KTM 450 SMR (2012) Handleiding
Lees hieronder de 📖 handleiding in het Nederlandse voor KTM 450 SMR (2012) (96 pagina's) in de categorie Motor. Deze handleiding was nuttig voor 40 personen en werd door 2 gebruikers gemiddeld met 4.5 sterren beoordeeld
Pagina 1/96
OWNER'S MANUAL 2012
450 SMR
Art. no. 3211729en
DEAR KTM CUSTOMER 1
DEAR KTMCUSTOMER
DEAR KTMCUSTOMER
DEAR KTMCUSTOMER
DEAR KTMCUSTOMERDEAR KTMCUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you a lot of enjoyment in riding this vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 9) Dealer's stamp
Engine number ( p. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2011 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
TABLE OF CONTENTS 3
WHEELS, TIRES ............................................................... 54
Removing the front wheel .......................................... 54x
Installing the front wheel ........................................... 54x
Removing the rear wheel ........................................... 55x
Installing the rear wheel ............................................ 56x
Checking the tire condition............................................. 57
Checking the tire air pressure ......................................... 57
Checking spoke tension.................................................. 57
ELECTRICAL SYSTEM ....................................................... 59
Removing the battery ................................................ 59x
Installing the battery ................................................. 59x
Recharging the battery .............................................. 59x
Removing the main fuse................................................. 60
Installing the main fuse ................................................. 61
COOLING SYSTEM ............................................................ 62
Cooling system .............................................................. 62
Checking the anti-freeze and coolant level ....................... 62
Checking the coolant level.............................................. 62
Draining the coolant .................................................. 63x
Refilling coolant ....................................................... 63x
TUNING THE ENGINE ....................................................... 64
Checking the play in the throttle cable............................. 64
Adjusting the play in the throttle cable ....................... 64x
Carburetor - idle ............................................................ 64
Carburetor - adjusting the idle speed .......................... 65x
Emptying the carburetor float chamber ....................... 65x
Ignition curve plug connection ........................................ 66
Changing the ignition curve ............................................ 66
Checking the basic position of the shift lever.................... 66
Adjusting the basic position of the shift lever .............. 67x
Antihopping clutch ........................................................ 67
Adjusting the antihopping clutch .................................... 68
SERVICE WORK ON THE ENGINE ...................................... 70
Checking engine oil level................................................ 70
Changing the engine oil and oil filter, cleaning the oil
screen ..................................................................... 70x
Adding engine oil .......................................................... 72
CLEANING, CARE ............................................................. 73
Cleaning motorcycle ...................................................... 73
STORAGE ......................................................................... 74
Storage......................................................................... 74
Preparing for use after storage ........................................ 74
TROUBLESHOOTING......................................................... 75
TECHNICAL DATA - ENGINE .............................................. 77
Capacity - engine oil ...................................................... 77
Capacity - coolant.......................................................... 77
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 78
TECHNICAL DATA - CARBURETOR..................................... 80
TECHNICAL DATA - CHASSIS ............................................ 81
Tires ............................................................................ 81
Capacity - fuel............................................................... 82
TECHNICAL DATA - FORK.................................................. 83
Capacity - fork oil .......................................................... 83
TECHNICAL DATA - SHOCK ABSORBER ............................. 84
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 85
SUBSTANCES................................................................... 86
AUXILIARY SUBSTANCES.................................................. 88
STANDARDS..................................................................... 90
INDEX .............................................................................. 91
MEANS OF REPRESENTATION 4
Symbols used
The symbols used are explained below.
Indicates an expected reaction (e.g. to a work step or a function).
Indicates an unexpected reaction (e.g. to a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs performed in an authorized KTM workshop. There, your motorcycle will be ser-
viced optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.
IMPORTANT INFORMATION 5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only in closed off areas remote from public road traffic.
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and
chassis is properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and chassis can lead to
damage and breakage of components.
Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above-average wear of components
such as the drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in
the service schedule is reached.
Pay careful attention to the prescribed running-in period and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record and in the ; otherwise, all warranty claims will be void. No warranty claim can be honored for damageKTM dealer.net
resulting from manipulation and/or other changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise
you.
You will find the current for your vehicle on the KTM website.KTM PowerParts
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Ensure that the vehicle is safe to operate after completing repair and maintenance work.
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
–Switch off the engine.
–Turn the handle of the fuel tap to the position. (Figure 500178-10 p. 12)OFF
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
IMPORTANT INFORMATION 6
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains information and
tips to help you operate and handle your motorcycle. Only then will you learn how to best adjust the motorcycle for your own use
and how to protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.
VIEW OF VEHICLE 7
3.1
3.1
3.1
3.13.1Vehicle view, front left
B00837-10
1 Hand brake lever ( p. 10)
2 Hot start lever ( p. 10)
3 Clutch lever ( p. 10)
4 Filler cap
5 Seat
6 Engine number ( p. 9)
7 Shift lever ( p. 12)
8 Fuel tap ( p. 12)
VIEW OF VEHICLE 8
3.2
3.2
3.2
3.23.2Vehicle view, rear right
B00838-10
1 Kill switch ( p. 10)
2 Electric starter button ( p. 11)
3 Throttle grip ( p. 10)
4 Fork compression adjustment
5 Fork rebound adjustment
6 Foot brake lever ( p. 13)
7 Shock absorber compression adjustment
8 Shock absorber rebound adjustment
SERIAL NUMBERS 9
4.1
4.1
4.1
4.14.1Chassis number
400193-10
The chassis number is stamped on the steering head on the right.
4.2
4.2
4.2
4.24.2Type label
400284-10
The type label is fixed to the front of the steering head.
4.3
4.3
4.3
4.34.3Engine number
B00425-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.4
4.4
4.4
4.44.4Fork part number
B00879-10
The fork part number is stamped on the inner side of the fork stub.
4.5
4.5
4.5
4.54.5Shock absorber part number
B00840-10
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
CONTROLS 10
5.1
5.1
5.1
5.15.1Clutch lever
100826-10
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
5.2
5.2
5.2
5.25.2Hot start lever
100826-11
The hot start lever is fitted on the left side of the handlebar.
If you pull the hot start lever to the handlebar during the start procedure, a bore is
opened in the carburetor through which the engine can draw in extra air. This gives a
leaner fuel-air mixture, which is needed for a hot start.
Possible states
• Hot start function activated Hot start lever is pulled out to the stop.–
• Hot start function deactivated Hot start lever is pushed back to the stop.–
5.3
5.3
5.3
5.35.3Hand brake lever
100827-10
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
5.4
5.4
5.4
5.45.4Throttle grip
B00839-10
The throttle grip is fitted on the right side of the handlebar.
5.5
5.5
5.5
5.55.5Kill switch
100825-10
Kill switch is fitted on the left side of the handlebar.
Possible states
• Kill switch in basic position In this position, the ignition circuit is closed, and–
the engine can be started.
• Kill switch pressed In this position, the ignition circuit is interrupted, a run-–
ning engine stops, and a non-running engine will not start.
CONTROLS 11
5.6
5.6
5.6
5.65.6Electric starter button
100828-10
Electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed In this position, the electric starter is actuated.–
5.7
5.7
5.7
5.75.7Opening filler cap
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
B00841-10
–Press release button , turn filler cap counterclockwise and lift it upwards and
remove.
5.8
5.8
5.8
5.85.8Closing filler cap
B00842-10
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Route the fuel tank breather hose without kinking.
CONTROLS 12
5.9
5.9
5.9
5.95.9Fuel tap
500178-10
With the tap handle on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
• Fuel supply closed No fuel can flow from the tank to the carburetor.OFF –
• Fuel supply open Fuel can flow from the tank to the carburetor. The fuel tankON –
empties completely.
5.10
5.10
5.10
5.105.10Choke
B00843-10
Choke is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated The choke lever is pulled out to the stop.–
• Choke function deactivated The choke lever is pushed in to the stop.–
5.11
5.11
5.11
5.115.11Shift lever
B00426-11
The shift lever is mounted on the left side of the engine.
B00426-10
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
CONTROLS 13
5.12
5.12
5.12
5.125.12Foot brake lever
400205-10
Foot brake lever is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
5.13
5.13
5.13
5.135.13Plug-in stand
B00844-10
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
To stand the motorcycle, plug the plug-in stand into the left side of the wheel spin-
dle.
Info
Before riding, remove the plug-in stand.
PREPARING FOR USE 14
6.1
6.1
6.1
6.16.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
–The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical riding behavior due to inappropriate riding.
–Adapt your riding speed to the road conditions and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
–Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
–If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take
your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Unstable riding behavior.
–Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
–Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
–Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
–Before your first trip, read the entire operating instructions carefully.
–Get to know the controls.
–Adjust the basic position of the clutch lever. ( p. 45)
–Adjust the basic position of the hand brake lever. ( p. 47)
–Adjust the basic position of the foot brake lever. ( p. 51)x
–Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Your motorcycle is not authorized for riding on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
–Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
–Do not make any offroad trips that over-stress your ability and experience.
–Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–Do not exceed the overall maximum permitted weight and the axle loads.
PREPARING FOR USE 15
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
–Run in the engine. ( p. 15)
6.2
6.2
6.2
6.26.2Running-in the engine
–During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first operating hour 7,000 rpm
Maximum engine performance
During the first 3 operating hours 75 %≤
–Avoid fully opening the throttle!
RIDING INSTRUCTIONS 16
7.1
7.1
7.1
7.17.1Checks and maintenance when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when used.
