions Engine will not start Kick starter The motorcycle has been out of The easily inflammable components of the new fuels evaporate operation for a longer period of during longer periods of standstill time Therefore old fuel has accu When the motorcycle has been out of operation for more than mulated in the float chamber a week it is therefore recommended to drain the old fuel from the float
59. ed up position CAUTION THE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE IF YOU GET ON THE MOTORCYCLE AND THUS PUT ADDITIONAL WEIGHT ON THE SIDE STAND THE SIDE STAND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE MAY FALL ON THE SIDE ALWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE SIDE STAND AS FAR AS POSSIBLE IF THE STAND TOUCHES THE GROUND WHILE YOU ARE DRIVING YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs Remove the protecting cap Turn the adjusting screws clockwise to increase damping turn it counter clockwise to reduce damping during compression STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go turn it back by as many clicks as are specified for the relevant type of fork WP 1418W710 20 clicks SX WP 0518W712 20 clicks EXC MXC Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound By turning the adjusting screw REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during rebounding STANDARD ADJUSTMENT turn adjusting screw clockwise as far as it will go
60. eel SON Speedometer indicator lamps EXC AUS The mileage indicator in the speedometer indicates overall mileage A gt When the turn indicator is on the green indicator lamp will be flashing in 60 the same rhythm in 0002 ue The blue indicator lamp will be lit when the high beam is on 150 Short circuit button SX MXC The short circuit button turns off the engine When pressing this button 8 the ignition circuit is short cicuited imis Combination switch EXC The light switch has 2 respetively 3 switch positions Light off this function is not available in all models Low beam on Q High beam on You may use button to actuate the horn The red short circuit button serves to switch off the engine Leave the switch pressed until the engine stops Headlamp switch EXC USA In this model the headlamp is switched on with the pull switch Flasher switch Flasher left gt Flasher right Emergency OFF button EXC The red emergency OFF button is arranged adjacent to the throttle grip To turn off the engine push the button until the engine comes to a standstill 9 Pushing of the black starter button actuates the E starter A WARNING A ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE WILL
61. engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate Once the motorcycle has cooled down oil or grease all sliding and bearing points Treat the chain with a chain spray Also oil the fuel tap To avoid any malfunction of the electric system you should treat emergency OFF switch short circuit button light switch and socket connectors with a contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take pre cautions against the aggressive road salt clean motorcycle thoroughly and let it dry after each riding treat engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corrosion agent A WARNING A KEEP ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER CAUTION AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL STORAGE Should you desire to make a pause over a longer space of time please observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil short and long oil filters old engine oil contains aggressive contaminations
62. equirements Shell Advance Ultra 4 of API classes SG or SH informations on bottles or higher CAUTION POOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE WEAR E 10W 40 15W 40 10W 50 15W 50 ASSEMBLY CLEARANCE WEAR LIMIT 400 520 Crankshaft axial clearance run out of crank stud 0 03 0 15 mm 0 0012 0 006 in max 0 08 mm 0 003 in Conrod bearing radial clearance axial clearance max 0 05 mm 0 002 in max 1 10 mm 0 043 in Cylinder bore diameter size I bore diameter size 11 89 000 89 012 mm 3 5039 3 5044 in 89 013 89 025 mm 3 5039 3 5049 in 95 000 95 012 mm 3 7401 3 7406 in 95 013 95 025 mm 3 7406 3 7411 in Piston 400 cast diameter size diameter size II assembly clearance size I assembly clearance size Il 88 926 88 936 mm 3 5010 3 5014 in 88 937 88 946 mm 3 5014 3 5018 in 0 064 0 086 mm 0 0025 0 0033 in 0 066 0 089 mm 0 0026 0 0035 in 94 946 94 954 mm 3 7380 3 7383 in 94 955 94 962 mm 3 7383 3 7386 in 0 046 0 066 mm 0 0018 0 0025 in 0 050 0 071 mm 0 0019 0 0028 in wear limit 0 12 mm 0 0047 in 0 10 mm 0 0039 in max 0 80 mm 0 03 in max 1 00 mm 0 04 in Piston ring end gap compression ring oil scraper ring Valves seat sealing intake max 1 50 mm 0 06 in seat sealing exhaust max 2 00 mm 0 078 in run out of valve heads max 0 05 mm 0 002 in valve guides diameter max 6 05 mm