–Check the engine oil level. ( p. 70)
–Check the front brake fluid level. ( p. 48)
–Check the rear brake fluid level. ( p. 52)
–Check the front brake linings. ( p. 49)
–Check the rear brake linings. ( p. 53)
–Check that the brake system is functioning properly.
–Check the coolant level. ( p. 62)
–Check for chain dirt accumulation. ( p. 40)
–Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 42)
–Check the chain tension. ( p. 41)
–Check the tire condition. ( p. 57)
–Check the tire air pressure. ( p. 57)
–Check the spoke tension. ( p. 57)
–Clean the dust boots of the fork legs. ( p. 28)
–Bleed fork legs. ( p. 28)
–Check the air filter.
–Check the settings of all controls and ensure that they can be operated smoothly.
–Check all screws, nuts and hose clamps regularly for tightness.
–Check the fuel reserves.
7.2
7.2
7.2
7.27.2Starting
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause may be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds before trying again.
400733-01
Engine has been out of use for more than 1 week
–Empty the carburetor float chamber. ( p. 65)x
–Turn the handle of the fuel tap to the position. (Figure 500178-10 p. 12)ON
Fuel can flow from the fuel tank to the carburetor.
–Remove the motorcycle from the stand.
–Shift transmission to neutral.
The engine is cold
–Pull choke lever out as far as possible.
The engine is hot
–Pull the hot start lever out to the stop.
–Press the electric starter button .
Info
Do not open the throttle.
RIDING INSTRUCTIONS 17
The engine is hot and running
–Push back the hot start lever to the stop with the engine running.
7.3
7.3
7.3
7.37.3Starting off
–Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
7.4
7.4
7.4
7.47.4Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
–Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
First gear is used for starting off or for steep inclines.
–When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
–If the choke function was activated, deactivate it after the engine has warmed up.
–When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. This barely reduces
vehicle speed but lowers fuel consumption considerably.
– –Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption.
–To shift down, brake and close the throttle at the same time.
–Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
–Switch off the engine if you expect to be stationary for a long time.
Guideline
≥2 min
–Avoid frequent and prolonged slipping of the clutch. This causes heat build-up in the engine oil, the engine and the cooling sys-
tem.
–Ride at lower engine speeds instead of high revs and a slipping clutch.
7.5
7.5
7.5
7.57.5Braking
Warning
Danger of accidents If you brake too hard, the wheels can lock.
–Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
–Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
–Clean or dry dirty or wet brakes by riding and braking gently.
–On sandy, wet or slippery surfaces, use the rear brake.
–Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
–On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to brake far less and the brakes do not overheat.
RIDING INSTRUCTIONS 18
7.6
7.6
7.6
7.67.6Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
–Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo-
nents to cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
–Brake the motorcycle.
–Shift transmission to neutral.
–Press and hold the kill switch while the engine is idling until the engine stops.
–Turn the handle of the fuel tap to the position. (Figure 500178-10 p. 12)OFF
–Park the motorcycle on firm ground.
7.7
7.7
7.7
7.77.7Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
–Switch off engine.
–Open the filler cap. ( p. 11)
AA
400382-10
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Total fuel tank
capacity, approx.
7.5 l
(1.98 US gal)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 87)
–Close the filler cap. ( p. 11)
SERVICE SCHEDULE 19
8.1
8.1
8.1
8.18.1Service schedule
S1N S10A S20A S30A
Check and charge the battery. x• • •
Change the engine oil and oil filter, clean the oil screen. ( p. 70)x• • • •
Check the front brake linings. ( p. 49) • • •
Check the rear brake linings. ( p. 53) • • •
Check the brake discs. ( p. 47) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. ( p. 52) • • •
Check the free travel of the foot brake lever. ( p. 51) • • •
Check the frame and swingarm. x• • •
Check the swingarm bearing. x•
Check the shock absorber linkage. x• • •
Conduct a minor fork service. x• • •
Conduct a major fork service. x•
Check the tire condition. ( p. 57) • • • •
Check the tire air pressure. ( p. 57) • • • •
Check the wheel bearing for play. x• • •
Check the wheel hubs. x• • •
Check the rim run-out. x• • • •
Check the spoke tension. ( p. 57) • • • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 42) • • •
Check the chain tension. ( p. 41) • • • •
Lubricate all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x• • •
Check the fluid level of the hydraulic clutch. ( p. 46) • • •
Check the front brake fluid level. ( p. 48) • • •
Check the free travel on the hand brake lever. ( p. 47) • • •
Check the steering head bearing play. ( p. 32) • • • •
Check the valve clearance. x• •
Check the clutch. x• • •
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks and
correct routing. x• • • •
Check the anti-freeze and coolant level. ( p. 62) • • • •
Check the cables for damage and routing without sharp bends. x• • •
Check that the cables are undamaged, routed without sharp bends and set correctly. • • • •
Clean the air filter and air filter box. ( p. 37)x• • • •
Change the glass fiber yarn filling of the main silencer. ( p. 38)x• • •
Check the screws and nuts for tightness. x• • • •
Check idle. x• • • •
Final check: Check the vehicle for safe operation and take a test ride. • • • •
Make the service entry in and in the service record.KTM DEALER.NET x• • • •
S1N: Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal)
S10A: Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S30A: Every 30 operating hours - corresponds to about 210 liters of fuel (55.5 US gal)
SERVICE SCHEDULE 20
8.2
8.2
8.2
8.28.2Service work (as additional order)
S20N S20A S40A S80A J1A
Change the front brake fluid. x•
Change the rear brake fluid. x•
Change the hydraulic clutch fluid. ( p. 46)x•
Grease the steering head bearing. ( p. 33)x•
Check/set the carburetor components. • • •
Service the shock absorber. x• • •
Change the spark plug and spark plug connector. x• •
Change the piston. x• •
Change the piston. (in difficult operating conditions) x• • •
Check/measure the cylinder. x• •
Check the cylinder head. x• •
Change the valves, valve springs and valve spring seats. x•
Check the camshaft and cam lever. x• •
Change the connecting rod, conrod bearing and crank pin. x• •
Change the crankshaft bearing. x• •
Check the transmission and shift mechanism. x• •
Check the oil pressure regulator valve. x• •
Check the oil pumps and lubrication system. x• •
Check the timing assembly. x• •
Change all engine bearings. x•
S20N: Once after 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal)
S80A: Every 80 operating hours - corresponds to about 560 liters of fuel (148 US gal)
J1A: Annually
TUNING THE CHASSIS 21
9.1
9.1
9.1
9.19.1Checking the basic suspension setting against the rider's weight
Info
When adjusting the basic suspension setting, first adjust the shock absorber and then the fork.
401030-01
–For optimal motorcycle riding characteristics and to avoid damage to forks, shock
absorbers, swingarm and frame, the basic settings of the suspension components
must match the rider's weight.
–As delivered, KTM offroad motorcycles are adjusted for a standard rider weight
(with full protective clothing).
Guideline
Standard rider weight 75… 85 kg (165… 187 lb.)
–If the rider's weight is above or below the standard range, the basic setting of the
suspension components must be adjusted accordingly.
–Small weight differences can be compensated by adjusting the spring preload, but
in the case of large weight differences, the springs must be replaced.
9.2
9.2
9.2
9.29.2Compression damping of shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear wheel suspension compresses more quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses more
slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in
the high-speed range affect the compression damping in the low-speed range and vice versa.
9.3
9.3
9.3
9.39.3Adjusting the low-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
B00290-10
–Turn adjusting screw clockwise with a screwdriver up to the last perceptible
click.
Info
Do not loosen nut !
–Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
Comfort 21 clicks
Standard 18 clicks
TUNING THE CHASSIS 22
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
9.4
9.4
9.4
9.49.4Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
B00289-10
–Turn adjusting screw all the way clockwise with a socket wrench.
Info
Do not loosen nut !
–Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
9.5
9.5
9.5
9.59.5Adjusting the rebound damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
B00291-10
–Turn adjusting screw clockwise up to the last perceptible click.
–Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
Comfort 14 clicks
Standard 12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
TUNING THE CHASSIS 23
9.6
9.6
9.6
9.69.6Measuring rear wheel sag unloaded
– Raise the motorcycle with the lift stand. ( p. 28)
0
0
0
0
00AA
400389-10
– – –Measure the distance as vertically as possible between the rear axle and a fixed
point, such as a mark on the side cover.
– Make note of the value as measurement .
– Remove the motorcycle from the lift stand. ( p. 28)
9.7
9.7
9.7
9.79.7Checking static sag of shock absorber
00
0
0
0
0BB
0
0
0
0
00AA
400383-10
– Measure distance of rear wheel unloaded. ( p. 23)
– Ask someone to help you by holding the motorcycle upright.
– Measure the distance between the rear axle and the fixed point again.
– Make a note of the value as measurement .
Info
The static sag is the difference between measurements and .
– Check the static sag.
Static sag 20 mm (0.79 in)
» If the static sag is less or more than the specified value:
–Adjust the spring preload of the shock absorber. ( p. 24)x
9.8
9.8
9.8
9.89.8Checking riding sag of shock absorber
CC
0
0
0
0
00
AA
400384-10
– Measure distance of rear wheel unloaded. ( p. 23)
– With the help of another person holding the motorcycle, the rider, wearing com-
plete clothing, sits on the motorcycle in a normal position (feet on footrests) and
rocks up and down a few times so that the rear wheel suspension levels out.
– Another person now measures the distance between the rear axle and the fixed
point.
– Make a note of the value as measurement .
Info
The riding sag is the difference between measurements and .
– Check the riding sag.