63. eter 26 Headlamp switch EXC 6 Check set distance of magnetic sensor 27 Flasher Switch it craked sane ee wane ee ot 6 Battery 28 Emergency OFF button EXC 6 Charging battery 28 Emergency OFF switch EXC Australia 6 Fuse MXC EXC 6 cee eee nnne 29 RINGER CAD aod o sc eter DERI se ih a can 7 Replacing head light parking light lamp 29 Fiela toan N veh Phd 7 30 SERE e ee a Cee TAO EE 7 Checking the coolant level 30 C de an wie a ME 8 Bleeding the cooling system 30 POTERE 2 Cleaning the air filter 31 Replacing the glass fiber yarn packing of the silencer 31 Kickstarter deerit eta ceed 3 Cleaning the spark arrestor MXC EXC USA 31 Foot brake pedal oss csi edis edis 8 Checking adjustment of the hand decompression release cable 32 Side stand 8 Adjust the throttle cables 32 Compression damping of fork 9 Checking the oil level of the hydraulic clutch 32 Rebound damping of fork 9 Bleeding of the hydraulic clutch 32 Damping action during compression of shock absorber SX 9 Carburetor adjust idling
64. g needs to be replaced more often than the rear silencing mat O For this purpose remove the silencer from the vehicle and dismount the front cap Pull the front glass fiber yarn packing together with the inner exhaust pipe out of the silencer Clean the front inner exhaust pipe To facilitate the mounting procedure you can make a mounting tool 6 out of wood plastic or metal Insert the mounting tool into the inner pipe and mount the glass fiber packing Push the inner pipe containing the packing into the silencer such that the slot engages the web Use a blunt ended object to stuff the glass fiber yarn packing all the way into the silencer and mount the front cap To change the rear silencing mat start by removing the front packing and the inner exhaust pipe Then drill open the rivets and remove the end cap NOTE In every exhaust repair procedure the O rings must be replaced by new ones Glass fiber yarn packings are available at your licensed KTM mechanic A WARNING A THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN Cleaning the spark arrester MXC EXC USA The spark arrester should be cleaned every time the glass fiber yarn filling is changed or at least once annually For this purpose dismount the silencer cap and remove any deposits that might exist in region Renew the O ring and mount the silencer
65. hain rear sprockets and chain guides for wear fit and tension e e Lubricate chain Check clearance of wheel bearings IMPORTANT RECOMMENDED MAINTENANCE WORK THAT CAN BE CARRIED OuT BY EXTRA ORDER at least once a year Complete maintenance of fork Complete maintenance of shock absorber Clean and grease steering head bearings and gasket elements Clean and adjust carburetor Replace glass fibre yarn filling of the exhaust main silencer Treat electric contacts and switches with contact spray Treat battery connections with contact grease Change hydraulic clutch fluid Change brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 2 HOURS OR 15 LITERS OF FUEL MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER IMPORTANT CHECKS AND MAINTENANCE TO BE CARRIED OUT BY THE RIDER Befor each start After every cleaning For cross country use Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean fork dust bellows regulary Clean and lubricate chain check tension and adjust if necessary Clean air filter
66. however that there may exist minor discrepancies resulting from further design upgrades of these motorcycles This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it Many motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform those steps marked described in the chapter entitled Maintenance Work on Chassis and Engine of this manual For your own safety use only KTM approved parts and accessories KTM is not liable for damage that arises in connection with the use of other products Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle Have services carried out by a KTM dealer so that your warranty claim remains intact We wish you a lot of fun when driving ISO 9001 REG NO 12 100 6061 KTM Austria s certificate of achievement for its Quality System ISO 9001 is the beginning of an on going total re engineering quality plan for a brighter tomorrow KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA Attachments Spare parts manual chassis amp engine ALL RIGHTS RESERVED TO MAKE ALTERA
67. ift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled A WARNING A IF YOU WANT TO START THE ENGINE MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MIGHT SLIP OFF THE KICK STARTER OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE ALWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE KICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM AND AN OPENED THROTTLE GRIP INCREASE THE KICK BACK HAZARD Foot brake pedal The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to your seat position see maintenance work A WARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Side stand Push the side stand to the ground with your foot and load it with the motorcycle Make sure that you put your bike on solid ground and in a secure position For off road riding you can use the rubber band to additionally secure the center stand in its fold
68. ives at the short oil filter which also filters the fine particles Now the purified engine oil is pumped past the bypass valve to the con rod bearing and sprayed from below onto the piston through a nozzle The second oil pump 6 draws the engine oil via the short oil screen out of the crankcase thereby lubricating the transmission gears Checking the engine oil level The engine oil level can be checked with the engine being either warm or cold Place the motorcycle in an upright position and on a horizontal surface not on the side stand If the engine is cold the engine oil must be visible at the lower edge of the inspection glass Q If the engine is warm the engine oil must be visible up to the upper edge of the inspection glass Replenish the engine oil if necessary CAUTION INSUFFICIENT AMOUNTS OF OR LOW GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN THE ENGINE API SG SH TEMPERATUR umm E 10W 40 15W 40 10W 50 15W 50 Engine oil Only use fully synthetic branded oils Shell Advance Ultra 4 meeting or sur passing the quality requirements of API classes SG or SH see specifications on the container CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE Changing the engine oil NOTE WHEN CHANGING THE ENGINE OIL IT IS NECESSARY TO CLEAN THE SHORT AND LONG OIL SCREENS AND TO REPLACE BOTH OIL FILTERS
69. larity Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first NOTE Before you put your motorcycle away for the winter you have to check all parts for their function and wear Should any ser vice jobs repairs or any refitting be necessary you should have them carried out during the off season lower workload at mechanics shops This way you can avoid the long waiting times at your mechanic at the beginning of the next biking season TECHNICAL DATA ENGINE 400 520 SX MXC EXC RACING 2002 Type 400 SX 400 MXC 400 EXC 520 SX 520 MXC 520 EXC Design Liquid cooled single cylinder 4 stroke engine with balancer shaft Displacement 398 ccm 510 ccm Bore Stroke 89 64 mm 95 72 mm Ratio 11 1 Fuel unleaded premium gasoline with at least RON 95 Valve Timing 4 valves over rocker arm and 1 overhead camshaft camshaft drive through single chain Camshaft 0121 5521 Valve diameter Intake 35 mm Valve diameter Exhaust 30 mm Valve clearence cold Intake 0 10 mm Valve clearence cold Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy cast alluminium alloy forged Piston ring
70. le of the emergency OFF switch and the short circuit short circuit button faulty button respectively and check the ignition spark If a spark is generated look for the problem in the short circuit circuit The plug connection of the CDI Remove the seat and the fuel tank Clean the plug connection unit the pulse generator or the and treat it with contact spray ignition coil has oxydized Water in carburetor or jets blocked Dismount and clean carburetor Engine fails to idle Glogged idling jet Disassemble carburetor and clean jets Oncorrect adjustment of adjusting Have carburetor adjusted screws on carburetor Defective spark plug Replace spark plug Defective ignition system Have ignition system checked ml U 2 37 TROUBLE CAUSE REMEDY Engine does not rev high Carburettor fuel level too high Dismount carburettor and check if worn out because float needle valve is dirty or worn out Loose carburettor jets Tighten jets Electronical ignition timing faulty Have ignition system checked Engine will not reach full Fuel supply partically interrupted or Clean and check fuel system as well as carburettor power carburettor dirty Float leaks Replace the float Air filter very dirty Clean or replace air filter Exhaust system is not tight defor Check if exhaust is damaged replace glas fibre yarn in exhaust med or the silencer contains not silencer enough glass fiber yarn Valve gap to sma