Riding sag 75 mm (2.95 in)
» If the riding sag differs from the specified measurement:
–Adjust the riding sag. ( p. 24)x
TUNING THE CHASSIS 24
9.9
9.9
9.9
9.99.9Adjusting the spring preload of the shock absorber x
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop
will be glad to help.)
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
–Remove the shock absorber. ( p. 34)x
– After removing the shock absorber, clean it thoroughly.
401025-10
– Loosen screw .
– Turn adjusting ring until the spring is no longer under tension.
Hook wrench (T106S)
– Measure the overall spring length when not under tension.
– Tighten the spring by turning adjusting ring to measurement .
Guideline
Spring preload 19 mm (0.75 in)
Info
Depending on the static sag and/or the riding sag, it may be necessary to
increase or decrease the spring preload.
– Tighten screw .
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
–Install the shock absorber. ( p. 35)x
9.10
9.10
9.10
9.109.10Adjusting the riding sag x
–Remove the shock absorber. ( p. 34)x
– After removing the shock absorber, clean it thoroughly.
B00292-10
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 65… 75 kg (143…
165 lb.)
54 N/mm (308 lb/in)
Weight of rider: 75… 85 kg (165…
187 lb.)
57 N/mm (325 lb/in)
Weight of rider: 85… 95 kg (187…
209 lb.)
60 N/mm (343 lb/in)
Info
The spring rate is shown on the outside of the spring.
–Install the shock absorber. ( p. 35)x
– Check the static sag of the shock absorber. ( p. 23)
– Check the riding sag of the shock absorber. ( p. 23)
– Adjust the rebound damping of the shock absorber. ( p. 22)
TUNING THE CHASSIS 25
9.11
9.11
9.11
9.119.11Checking basic setting of fork
Info
For various reasons, no exact riding sag can be determined for the forks.
401000-01
– As with the shock absorber, smaller differences in the rider's weight can be com-
pensated by the spring preload.
– However, if the fork is often overloaded (hard end stop on compression), harder
springs must be fit to avoid damage to the fork and frame.
9.12
9.12
9.12
9.129.12Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
B00848-10
– Turn adjusting screws clockwise all the way.
Info
Adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
9.13
9.13
9.13
9.139.13Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
B00849-10
– Remove protection caps .
– Turn adjusting screws clockwise all the way.
Info
Adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
– Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damp-
ing.
TUNING THE CHASSIS 26
– Mount protection covers .
9.14
9.14
9.14
9.149.14Fork offset
800009-10
You can see the currently set offset if you remove screw .
The fork offset has an impact on the handling of the vehicle. It is calculated from
the center of the fork leg to the center of the steering head bearing.
The fork offset can optionally be adjusted.
Marking to the front gives greater stability on fast racetracks.
Fork offset
Front marking 14 mm (0.55 in)
Marking to the rear gives better handling in bends.
Fork offset
Rear marking 16 mm (0.63 in)
9.15
9.15
9.15
9.159.15Adjusting the fork offset x
–Remove the lower triple clamp. ( p. 30)x
500104-10
– Remove screw . Remove the steering stem.
– Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten
screw .
Guideline
Screw, bottom steering
head
M20x1.5 60 Nm
(44.3 lbf ft)
Loctite®243™
–Install the lower triple clamp. ( p. 31)x
9.16
9.16
9.16
9.169.16Handlebar position
0
0
0
0
00BB
0
0
0
0
00AA
400271-11
On the upper triple clamp, there are 2 holes at a distance of to each other.
Hole distance A 15 mm (0.59 in)
The holes on the handlebar support are placed at a distance of from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar can be mounted in four different positions. In this way, the handlebar
can be mounted in the position that is most comfortable for the rider.
9.17
9.17
9.17
9.179.17Adjusting handlebar position x
0
0
0
0
0022
0
0
0
0
0011
0
0
0
0
0022
11
B00375-10
– Remove the four screws . Remove the handlebar clamp. Remove the handlebar
and lay it to one side.
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
– Remove screws . Remove the handlebar support.
– Place the handlebar support in the required position. Mount and tighten screws .
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
TUNING THE CHASSIS 27
Info
Position the left and right handlebar supports evenly.
– Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
– Position the handlebar clamp. Fit and evenly tighten the four screws .
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
SERVICE WORK ON THE CHASSIS 28
10.1
10.1
10.1
10.110.1Raising the motorcycle with the lift stand
B00845-01
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Raise the motorcycle at the frame underneath the engine.
Lift stand (59229055000)
The wheels must no longer touch the ground.
– Secure the motorcycle against falling over.
10.2
10.2
10.2
10.210.2Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
B00844-10
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
– To park the motorcycle, insert plug-in stand into the left side of the wheel spin-
dle.
Info
Remove the plug-in stand before starting on a trip.
10.3
10.3
10.3
10.310.3Bleeding fork legs
– Raise the motorcycle with the lift stand. ( p. 28)
B00850-10
– Remove bleeder screws briefly.
Any excess pressure escapes from the interior of the fork.
– Mount and tighten bleeder screws.
– Remove the motorcycle from the lift stand. ( p. 28)
10.4
10.4
10.4
10.410.4Cleaning the dust boots of the fork legs
– Raise the motorcycle with the lift stand. ( p. 28)
– Remove the fork protector. ( p. 30)
B00851-10
– Push dust boots of both fork legs downwards.
Info
The dust boots should remove dust and coarse dirt particles from the fork
tubes. Over time, there is an ingress of dirt inside the boots. If this dirt is
not removed, it may cause the oil seals to leak.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
– Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
– Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( p. 89)
SERVICE WORK ON THE CHASSIS 29
–Press the dust boots back into their normal position.
–Remove excess oil.
–Install the fork protector. ( p. 30)
–Remove the motorcycle from the lift stand. ( p. 28)
10.5
10.5
10.5
10.510.5Removing the fork legs x
–Remove the front wheel. ( p. 54)x
500200-12
–Remove screws and take off clamp.
–Hang the brake caliper and the brake line loosely to the side.
B00853-10
–Loosen screw . Remove the fork leg on the left.
–Loosen screw . Remove the fork leg on the right.
10.6
10.6
10.6
10.610.6Installing the fork legs x
B00850-10
–Position the fork legs.
Info
The lowest milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the front.
B00853-11
–Tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
–Tighten screws .
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
B00855-10
–Position the brake line. Put the clamp on, and mount and tighten screws .
–Install the front wheel. ( p. 54)x
SERVICE WORK ON THE CHASSIS 30
10.7
10.7
10.7
10.710.7Removing the fork protector
B00852-11
–Remove screws and take off clamp.
–Remove screws on left fork leg. Remove the fork protector.
–Remove the screws on the right fork leg. Remove the fork protector.
10.8
10.8
10.8
10.810.8Installing the fork protector
B00852-10
–Position the fork protector on the left fork leg. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Position the brake line. Put the clamp on, and mount and tighten screws .
–Position the fork protector on the right fork leg. Mount and tighten the screws.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
10.9
10.9
10.9
10.910.9Removing the lower triple clamp x
–Remove the fork legs. ( p. 29)x
–Remove the start number plate. ( p. 33)
–Remove the front fender. ( p. 34)
–Remove the handlebar cushion.
B00856-10
–Remove screw . Remove screw , take off the top triple clamp with the handle-
bar, and place it on one side.
Info
Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.
B00858-10
–Remove O-ring . Remove protective ring .
–Take out the lower triple clamp with the steering stem.
–Remove the upper steering head bearing.
SERVICE WORK ON THE CHASSIS 31
10.10
10.10
10.10
10.1010.10Installing the lower triple clamp x
0
0
0
0
0022
0
0
0
0
0011
0
0
0
0
0033
500098-10
–Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 88)
–Insert the lower triple clamp with the steering stem. Mount the upper steering head
bearing.
–Check whether the top steering head seal is correctly positioned.
–Slide on protective ring and O-ring .
B00856-11
–Position the upper triple clamp with the steering.
–Mount screw but do not tighten yet.
B00850-11
–Position the fork legs.
Info
The lowest milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws toward the front.
B00853-12
–Fully tighten screws .
Guideline
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)
B00857-10
–Tighten screw .
Guideline
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)
SERVICE WORK ON THE CHASSIS 32
B00857-11
–Mount and tighten screw .
Guideline
Screw, top steering stem M8 17 Nm
(12.5 lbf ft)
Loctite®243™
B00853-13
–Fully tighten screws .
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
–Install the front fender. ( p. 34)
–Install the start number plate. ( p. 33)
–Mount the handlebar cushion.
–Check that the wiring harness, cables, and brake and clutch lines can move freely
and are routed correctly.
–Install the front wheel. ( p. 54)x
–Check the steering head bearing play. ( p. 32)
10.11
10.11
10.11
10.1110.11Checking steering head bearing play
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
–Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
Info
If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-
aged over time.
–Raise the motorcycle with the lift stand. ( p. 28)
400738-11
–Move the handlebar to the straight-ahead position. Move the fork legs to and fro in
the direction of travel.
No play should be noticeable in the steering head bearing.
» If there is noticeable play present:
–Adjust play of the steering head bearing ( p. 32)x
–Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No
click positions should be noticeable.
» If click positions are noticeable:
–Adjust play of the steering head bearing ( p. 32)x
–Check the steering head bearing and replace if required.
–Remove the motorcycle from the lift stand. ( p. 28)
10.12
10.12
10.12
10.1210.12Adjusting play of steering head bearing x
–Raise the motorcycle with the lift stand. ( p. 28)
SERVICE WORK ON THE CHASSIS 34
10.16
10.16
10.16
10.1610.16Removing the front fender
B00859-10
–Remove screws . Remove the front fender.
–Make sure the spacers remain in place.