71. liper floated Air pressure offroad Air pressure road driver only 1 0 bar 14 psi 1 0 bar 14 psi 2 0 bar 28 psi Rear brake Disk brake with carbon steel brake disc 220 mm 8 7 in brake caliper floated Brake disc Wear limit max 0 4 mm 0 016 in Front tires 80 100 21 90 90 21 80 100 21 Air pressure offroad 1 0 bar 14 psi 1 0 bar 14 psi 1 0 bar 14 psi Air pressure road driver only 1 5 bar 1 5 bar 21 psi Rear tires 110 90 19 140 80 18 110 100 18 1 0 bar 14 psi 2 0 bar 28 psi Fuel tank capacity 7 5 Liter 2 US Gallons EXC 8 5 Liter 2 1 US Gallons MXC 13 Liter 3 5 Gallons Final drive ratio 400 14 50t 520 14 48t 400 15 45t 520 15 40t 400 14 50t 520 14 48t Chain O Ring 5 8 x 1 4 Available final sprockets 38t 40t 42t 45t 48t 50t 52t Bulps headlight HS1 12V 35 35W parking light 12V 5W Sockel W2 1x9 5d instrument lights 12V 1 2W Sockel W2 1x4 6d brake rear light 12V 21 5W Sockel BaY15d flasher light 12V 10W Sockel 155 license plate illmination 12V 1 2W Sockel 1x4 6d Batterie maintenance free battery 12V 8Ah Steering head angle 63 5 Wheel base 1481 10 mm 58 3 0 4 in Seat hight unloaded Ground clearance unloaded Dead weight 925 mm 36 5 in 380 mm 15 1 in 107 kg 236 Ibs 112 kg 247 Ibs Dead weight without fuel
72. ll Adjust valve gap Loss of compression because hand Check setting of the hand decompression cable decompressor has no play Electronical ignition timing faulty Have ignition system checked Engine stops or splutters in Insuffient fuel Clean and check fuel system and carburettor carburettor Engine takes air out of control Check rubber sleeve and carburetor for tight fit Engine gets to hot Insufficient cooling liquid Refill cooling liquid see maintenace work check cooling system for leaks Not enough air stream Drive on briskly electric fan can be retrofitted Cooling system has not been bled Bleed cooling system Radiators very dirty Clean radiators with water jet Foam formation in cooling system Replace cooling liquid use anti freeze liquid with brand name Bent cooling hose Shorten or replace cooling hose Thermostat defective Dismount and check thermostat opening temperature 70 C 158 F or replace it High oil consumption Hose of engine ventilation is bent Dislocate i e replace non buckling vetilation hose Engine oil level too high Check engine oil level and if necessary correct it Motor oil too thin viscosity Use thicker engine oil see chapter Engine oil All switched on lamps blown Capacitor or voltage regulator Dismount seat and fuel tank and check connections have out faulty capacitor and voltage regulator checked Horn flasher lights and Blown fuse in the starter relay Dismount left
73. octite 243 150 Nm 132 ft Ib Allan head screw balancer shaft gear M6 Loctite 243 8 Nm 6 ft lb Hexagon collar screw clutch spring M6 8Nm 6 ft lb Allan head screw shift roller locking piece M6 Loctite 243 10 Nm 6 ft Ib Hexagon collar screw locking lever M5 Loctite 243 6 Nm 6 ft lb Hexagon collar screw shift roller M5 Loctite 243 6 Nm 6 ft Ib Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 8 Nm 6 ft Ib Hexagon collar screw clip M5 Loctite 243 6 Nm 4 ft Ib Hexagon collar screw chain adjuster M6 8 Nm 6 ft Ib Hexagon collar screw stator MXC EXC M6 Loctite 243 8 Nm 6 ft lb Hexagon collar screw stator SX M5 Loctite 243 6 Nm 5 Hexagon collar screw pulser coil M5 Loctite 243 6 Nm 5 ft Ib Hexagon collar nut flywheel M12x1 60 Nm 44 Hexagon collar screw bump part kickstarter M6 Loctite 243 8 Nm 6 ft Ib Hexagon collar screw spring hanger kickstarter M6 Loctite 243 10 Nm 6 ft lb Hexagon collar screw cover E starter only SX M6 Loctite 243 8 Nm 6 ft Ib Hexagon collar screw hanger vent hose M6 Loctite 243 8 Nm 6 ft lb Allan head screw kickstarter M8 Loctite 243 25 Nm 19 ft lb Hexagon collar screw shift lever M6 Loctite 243 10 Nm 6 ft lb Hexagon screw engine sprocket M10 Loctite 243 60 Nm 44 Spark plug M10 10 12Nm 7 8 ft Ib API SG SH TEMPERATUR Engine oil Use only fully synthetic oil brands which meet quality r
74. oil screen and drain plug magnet Z Check oil lines for damage or bends e e Replace spark plug after 30 hours Check and adjust valve clearance Check engine mounting bolts for tightness Check carburetor connection boot for cracks and leaks Check idle speed setting e e c5 Check vent hoses for damage or bends e e Check cooling system for leaks check quantity of anti freeze e e Check exhaust system for leaks and fitment e Check cables for damage smooth operation and bends e e amp adjust and lubricate Check fluid level of the clutch master cylinder Clean air filter and filter box Q Check electric wires for damage and bends a Check head lamp setting e Check function of electric systems low high beam break light indicator e e indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs e e X Check brake lines for damage and leaks e e Check smooth operation and adjust free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork for leaks and function Clean fork dust bellows Bleed fork legs e Q Check swing arm bearings o Check adjust steering head bearings e e Check tightness of chassis screws e e triple clamps fork leg axle passage Check spoke tension and rim joint e Check tyres and air pressure a Check c
75. ration and tank full Luggage Driver with protective clothing and helmet Pay attention to running in procedure Running in the Racing models Even very precisely machined sections of engine components have rougher surfaces than components which have been sli ding across one another for quite some time Therefore every engine needs to be broken in For this reason do not load the engine more than 5076 of its capacity during the first 3 operating hours Besides the engine speed must not exceed 7000 rpm Avoid going full throttle In the following 12 operating hours you may load the engine up to 75 of its capacity Use the motorcycle on various types of terrain road easy off road trails CAUTION THE 400 520 SC MXC EXC RACING MODELS WERE UNCOMPRO MISINGLY DESIGNED FOR OFF ROAD COMPETITION PURPOSES ONLY EVEN THOUGH THE EXC MODELS ARE APPROVED FOR USE ON PUBLIC ROADS THEIR USE ON ROADS IS RECOMMENDABLE ONLY TO A VERY LIMITED EXTENT AVOID EXTENDED ON ROAD RIDES AT FULL THROTTLE Starting when the engine is cold Open the fuel tap Swing up the side stand or center stand Put the gear in neutral Operate the choke Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E starter A WARNING A IF YOU WANT TO START THE ENGINE MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MIGHT SLIP OFF THE KICK STARTER OR THE ENGINE MAY KICK BAC
76. rder Before tightening the collar nut to 80 Nm 60 ft lb push the rear wheel forwards so that the chain tensioners lie on the tension screws A VVARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE REAR BRAKE UNTIL THE PRESSURE POINT RETURNS T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE TIRES AIR PRESSURE front rear Off road 1 0 bar 1 0 bar Road driver only 1 5 bar 2 0 bar Tires air pressure Tire type tire condition and air pressure level affect the way your motor cycle rides and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle Tire size can be found in the technical specifications and in their homolo gation certificate Tire condition has to be checked every time you want to ride your motorcycle Before leaving check tires for punctures and nails or other sharp objects that might have become embedded in them Refer to the specific regulations in your country for minimum tire tread req
77. s 1 compression ring 1 oil scraper ring Engine lubrication pressure circulation lubrication with two rotorpumps Engine oil fullsynthetic oil Shell Advance Ultra4 SAE 10W40 Quantity of engine oil 1 25 liters Primary ratio straight geared spur wheels 33 76 t Clutch multi disc clutch in oil bath Transmission claw shifted 6 speed 6 speed 6 speed 4 speed 6 speed 6 speed Gear ratio 1 Gear 16 32 16 32 14 34 16 32 16 32 14 34 2 Gear 18 30 18 30 17 31 18 30 18 30 17 31 3 Gear 20 28 20 28 19 28 20 28 20 28 19 28 4 Gear 22 26 22 26 22 26 22 26 22 26 22 26 5 Gear 24 24 24 24 24 23 24 24 24 23 6 Gear 21 18 21 18 26 21 21 18 26 21 Ignition system contactless DC CDI ignition with digital advanced system by KOKUSAN Generator 12V 40W 12V 110W Spark plug NGK CR8 EK Spark plug gap 0 6 mm Cooling system liquid cooled permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter 40 antifreeze 60 water at least 25 13 F Starting equipment kickstarter kick electric starter kickstarter kick electric starter BASIC CARBURETOR SETTING ORANG BUNT o sxracnc pcc serica Type Keihin CR39 Keihin CR39 Keihin CR39 Keihin CR39 Keihin CR39 Keihin CR39 Carb setting number 031299 130799 100699 250899 250401 240401 Main jet 175 175 175 175 175 175 Jet needle OBDTM OBDVR OBDTM OBDTM OBDVR OBDVR Idling jet 48 48 48 48 48 48 Main air jet 200 200 200 200 200 200 Idling air jet 100 100 100 100 100 100