10.17
10.17
10.17
10.1710.17Installing the front fender
B00859-10
–Ensure that the spacers are mounted in the fender.
–Position the front fender. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
Info
Make sure the holding lugs engage in the start number plate.
10.18
10.18
10.18
10.1810.18Removing the shock absorber x
–Raise the motorcycle with the lift stand. ( p. 28)
–Remove the main silencer. ( p. 37)
B00846-10
–Remove screw .
–Remove screw cap .
B00847-10
–Press angle lever toward the rear.
–Press linkage lever downward.
B00409-10
–Detach springs .
Spring hooks (50305017000)
–Remove screw .
SERVICE WORK ON THE CHASSIS 35
B00270-10
–Remove screw .
–Turn the shock absorber toward the rear and remove the exhaust manifold.
–Remove the shock absorber from the top.
10.19
10.19
10.19
10.1910.19Installing the shock absorber x
B00272-10
–Insert the shock absorber from above.
–Turn the shock absorber toward the rear and position the exhaust manifold.
–Position the shock absorber.
–Mount and tighten screw .
Guideline
Screw, top shock absorber M10 60 Nm
(44.3 lbf ft)
Loctite®2701
B00409-11
–Mount and tighten screw .
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
–Attach springs .
Spring hooks (50305017000)
B00846-11
–Position the angle lever and linkage lever.
–Mount and tighten screw cap .
Guideline
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft)
–Mount and tighten screw .
Guideline
Screw, bottom shock
absorber
M10 60 Nm
(44.3 lbf ft)
Loctite®2701
–Install the main silencer. ( p. 38)
–Remove the motorcycle from the lift stand. ( p. 28)
10.20
10.20
10.20
10.2010.20Removing the seat
B00873-10
–Remove screw .
–Lift up the seat at the rear, pull it back and then remove it from above.
SERVICE WORK ON THE CHASSIS 36
10.21
10.21
10.21
10.2110.21Mounting the seat
B00410-01
–Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear
and simultaneously push it forward.
–Make sure that the seat is correctly locked in.
–Mount and tighten the screw of the seat fixing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
10.22
10.22
10.22
10.2210.22Removing the air filter box lid
B00874-10
–Pull off the air filter box lid in area to the side and remove to the front.
10.23
10.23
10.23
10.2310.23Installing the air filter box lid
B00874-11
–Insert the air filter box lid into the rear area and clip it into the front area .
10.24
10.24
10.24
10.2410.24Removing the air filter x
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
–Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
–Remove the air filter box lid. ( p. 36)
B00875-10
–Detach air filter holder at the bottom and swing it to one side. Remove the air
filter with the air filter support.
–Remove the air filter from the air filter support.
SERVICE WORK ON THE CHASSIS 38
B00876-10
–Disconnect spring .
–Remove screws and take off main silencer.
10.28
10.28
10.28
10.2810.28Installing the main silencer
B00876-11
–Mount the main silencer. Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Reconnect spring .
10.29
10.29
10.29
10.2910.29Changing the glass fiber yarn filling of the main silencer x
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
–Allow the exhaust system to cool down. Do not touch hot components.
Info
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.
–Remove the main silencer. ( p. 37)
0
0
0
0
00
33
0
0
0
0
0044
0
0
0
0
0022
0
0
0
0
0011
B00420-10
–Remove the screws of locking cap . Take off the locking cap and outer tube .
–Pull the glass fiber yarn filling from the inner tube .
–Clean the parts that are to be reinstalled.
–Mount the new glass fiber yarn filling on the inner tube.
–Slide the outer tube over the glass fiber yarn filling.
–Insert the locking cap into the outer tube.
–Mount and tighten all screws.
–Install the main silencer. ( p. 38)
SERVICE WORK ON THE CHASSIS 39
10.30
10.30
10.30
10.3010.30Removing the fuel tank x
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
–Remove the seat. ( p. 35)
B00877-10
–Turn the handle of the fuel tap to the position. (Figure 500178-10 p. 12)OFF
–Pull off the fuel hose.
Info
Remaining fuel may flow out of the fuel hose.
–Remove screws with the collar sleeve.
B00878-10
–Remove screw with the rubber bushing.
–Remove the tube from the fuel tank breather.
B00877-11
–Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.
10.31
10.31
10.31
10.3110.31Installing the fuel tank x
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
–Check the throttle cable routing. ( p. 45)
SERVICE WORK ON THE CHASSIS 40
B00877-12
–Position the fuel tank and fit the two spoilers to the sides of the radiator bracket.
–Make sure that no cables are trapped or damaged.
B00878-11
–Mount the fuel tank vent hose.
–Mount and tighten screw with the collar bushing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
B00877-13
–Mount and tighten screws with the collar bushing.
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Connect the fuel hose.
–Mount the seat. ( p. 36)
10.32
10.32
10.32
10.3210.32Checking for chain dirt accumulation
400678-01
–Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
–Clean the chain. ( p. 40)
10.33
10.33
10.33
10.3310.33Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
–Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
SERVICE WORK ON THE CHASSIS 41
400725-01
–Clean the chain regularly and then treat with chain spray.
Chain cleaner ( p. 88)
Off-road chain spray ( p. 88)
10.34
10.34
10.34
10.3410.34Checking the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
–If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–Raise the motorcycle with the lift stand. ( p. 28)
B00862-10
–Push the chain at the end of the chain sliding component upwards to measure the
chain tension .
Info
The lower chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension 53… 55 mm (2.09… 2.17 in)
» If the chain tension does not meet specifications:
–Adjust the chain tension. ( p. 41)
–Remove the motorcycle from the lift stand. ( p. 28)
10.35
10.35
10.35
10.3510.35Adjusting the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
–If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-
ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if neces-
sary.
–Raise the motorcycle with the lift stand. ( p. 28)
–Check the chain tension. ( p. 41)
SERVICE WORK ON THE CHASSIS 42
B00343-11
–Loosen nut .
–Loosen nuts .
–Adjust the chain tension by turning the adjusting screws left and right.
Guideline
Chain tension 53… 55 mm (2.09… 2.17 in)
Turn adjusting screws on the left and right so that the markings on the left
and right chain adjusters are in the same position relative to the reference
marks . The rear wheel is then correctly aligned.
–Tighten nuts .
–Make sure that chain adjusters are fitted correctly on adjusting screws .
–Tighten nut .
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
Chain adjusters can be turned by 180°.
–Remove the motorcycle from the lift stand. ( p. 28)
10.36
10.36
10.36
10.3610.36Checking the chain, rear sprocket, engine sprocket and chain guide
–Raise the motorcycle with the lift stand. ( p. 28)
400227-01
–Shift gear to neutral.
–Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
–Change the rear sprocket or engine sprocket. x
Info
The engine sprocket, rear sprocket and chain should always be
replaced together.
1 2 3 16 17 18
00
0
0
0
0
BB
0
0
0
0
00AA
400385-10
–Pull on the upper part of the chain with the specified weight .
Guideline
Weight of chain wear measurement 10… 15 kg (22… 33 lb.)
–Measure the distance of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance at the longest
chain section
272 mm (10.71 in)
» If the distance is greater than the specified measurement:
–Change the chain. x
Info
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
SERVICE WORK ON THE CHASSIS 43
B00864-10
–Check the chain sliding guard for wear.
» If the bottom edge of the chain bolt is in line with or below the chain sliding
guard:
–Change the chain sliding guard. x
–Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
–Tighten the chain sliding guard.
Guideline
Screw, chain sliding
guard
M6 6 Nm
(4.4 lbf ft)
Loctite®243™
B00865-10
–Check the chain sliding piece for wear.
» If the bottom edge of the chain bolt is in line with or below the chain sliding
piece:
–Change the chain sliding piece. x
–Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
–Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece M8 15 Nm
(11.1 lbf ft)
400985-01
–Check the chain guide for wear.
Info
Wear is visible on the front of the chain guide.
» If the light part of the chain guide is worn:
–Change the chain guide. x
B00863-01
–Check that the chain guide is firmly seated.
» If the chain guide is loose:
–Tighten the chain guide.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Remove the motorcycle from the lift stand. ( p. 28)
SERVICE WORK ON THE CHASSIS 44
10.37
10.37
10.37
10.3710.37Adjusting the chain guide x
500194-10
–Remove the nut of screw .
–Remove screws and . Take off the chain guide.
Condition
Number of teeth: 44 teeth≤
–Insert nut in hole . Position the chain guide.
–Mount and tighten screws and .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Mount the nut on screw and tighten.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)
Condition
Number of teeth: 45 teeth≥
–Insert nut in hole . Position the chain guide.
–Mount and tighten screws and .
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
–Mount the nut on screw and tighten.
Guideline
Remaining nuts, chassis M6 10 Nm
(7.4 lbf ft)
10.38
10.38
10.38
10.3810.38Checking the frame x
800188-10
–Check the frame for cracking and deformation.
» If the frame exhibits cracking or deformation due to a mechanical impact:
–Change the frame. x
Info
A frame that has been damaged due to a mechanical impact must
always be changed. Repair of the frame is not authorized by KTM.
10.39
10.39
10.39
10.3910.39Checking the swingarm x
500285-01
–Check the swingarm for damage, cracking, and deformation.
» If the swingarm shows signs of damage, cracking, or deformation:
–Change the swingarm. x
Info
A damaged swingarm must always be changed. Repair of the
swingarm is not authorized by KTM.
SERVICE WORK ON THE CHASSIS 45
10.40
10.40
10.40
10.4010.40Checking the throttle cable routing
–Remove the fuel tank. ( p. 39)x
B00861-01
–Check the throttle cable routing.