78. side paneling and filter box cover replace fuse E starter do not work The battery is discharged The battery isn t charged by the Remove seat and fuel tank and check voltage regulator generator because connections voltage regulator and generator should be checked by a KTM dealer CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE DESTRUCTION OF THESE PARTS You should use normal brand name detergents to clean the motorcycle Especially dirty parts should be cleaned additionally with the help of a paint brush Befor cleaning with water plug the exhaust pipe to prevent water ingress After the motorcycle has been rinsed with a soft water jet it should be dried by air pressure and a cloth Drain the float chamber of the carburetor Then take a short drive until the engine has reached the working temperature and also use the brakes By warming these components the residual water can evaporate from inaccessable parts of the
79. spindle NOTE The wheel spindle can be easily removed if you slightly revolve it with a ring span ner SW 21 mm or a hexagon socket screw key 6 mm Remove front wheel carefully from the fork and take the speedometer drive off the hub NOTE Models with a digital speedometer have a distance bushing instead of the speed ometer drive l CAUTION Do NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL OTHERWISE THE BRAKE DISC CAN BE DAMAGED Prior to mounting the front wheel clean and grease sealing ring and running surface at the speedometer drive Lift front wheel into fork and insert speedometer drive or distance sleeve into hub Make sure that the driving tabs engage with the slot of the drive Position front wheel and speedometer drive or distance sleeve and mount wheel spindle I d ml i e 23 The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer Mount the collar nut turn the speedometer drive such that the speedo meter shaft leads upward parallel to the fork leg see photo tighten the clamping sceews on the right side to prevent the wheel spindle from tur ning and tighten the collar nut to 40 Nm 30 ft Ib Loosen the clamping screews on the right side Take the motorcycle off the stand and
80. ss 5 Digital speedometer indicator lamps 5 Dismounting and mounting the front wheel 23 Page Dismounting and mounting the rear wheel 24 Draining of float chamber of the carburetor 34 Driving esien ene 11 Emergency OFF button EXC 6 Emergency OFF switch EXC 6 Engine number engine type 4 Engine oll irn rte emite 35 Fille Cap siet eer ree eat e 7 Flasher switch ete pet ede 6 Foot brake pedal nd ee mre be i 8 F el ELM doit et atto tene 7 F eldap a matu tee terr topi bera Tet Lie 7 Fuse meme eren 29 General informations about KTM disc brakes 20 Hand brake lever 4 Hand decompression lever 4 Head Word index redet 44 Headlamp switch EXC 6 How to change the handlebar position 18 Kickstarter uie teet o a Rc ee 8 Maintenance work on chassis and engine 16 Odometer EXC 15 5 Oil circulin eee eee aa eo 34 Operation Instrument 4 Periodic Lubrication and maintenance schedule 14 Pivot bearing
81. throttle fuel will be injected into the intake passage When starting be sure that you open the throttle completely only once Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and open throttle at the same time A WARNING A BEFORE YOU START OFF CHECK THAT THE SIDE STAND HAS BEEN SWUNG UP FULLY IF THE STAND DRAGS ON THE GROUND THE MOTORCYCLE CAN GO OUT OF CONTROL ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the conditions traffic hill size etc you can shift to a higher gear Close throttle at the same time pull clutch lever in and shift to the next higher gear Let clutch lever go again and give gas If you turned on the choke make sure you turn it off again as soon as engine is warm When you reach full speed through opening the throttle all the way turn throttle back to 3 4 the speed hardly decreases although the engine will use less gas Only give as much gas as the engine can handle Through quick and high reving of throttle the fuel usage increases By shifting down use the brakes if necessary and close throttle at the same time Pull clutch lever and shift down to the next gear Let clutch lever go slowely and open throttle or shift down again NOTE DEDICATED TO NOTHING BUT OFFROAD RACING
82. uirements We recommend you replace the tires at the latest when the tread is down to 2 mm 0 08 in Tire pressure should be checked regularly on a cold tire Proper pres sure ensures optimum driving comfort and extends the life of your tires A WARNING A Do NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT USE HOMOLOGATED TIRES FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES F AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unba lanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer A WARNING A SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE EXCESSIVELY TENSIONED SPOKE