Both throttle cables must be routed to the carburetor side by side behind the
handlebars and above the tank bearing.
» If the throttle cable is not routed as specified:
–Correct the throttle cable routing.
–Install the fuel tank. ( p. 39)x
10.41
10.41
10.41
10.4110.41Checking the rubber grip
401197-01
–Check the rubber grips on the handlebar for damage and wear and to ensure they
are firmly seated.
» If a rubber grip is damaged, worn or loose:
–Change and secure the rubber grip.
Grip rubber adhesive (00062030051) ( p. 88)
10.42
10.42
10.42
10.4210.42Additionally securing the rubber grip
–Check the rubber grip. ( p. 45)
401198-01
–Secure the rubber grip at two points using the securing wire.
Securing wire (54812016000)
Wire twister forceps (U6907854)
The twisted wire ends face away from the hands and are bent toward the rub-
ber grip.
10.43
10.43
10.43
10.4310.43Adjusting basic position of clutch lever
100835-10
–Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw .
Info
Turn the adjusting screw counterclockwise to increase the distance between
the clutch lever and the handlebar.
Turn the adjusting screw clockwise to decrease the distance between the
clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
SERVICE WORK ON THE CHASSIS 46
10.44
10.44
10.44
10.4410.44Checking the fluid level of hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
100836-10
–Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screws .
–Remove cover with membrane .
–Check the fluid level.
Fluid level below container rim 4 mm (0.16 in)
» If the level of the fluid does not meet specifications:
–Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( p. 86)
–Position the cover with the membrane. Mount and tighten the screws.
10.45
10.45
10.45
10.4510.45Changing the hydraulic clutch fluid x
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
100836-10
–Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screws .
–Remove cover with membrane .
500224-10
–Fill bleeding syringe with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
Hydraulic fluid (15) ( p. 86)
–On the slave cylinder, remove bleeder screw and mount bleeding syringe .
100837-10
–Inject the liquid into the system until it escapes from bore hole of the master
cylinder without bubbles.
–To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
–Remove the bleeding syringe. Mount and tighten the bleeder screw.
–Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim 4 mm (0.16 in)
–Position the cover with the membrane. Mount and tighten the screws.
BRAKES 47
11.1
11.1
11.1
11.111.1Checking free travel on hand brake lever
Warning
Danger of accidents Brake system failure.
–If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due
to overheating. Adjust free travel on hand brake lever according to specifications.
100829-10
–Push the hand brake lever forwards and check the free travel .
Free travel of hand brake lever 3 mm ( 0.12 in)≥ ≥
» If the free travel does not meet specifications:
–Adjust the basic position of the hand brake lever. ( p. 47)
11.2
11.2
11.2
11.211.2Adjusting the basic position of the hand brake lever
100830-10
–Check the free travel on the hand brake lever. ( p. 47)
–Adjust the basic setting of the hand brake lever to your hand size by turning adjust-
ing screw .
Info
If you turn the adjusting screw clockwise (as seen in the direction of travel),
the hand brake lever moves nearer to the handlebar.
If you turn the adjusting screw counterclockwise (as seen in the direction of
travel), the hand brake lever moves away from the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
11.3
11.3
11.3
11.311.3Checking the brake discs
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
–Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
0
0
0
0
00AA
400388-10
–Check the thickness of the front and rear brake discs at several places on the disk
to see if it conforms to measurement .
Info
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Brake discs - wear limit
Front 4.5 mm (0.177 in)
Rear 3.5 mm (0.138 in)
» If the brake disc thickness is less than the specified value:
–Change the brake disc.
–Check the front and rear brake discs for damage, cracking and deformation.
» If the brake disc shows signs of damage, cracking or deformation:
–Change the brake disc.
BRAKES 48
11.4
11.4
11.4
11.411.4Checking the front brake fluid level
Warning
Danger of accidents Failure of the brake system.
–If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
100831-10
–Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–Check the brake fluid level in the brake fluid reservoir .
» If the brake fluid is below the marking:MIN
–Add front brake fluid. ( p. 48)x
11.5
11.5
11.5
11.511.5Adding front brake fluid x
Warning
Danger of accidents Failure of the brake system.
–If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container.
100832-10
–Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screw cap .
–Remove plastic ring with membrane .
–Add brake fluid to level .MAX
Brake fluid DOT 4 / DOT 5.1 ( p. 86)
–Insert the membrane and plastic ring. Mount and tighten the screw cap.
BRAKES 49
Info
Clean up overflowed or spilt brake fluid immediately with water.
11.6
11.6
11.6
11.611.6Checking the front brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
B00869-10
–Check the brake linings for minimum thickness .
Minimum thickness 1 mm ( 0.04 in)≥ ≥
» If the minimum thickness is less than specified:
–Change the front brake linings. ( p. 49)x
–Check the brake linings for damage and cracking.
» If damage or cracking is visible:
–Change the front brake linings. ( p. 49)x
11.7
11.7
11.7
11.711.7Changing the front brake linings x
Warning
Danger of accident Brake system failure.
–Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.
–Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-
tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container!
BRAKES 50
B00867-10
–Remove locking split pins .
B00867-11
–Press the spring hanger of the spring forward and pull out pin .
–Take off springs . Remove the brake linings.
B00866-10
–Remove screws with washers and take off the brake caliper.
–Clean the brake caliper.
B00868-10
–Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–Remove screw cap .
–Remove plastic ring with membrane .
–Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
–Add brake fluid to level .MAX
Brake fluid DOT 4 / DOT 5.1 ( p. 86)
–Insert the membrane and plastic ring. Mount and tighten the screw cap.
Info
Clean up overflowed or spilt brake fluid immediately with water.
B00866-10
–Position the brake caliper. Mount screws with washers but do not tighten yet.
B00867-12
–Insert the brake linings. Position springs and mount pins .
Info
The spring hanger of springs should be positioned at the top.
BRAKES 51
B00867-10
–Mount locking split pins .
–Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point. Fix the hand brake lever in the activated position.
The brake caliper straightens.
–Fully tighten screws .
Guideline
Screw, front brake caliper M10x1.25 45 Nm
(33.2 lbf ft)
Loctite®243™
–Remove the fixation of the hand brake lever.
11.8
11.8
11.8
11.811.8Checking the free travel of the foot brake lever
Warning
Danger of accidents Brake system failure.
–If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
400205-11
–Disconnect spring .
–Move the foot brake lever backwards and forwards between the end stop and the
foot brake cylinder piston bracket and check free travel .
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
–Adjust the basic position of the foot brake lever. ( p. 51)x
–Reconnect spring .
11.9
11.9
11.9
11.911.9Adjusting the basic position of the foot brake lever x
Warning
Danger of accidents Brake system failure.
–If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to
overheating. Adjust free travel on foot brake lever according to specifications.
400232-10
–Disconnect spring .
–Loosen nut and, with push rod , turn it back until you have maximum free
travel.
–To adjust the basic position of the foot brake lever individually, loosen nut and
turn screw accordingly.
Info
The range of adjustment is limited.
–Turn push rod accordingly until you have free travel . If necessary, adjust the
basic position of the foot brake lever.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
–Hold screw and tighten nut .
Guideline
Nut, foot brake lever stop M8 20 Nm
(14.8 lbf ft)
–Hold push rod and tighten nut .
Guideline
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)
–Reconnect spring .
BRAKES 52
11.10
11.10
11.10
11.1011.10Checking rear brake fluid level
Warning
Danger of accidents Failure of the brake system.
–If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
800187-10
–Stand the vehicle upright.
–Check the brake fluid level in the sight glass .
» If there is an air bubble in the sight glass visible:
–Add brake fluid to the rear brake circuit. ( p. 52)x
11.11
11.11
11.11
11.1111.11Adding brake fluid to the rear brake circuit x
Warning
Danger of accidents Failure of the brake system.
–If the brake fluid level falls below the mark, this indicates a leakage in the brake system or worn-out brake linings.MIN
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
100834-10
–Stand the vehicle upright.
–Remove screw cap with membrane and the O-ring.
–Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 86)
–Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
BRAKES 53
11.12
11.12
11.12
11.1211.12Checking rear brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
500266-11
–Check the brake linings for minimum thickness .
Minimum thickness 1 mm ( 0.04 in)≥ ≥
» If the minimum thickness is less than specified:
–Change the rear brake linings. ( p. 53)x
–Check the brake linings for damage and cracking.
» If damage or cracking is visible:
–Change the rear brake linings. ( p. 53)x
11.13
11.13
11.13
11.1311.13Changing the rear brake linings x
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–Avoid contact with skin and eyes, and keep out of the reach of children.
–Wear suitable protective clothing and goggles.
–If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will
be glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5
brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid is corrosive!
Use only clean brake fluid from a sealed container.
100834-10
–Remove the rear brake linings. x
–Stand the vehicle upright.
–Remove screw cap with membrane and the O-ring.
–Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
–Mount the rear brake linings. x
–Add brake fluid to level .
Brake fluid DOT 4 / DOT 5.1 ( p. 86)
–Mount the screw cap with the membrane and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
WHEELS, TIRES 54
12.1
12.1
12.1
12.112.1Removing the front wheel x
–Raise the motorcycle with the lift stand. ( p. 28)
B00870-10
–Remove screw .
–Loosen screw .
B00866-11
–Remove screws with washers and take off the brake caliper.
Info
Do not pull the hand brake lever when the brake caliper is removed.
B00871-10
–Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
B00872-10
–Remove spacing sleeves .
12.2
12.2
12.2
12.212.2Installing the front wheel x
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
B00872-11
–Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing. x
–Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 88)
–Insert the spacers.
WHEELS, TIRES 55
B00870-12
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .
Guideline
Screw, front wheel spindle M24x1.5 45 Nm
(33.2 lbf ft)
B00866-11
– Position the brake caliper. Mount screws with washers but do not tighten yet.
– Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point. Fix the hand brake lever in the activated position.
The brake caliper straightens.
– Tighten screws .
Guideline
Screw, front brake caliper M10x1.25 45 Nm
(33.2 lbf ft)
Loctite®243™
– Remove the fixation of the hand brake lever.
B00870-11
– Remove the motorcycle from the lift stand. ( p. 28)
– Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
– Fully tighten screws .
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
12.3
12.3
12.3
12.312.3Removing the rear wheel x
– Raise the motorcycle with the lift stand. ( p. 28)
500268-10
– Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
– Remove nut .
– Remove chain adjuster . Withdraw wheel spindle only enough to allow the rear
wheel to be pushed forward.
– Push the rear wheel forward as far as possible. Remove the chain from the rear
sprocket.
– Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swingarm.
Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
WHEELS, TIRES 56
500270-11
– Remove spacers .
12.4
12.4
12.4
12.412.4Installing the rear wheel x
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
500270-10
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
–Change the wheel bearing. x
– Clean and grease shaft seal rings and bearing surface of the spacers.
Long-life grease ( p. 88)
– Insert the spacers.
500269-10
– Lift the rear wheel into the swingarm, position it, and insert wheel spindle .
– Attach the chain.
500265-12
– Position chain adjuster . Mount nut but do not tighten it yet.
– Make sure that chain adjusters are fitted correctly on adjusting screws .
– Check the chain tension. ( p. 41)
– Tighten nut .
Guideline
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft)
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in))
enables different secondary ratios with the same chain length.
Chain adjusters can be turned by 180°.
– Operate the foot brake lever repeatedly until the brake linings are in contact with
the brake disc and there is a pressure point.
– Remove the motorcycle from the lift stand. ( p. 28)
WHEELS, TIRES 57
12.5
12.5
12.5
12.512.5Checking the tire condition
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on vehicle handling.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
400602-10
– Examine the front and rear tires for cuts, foreign bodies and other damage.
» If you find cuts, foreign bodies or other damage on a tire:
– Change the tire.
– Check the tire age.
Info
The tire manufacture date is usually included in the tire identification num-
ber and comprises the last four digits of the code. The first two digitsDOT
indicate the week of manufacture and the last two digits the year of manu-
facture.
KTM recommends that the tires be changed after 5 years at the latest,
regardless of the actual state of wear.
» If the tire is older than five years:
– Change the tire.
12.6
12.6
12.6
12.612.6Checking the tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
400695-01
– Remove the dust cap.
– Check tire air pressure when tires are cold.
Tire air pressure
Front 1.6 bar (23 psi)
Rear 1.6 bar (23 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.
12.7
12.7
12.7
12.712.7Checking spoke tension
Warning
Danger of accidents Instable handling due to incorrect spoke tension.
– Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
Info
A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
WHEELS, TIRES 58
400694-01
– Tap each spoke with a screwdriver.
Info
The sound frequency depends on the length and thickness of the spoke.
If there are different sound frequencies in spokes with the same length and
thickness, this indicates different spoke tensions.
You should hear a high note.
» If the spoke tension varies:
–Correct the spoke tension. x
– Check the spoke torque.
Guideline
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7…
4.4 lbf ft)
Spoke nipple, rear wheel M5 5… 6 Nm (3.7…
4.4 lbf ft)
Torque wrench with various accessories in set (58429094000)
ELECTRICAL SYSTEM 59
13.1
13.1
13.1
13.113.1Removing the battery x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 35)
B00361-10
–Disconnect the negative (minus) cable of the battery.
–Pull back the positive terminal cover and disconnect the positive (plus) cable of
the battery.
–Detach rubber band at the bottom.
–Lift the battery up and out.
13.2
13.2
13.2
13.213.2Installing the battery x
101394-10
–Insert the battery into the battery compartment with the terminals facing to the
front.
Condition
External temperature: 10 °C ( 50 °F)≥ ≥
3Ah battery (YTX4L-BS) ( p. 81)
Condition
External temperature: 10 °C ( 50 °F)≤ ≤
Battery (YTX5L-BS) ( p. 81)
–Attach rubber band .
–Connect the positive cable and negative cable .
Guideline
Screw, battery terminal M5 2.5 Nm
(1.84 lbf ft)
Info
Contact disks must be mounted between battery terminals and cable
sockets with the claws facing up.
–Slide positive terminal cover over the positive terminal.
–Mount the seat. ( p. 36)
13.3
13.3
13.3
13.313.3Recharging the battery x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a physician.
ELECTRICAL SYSTEM 60
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the
battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
–Switch off all power consumers and switch off the engine.
–Remove the seat. ( p. 35)
–Disconnect the negative cable of the battery to avoid damage to the onboard elec-
tronics.
400240-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and starting
voltage of the battery, and to test the alternator. With this device, you cannot over-
charge the battery.
Info
Never remove lid .
Charge the battery with a maximum of 10% of the capacity specified on
battery housing .
–Switch off the battery charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
3 months
–Mount the seat. ( p. 36)
13.4
13.4
13.4
13.413.4Removing the main fuse
–Switch off all power consumers and switch off the engine.
–Remove the air filter box lid. ( p. 36)
B00362-10
–Pull starter relay off of the holder.
Info
The main fuse is located in the starter relay under the air filter box lid.
ELECTRICAL SYSTEM 61
B00363-10
–Remove protective cover .
–Remove main fuse.
13.5
13.5
13.5
13.513.5Installing the main fuse
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
–Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
B00363-11
–Insert the main fuse.
Fuse (58011109110) ( p. 81)
Info
A reserve fuse is located in the starter relay.
Replace a faulty fuse by an equivalent fuse only.
–Replace the protective cover.
–Mount the starter relay on the holder.
–Install the air filter box lid. ( p. 36)
COOLING SYSTEM 62
14.1
14.1
14.1
14.114.1Cooling system
400242-10
Water pump in the engine circulates the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve
in radiator cap . This ensures that operating the vehicle at the specified coolant tem-
perature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-
ing effect.
14.2
14.2
14.2
14.214.2Checking the anti-freeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
Engine is cold.
400243-10
–Stand the motorcycle upright on a horizontal surface.
–Remove radiator cap.
–Check the anti-freeze of the coolant.
− − − −25… 45 °C ( 13… 49 °F)
» If the anti-freeze of the coolant does not meet specifications:
–Correct the anti-freeze of the coolant.
–Check the coolant level in the radiator.
Coolant level above radiator fins. 10 mm (0.39 in)
» If the level of the coolant does not meet specifications:
–Correct the coolant level.
Alternative 1
Coolant ( p. 86)
Alternative 2
Coolant (mixed ready to use) ( p. 86)
–Refit the radiator cap.
14.3
14.3
14.3
14.314.3Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
COOLING SYSTEM 63
400243-10
–Stand the motorcycle upright on a horizontal surface.
–Remove radiator cap.
–Check the coolant level in the radiator.
Coolant level above the radiator fins. 10 mm (0.39 in)
» If the coolant level does not meet specifications:
–Correct the coolant level.
Alternative 1
Coolant ( p. 86)
Alternative 2
Coolant (mixed ready to use) ( p. 86)
–Mount the radiator cap.
14.4
14.4
14.4
14.414.4Draining the coolant x
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the
engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
400242-11
–Stand the motorcycle upright.
–Place a suitable container under the water pump cover.
–Remove screw . Remove the radiator cap .
–Completely drain the coolant.
–Mount and tighten screw with a new seal ring.
Guideline
Screw, water pump cover M6 10 Nm (7.4 lbf ft)
14.5
14.5
14.5
14.514.5Refilling coolant x
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con-
tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi-
ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
400244-10
–Make sure that the screw is tightened.
–Stand the vehicle upright.
–Pour coolant in up to measurement above the radiator fins.
Guideline
10 mm (0.39 in)
Coolant 1.2 l (1.3 qt.) Coolant ( p. 86)
Coolant (mixed ready to use) ( p. 86)
–Refit the radiator cap.
–Make a short test ride.
–Check the coolant level. ( p. 62)
TUNING THE ENGINE 64
15.1
15.1
15.1
15.115.1Checking the play in the throttle cable
400192-10
–Check the throttle grip for smooth operation.
–Move the handlebar to the straight-ahead position. Move the throttle grip back-
wards and forwards to ascertain the play in the throttle cable.
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
–Adjust the play in the throttle cable. ( p. 64)x
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
» If the idle speed changes:
–Adjust the play in the throttle cable. ( p. 64)x
15.2
15.2
15.2
15.215.2Adjusting the play in the throttle cable x
–Remove the fuel tank. ( p. 39)x
–Check the throttle cable routing. ( p. 45)
400269-10
–Move the handlebar to the straight-ahead position.
–Push back sleeves .
–Loosen nut . Turn adjusting screw in as far as possible.
–Loosen nut . Turn adjusting screw so that there is play in the throttle cable at
the throttle grip.
Guideline
Play in throttle cable 3… 5 mm (0.12… 0.2 in)
–Tighten nut .
–Press and hold the throttle grip in the closed setting. Turn adjusting screw out
until there is no play in the throttle cable .
–Tighten nut .
–Push sleeves on. Check the throttle grip for smooth operation.
–Install the fuel tank. ( p. 39)x
–Check the play in the throttle cable. ( p. 64)
15.3
15.3
15.3
15.315.3Carburetor - idle
500273-10
The idle setting of the carburetor has a big influence on the starting behavior, stable
idling, and the response to throttle opening. That means that an engine with a correctly
set idle speed is easier to start than if the idle is set wrongly.