83. urelle HF E15 Biodegradable hydrau lic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLIN DER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID CARBURETOR Adjust idling Keihin CR39 Idling adjustment of the carburetor strongly affects the engine s starting behavior That is an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly The idle speed is controlled by means of the adjusting wheel and the mixture control screw The adjusting wheel is used to adjust the basic setting of the slide The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system Clockwise turning reduces the fuel quantity lean mixture counterclockwise turning increases the fuel quantity rich mixture TO ADJUST IDLING CORRECTLY PROCEED AS FOLLOWS 1 Turn in mixture control screw up to the stop and turn it back out to the basic position see tecnical date engine 2 Warm up the engine 3 Use the adjusting wheel to set the normal idl
84. ust be 2 4 mm 0 08 0 16 in otherwise malfunctions on the speedometer might occur This distance can be corrected by screwing in or off the sensor HSITIDNGA Battery MXC EXC The battery is located under the seat and is maintenance free It is not necessary to check the electrolyte level or to refill water Simply keep the battery poles clean and slightly grease them with an acid free grease if necessary Removing the battery First disconnect the negative and then the positive pole of the battery Remove filter box cover and unhitch both rubber bands Remove battery Install the battery with the terminals facing the front see illustration connecting the netative terminal post to the battery last A WARNING A F ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS N THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER N THE CASE OF CONTACT WITH THE EYES THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 15 MINUTES IMMEDIATELY CONSULT A DOCTOR THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY DEFECT BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES i CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING
85. ust pro tection bellows into the outer tubes by hand Adjusting the spring preload on the fork SX The spring preload on the SX models can be adjusted changed by 10 mm by turning adjusting screw Turning in a clockwise direction will increase the prestress turning in a counterclockwise direction will decrease the prestress Changing the spring preload will not affect the rebound damping adjust ment Generally if the spring preload is higher the rebound damping should also be set higher Standard setting Unscrew the adjusting screw to the limit and then back 2 turns d U 2 m How to change the handlebar position The handlebar position can be readjusted by 22 mm Thus you can put the handlebar to the position that is the most convenient for you The upper tri ple clamp includes 2 bores arranged at a distance of 15 mm 0 6 in from one another The bores at the handlebar support are offset from the cen ter by 3 5 mm 0 13 in Accordingly you can mount the handlebar in 4 different positions For this purpose remove screws of the handlebar clamps and screws of the handlebar support Position handlebar support and tighten screws to 40 Nm 30 ft lb Mount handlebar and handlebar clamps and tighten screws amp to 20 Nm 15 ft lb The gap between handlebar support and handlebar clamps is to be of equal size in the front and in the rear m e A z L 0 Ch
86. vel of the hydraulic clutch To check the oil level in the master cylinder of the clutch remove the cover For this purpose remove screws amp and cover together with the rubber boot O The oil level in the horizontal standing master cylin der should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLIN DER NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID Bleeding of the hydraulic clutch For bleeding the cover of the master cylinder of the clutch needs to be removed For this purpose remove screws and take off cover together with rubber bellows At the slave cylinder of the clutch remove the blee der nipple At its place mount the bleeder syringe which is filled with SAE 10 hydraulic oil Refill oil until oil is discharged from the bore of the master cylinder in a bubble free state Make sure that the oil does not over flow The bleeder syringe can be purchased at your KTM dealer Having completed the bleeding procedure you have to verify that the oil level in the master cylinder is correct If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Nat

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