Info
The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.
The idle speed is adjusted with adjusting screw .
The idle mixture is adjusted with the idle mixture adjusting screw .
TUNING THE ENGINE 65
15.4
15.4
15.4
15.415.4Carburetor - adjusting the idle speed x
500273-10
–Screw in idle mixture adjusting screw all the way and then turn it to the pre-
scribed basic setting.
Guideline
Idle mixture adjusting screw
Open 1.5 turns
Adjustment tool for mixture control screw (77329034000)
–Run the engine until warm.
Guideline
Warm-up time 5 min≥
–Adjust the idle speed with adjusting screw .
Guideline
Choke function deactivated The choke lever is pushed in to the stop. ( p. 12)–
Idle speed 1,550… 1,650 rpm
–Turn idle mixture adjusting screw slowly clockwise until the idle speed begins to
fall.
–Note the position and turn the idle mixture adjusting screw slowly counterclockwise
until the idle speed falls.
–Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extreme sport motorcyclist will set the mixture about 1/4 of a turn back
from this ideal value (leaner, in a clockwise direction) since the engine
becomes hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle mixture adjusting screw to the end without any
change of engine speed, you have to fit a smaller idling jet.
The idle mixture adjusting screw must not be opened more than two turns.
If more than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
–Adjust the idle speed with adjusting screw .
Guideline
Choke function deactivated The choke lever is pushed in to the stop. ( p. 12)–
Idle speed 1,550… 1,650 rpm
Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.
15.5
15.5
15.5
15.515.5Emptying the carburetor float chamber x
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
TUNING THE ENGINE 66
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
Carry out this work with a cold engine.
–Turn the handle of the fuel tap to the position. (Figure 500178-10 p. 12)OFF
No more fuel flows from the tank to the carburetor.
500273-11
–Guide the hose coming down behind the engine into a suitable container.
Info
Water in the float chamber results in malfunctioning.
–Undo the screw (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.
–Tighten screw .
15.6
15.6
15.6
15.615.6Ignition curve plug connection
B00424-10
The plug connection is located under the seat near the upper shock absorber fixa-
tion.
Possible states
• Soft The plug connection is disconnected to achieve better driveability.–
• Performance The plug connection is connected to achieve higher performance.–
15.7
15.7
15.7
15.715.7Changing the ignition curve
Change the ignition curve from Performance to Soft.
–Disconnect plug connection . (Figure B00424-10 p. 66)
Soft better driveability–
Change the ignition curve from Soft to Performance.
–Connect plug connection . (Figure B00424-10 p. 66)
Performance higher performance–
15.8
15.8
15.8
15.815.8Checking the basic position of the shift lever
00
0
0
0
0AA
400692-10
–Sit on the vehicle in the riding position and determine the distance between the
upper edge of your boot and the shift lever.
Gap between the shift lever and the top
of the boot
10… 20 mm (0.39… 0.79 in)
» If the distance does not meet the specifications:
–Adjust the basic position of the shift lever. ( p. 67)x
TUNING THE ENGINE 67
15.9
15.9
15.9
15.915.9Adjusting the basic position of the shift lever x
100823-10
–Remove screw and take off shift lever .
100824-10
–Clean gear teeth of the shift lever and shift shaft.
–Mount the shift lever on the shift shaft in the required position and engage the
gearing.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle compo-
nents during the shift procedure.
–Mount and tighten screw.
Guideline
Screw, shift lever M6 14 Nm
(10.3 lbf ft)
Loctite®243™
15.10
15.10
15.10
15.1015.10Antihopping clutch
500276-01
The antihopping system reduces the force required to activate the clutch and improves
clutch handling; in addition, it increases riding stability by reducing slippage of the
rear wheel by means of engine braking action during downshifting.
AA
BB
CC
401360-10
The antihopping system uses a two-part inner clutch hub that is connected to a helical
gear.
The clutch spring preload can be adjusted if necessary.
The top illustration shows the largest and the bottom illustration the smallest preload
of the clutch springs.
Hard spring:
With small shim 0.5 mm ( 0.02 in)− −
With small shim (condi-
tion at delivery)
− −1.0 mm ( 0.039 in)
With two small shims 0.5… 1.0 mm ( 0.02… 0.039 in)− − − −
Info
The soft springs are contained in the separate enclosure.
TUNING THE ENGINE 68
DD
EE
401361-10
Soft spring:
With large thick shim 1.5 mm (0.059 in)
With large thin shim 1.0 mm (0.039 in)
Info
The use of soft springs can increase clutch wear.
When the engine load is high (large engine torque), the turning action presses the two
parts of the inner clutch hub against each other, corresponding to the helical gearing,
thereby pressing the clutch facings against each other in addition to the clutch springs.
This additional press force means that the clutch springs require less preloading; as a
result, when downshifting, slippage arises briefly at the clutch and prevents rear wheel
hopping.
15.11
15.11
15.11
15.1115.11Adjusting the antihopping clutch
Info
The characteristic can be influenced by the spring preload force but is strongly dependent on how the vehicle is used and on
the riding style of the rider.
Increasing the spring preload force causes the clutch to open later when braking (more engine braking force). The clutch also
engages differently when starting, but the differences are considerably less pronounced than when braking. The clutch behaves
somewhat more aggressively.
–Rest the vehicle on the plug-in stand.
500278-10
–Remove screws . Remove the outer clutch cover.
500279-10
–Remove screw together with the spring retainer and the clutch spring.
Info
Do not remove all screws at once!
–Remove or add the desired washer. Mount and tighten screw together with the
spring retainer and the clutch spring.
Guideline
Screw, clutch spring M5 6.5 Nm
(4.79 lbf ft)
–Remove screw together with the spring retainer and the clutch spring.
–Remove or add the desired washer. Mount and tighten screw together with the
spring retainer and the clutch spring.
Guideline
Screw, clutch spring M5 6.5 Nm
(4.79 lbf ft)
Info
The number and thickness of washers must be the same on all screws.
–Remove screw together with the spring retainer and the clutch spring.
–Remove or add the desired washer. Mount and tighten screw together with the
spring retainer and the clutch spring.
Guideline
Screw, clutch spring M5 6.5 Nm
(4.79 lbf ft)
TUNING THE ENGINE 69
Info
The number and thickness of washers must be the same on all screws.
500278-10
–Position the outer clutch cover. Mount and tighten screws .
Guideline
Screw, clutch cover M6 10 Nm (7.4 lbf ft)
SERVICE WORK ON THE ENGINE 70
16.1
16.1
16.1
16.116.1Checking engine oil level
Info
The engine oil level can be checked when the engine is cold or warm.
–Stand the motorcycle upright on a horizontal surface.
400212-10
Condition
Engine is cold.
–Check the engine oil level.
The engine oil level is up to the bottom edge of the level viewer.
» If the engine oil is not up to the bottom edge of the level viewer:
–Add engine oil. ( p. 72)
Condition
The engine is at normal operating temperature.
–Check the engine oil level.
Info
After switching off the engine, wait a minute and then check.
The engine oil level is up to the top edge of the level viewer .
» If the engine oil is not up to the top edge of the level viewer:
–Add engine oil. ( p. 72)
16.2
16.2
16.2
16.216.2Changing the engine oil and oil filter, cleaning the oil screen x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
–Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the engine oil only when the engine is warm.
–Park the motorcycle on a level surface.
800011-10
–Place a suitable container under the engine.
–Remove oil drain plug with the seal ring.
B00429-11
–Loosen screw plug by striking it lightly with a hammer a few times.
–Remove plug with oil screen and the O-rings.
–Completely drain the engine oil.
–Thoroughly clean the parts and sealing surfaces.
–Mount and tighten screw plug with oil screen and the O-rings.
Guideline
Plug, oil screen M32x1.5 30 Nm
(22.1 lbf ft)
Lubricated with
engine oil
SERVICE WORK ON THE ENGINE 71
800011-10
–Mount and tighten oil drain plug with the seal ring.
Guideline
Oil drain plug with magnet M12x1.5 20 Nm
(14.8 lbf ft)
B00430-10
–Remove screws . Remove the oil filter cover with the O-ring.
B00431-10
–Pull oil filter out of the oil filter housing.
Circlip pliers reverse (51012011000)
–Completely drain the engine oil.
–Thoroughly clean the parts and sealing area.
B00432-10
– ⅓Lay the motorcycle on its side and fill the oil filter housing about full with engine
oil.
–Fill the oil filter with engine oil and place in the oil filter housing.
–Oil the O-ring of the oil filter cover and mount it with the oil filter cover .
–Mount and tighten the screws.
Guideline
Screw, oil filter cover M5 6 Nm (4.4 lbf ft)
–Stand the motorcycle upright.
B00433-11
–Remove the oil filler plug on the clutch cover and fill up with engine oil.
Engine oil 1.35 l (1.43 qt.) Engine oil (SAE 10W/50) ( p. 86)
Info
Too little engine oil or poor-quality engine oil results in premature wear to
the engine.
–Mount and tighten the oil filler plug.
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–Start the engine and check that it is oil-tight.
–Check the engine oil level. ( p. 70)
SERVICE WORK ON THE ENGINE 72
16.3
16.3
16.3
16.316.3Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
500274-10
–Remove the oil filler plug on the clutch cover and fill up with engine oil.
Engine oil (SAE 10W/50) ( p. 86)
–Mount and tighten the oil filler plug.
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may
result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.
–Start the engine and check that it is oil-tight.
CLEANING, CARE 73
17.1
17.1
17.1
17.117.1Cleaning motorcycle
Note
Material damage Damage and destruction of components by high-pressure cleaning equipment.
–Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-
cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
401061-01
–Seal the exhaust system to keep water out.
–First remove coarse dirt particles with a gentle water spray.
–Spray very dirty areas with a normal motorcycle cleaner and then clean with a
paintbrush.
Motorcycle cleaner ( p. 88)
Info
Clean the vehicle with warm water containing normal motorcycle cleaner
and a soft sponge.
–After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
–Empty the carburetor float chamber. ( p. 65)x
Warning
Danger of accidents Reduced braking efficiency due to wet or dirty brakes.
–Clean or dry dirty or wet brakes by riding and braking gently.
–After cleaning, ride a short distance until the engine reaches operating tempera-
ture.
Info
The heat produced causes water at inaccessible positions in the engine and
the brakes to evaporate.
–Push back the protection covers of the handlebar grips to allow any water that has
penetrated to evaporate.
–After the motorcycle has cooled off, lubricate all moving parts and bearings.
–Clean the chain. ( p. 40)
–Treat bare metal parts (except for brake discs and exhaust system) with
anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 88)
–Treat all plastic parts and powder-coated parts with a mild cleaning and care prod-
ucts.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
surfaces ( p. 89)
STORAGE 74
18.1
18.1
18.1
18.118.1Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-
ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con-
tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.
401058-01
–Clean the motorcycle. ( p. 73)
–Change the engine oil and oil filter, clean the oil screen. ( p. 70)x
–Check the anti-freeze and coolant level. ( p. 62)
–Drain the fuel from the tanks into a suitable container.
–Empty the carburetor float chamber. ( p. 65)x
–Check the tire air pressure. ( p. 57)
–Remove the battery. ( p. 59)x
–Recharge the battery. ( p. 59)x
Guideline
Storage temperature of battery without
direct sunlight.
0… 35 °C (32… 95 °F)
–Place the vehicle on a dry storage place that is not subject to large temperature
variations.
Info
KTM recommends raising the motorcycle.
–Raise the motorcycle with the lift stand. ( p. 28)
–Cover the vehicle with an air-permeable cover or blanket.
Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot
warm up properly, the water vapor produced during combustion condenses
and causes valves and exhaust system to rust.
18.2
18.2
18.2
18.218.2Preparing for use after storage
401059-01
–Remove the motorcycle from the lift stand. ( p. 28)
–Install the battery. ( p. 59)x
–Refuel. ( p. 18)
–Perform checks and maintenance steps to prepare for use. ( p. 16)
–Take a test ride.
TROUBLESHOOTING 75
Faults Possible cause Action
The engine cannot be cranked (elec-
tric starter)
Operating error Go through the steps of starting the engine.–
( p. 16)
Battery discharged –Recharge the battery. ( p. 59)x
–Check the charging voltage. x
–Check the closed current. x
–Check the stator winding of the alternator. x
Main fuse blown Remove the main fuse. ( p. 60)–
–Install the main fuse. ( p. 61)
Low external temperature Use the battery supplied in the accessories–
package.
Battery (YTX5L-BS) ( p. 81)
Starter relay defective –Check the starter relay. x
Starter motor defective –Check the starter motor. x
Engine turns but does not start Operating error Go through the steps of starting the engine.–
( p. 16)
Motorcycle was out of use for a long
time and there is old fuel in the float
chamber
–Empty the carburetor float chamber. x
( p. 65)
Fuel feed interrupted Check the fuel tank breather.–
–Clean the fuel tap.
–Check/adjust the carburetor components. x
Spark plug oily or wet Clean and dry the spark plug or replace if nec-–
essary.
Electrode distance (plug gap) of spark
plug too wide
–Adjust the plug gap.
Guideline
Spark plug electrode gap
0.7 mm (0.028 in)
Ignition system defective –Check the ignition system. x
Kill switch cable in wiring harness
frayed, kill switch faulty
–Check the wiring harness. (visual check)
–Check the electrical system.
Plug connector of CDI control device,
pulse generator or ignition coil oxi-
dized.
–Clean the plug connector and treat it with con-
tact spray.
Water in carburetor or jets clogged –Check/adjust the carburetor components. x
Engine has no idle Idling jet clogged –Check/adjust the carburetor components. x
Adjusting screws on carburetor dis-
torted
–Carburetor - adjust the idle speed. x
( p. 65)
Spark plug defective Change spark plug.–
Ignition system defective –Check the ignition system. x
Engine does not speed up Carburetor running over because float
needle dirty or worn
–Check/adjust the carburetor components. x
Loose carburetor jets –Check/adjust the carburetor components. x
Ignition system defective –Check the ignition system. x
Engine has a lack of power Fuel feed interrupted Check the fuel tank breather.–
–Clean the fuel tap.
–Check/adjust the carburetor components. x
Air filter heavily contaminated –Clean the air filter and air filter box. x
( p. 37)
Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer
–Check exhaust system for damage.
–Change the glass fiber yarn filling of the main
silencer. ( p. 38)x
Valve clearance too little –Set the valve clearance. x
Ignition system defective –Check the ignition system. x
TROUBLESHOOTING 76
Faults Possible cause Action
Engine stalls or pops back into the
carburetor
Lack of fuel Turn the handle of the fuel tap to the– ON
position. (Figure 500178-10 p. 12)
– Refuel. ( p. 18)
The intake system has an air leak Check rubber sleeves and carburetor for tight-–
ness.
Engine overheats Too little coolant in cooling system Check the cooling system for leakage.–
– Check the coolant level. ( p. 62)
Insufficient airflow Switch off engine when stationary.–
Radiator fins very dirty Clean radiator fins.–
Foam formation in cooling system – Drain the coolant. ( p. 63)x
–Refill the coolant. ( p. 63)x
Bent radiator hose – Change the radiator hose. x
High oil consumption Engine vent hose bent Route the vent hose without bends or replace it–
if necessary.
Engine oil level too high Check the engine oil level. ( p. 70)–
Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean the–
oil screen. ( p. 70)x
Piston and cylinder worn Piston/cylinder - determine the mounting clear-–
ance x
Battery discharged Battery is not charged by alternator – Check the charging voltage. x
–Check the stator winding of the alternator. x
Unwanted power consumer – Check the closed current. x
TECHNICAL DATA - ENGINE 77
Design 1-cylinder 4-stroke engine, water-cooled
Displacement 449.3 cm³ (27.418 cu in)
Stroke 60.8 mm (2.394 in)
Bore 97 mm (3.82 in)
Compression ratio 12.5:1
Idle speed 1,550… 1,650 rpm
Control DOHC, four valves controlled via cam lever, drive via helical gear
pair and tooth-wheel chain
Valve diameter, intake 40.4 mm (1.591 in)
Valve diameter, exhaust 31.7 mm (1.248 in)
Valve clearance, cold, intake 0.07… 0.13 mm (0.0028… 0.0051 in)
Valve clearance, cold, exhaust 0.12… 0.18 mm (0.0047… 0.0071 in)
Crankshaft bearing 2 cylinder roller bearing
Conrod bearing Needle bearing
Piston pin bearing Bronze bush
Pistons Forged light alloy
Piston rings 1 compression ring, 1 oil scraper ring
Engine lubrication Pressure circulation lubrication with 3 rotor pumps
Primary transmission 29:74
Clutch Antihopping clutch in oil bath/hydraulically activatedAPTC™
Transmission 5-gear, claw shifted
Transmission ratio
1st gear 18:31
2nd gear 20:29
3rd gear 22:27
4th gear 24:25
5th gear 26:23
Alternator 12 V, 42 W
Ignition Contactless controlled fully electronic ignition with digital igni-
tion adjustment
Spark plug NGK CR 9 EKB
Spark plug electrode gap 0.7 mm (0.028 in)
Cooling Water cooling, permanent circulation of coolant by water pump
Starting aid Electric starter
20.1
20.1
20.1
20.120.1Capacity - engine oil
Engine oil 1.35 l (1.43 qt.) Engine oil (SAE 10W/50) ( p. 86)
20.2
20.2
20.2
20.220.2Capacity - coolant
Coolant 1.2 l (1.3 qt.) Coolant ( p. 86)
Coolant (mixed ready to use) ( p. 86)
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 78
Jet, engine case breather M4 On block Loctite®243™
Oil jet, cam lever lubrication M4 6 Nm (4.4 lbf ft) Loctite®243™
Oil jet, piston cooling M4 4 Nm (3 lbf ft) Loctite®243™
Locking screw for bearing M5 6 Nm (4.4 lbf ft) Loctite®243™
Oil jet, clutch oil supply M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, bearing bolt of oil pump idler
shaft
M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, camshaft bearing retaining
bracket
M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, clutch spring M5 6 Nm (4.4 lbf ft) –
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, ignition pulse generator adapter M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, locking lever M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, stator bracket M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, stator cable holder M5 6 Nm (4.4 lbf ft) Loctite®243™
Screw, timing train axle retaining
bracket
M5 6 Nm (4.4 lbf ft) Loctite®243™
Nut, cylinder head M6 10 Nm (7.4 lbf ft) Lubricated with engine oil
Nut, water-pump wheel M6 6 Nm (4.4 lbf ft) Loctite®243™
Oil jet, timing chain tensioner M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, alternator cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft) –
Screw, engine case M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, ignition pulse generator cable
holder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, oil pump casing M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift drum locating M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, shift lever M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, starter motor M6 10 Nm (7.4 lbf ft) –
Screw, valve cover M6 8 Nm (5.9 lbf ft) –
Screw, water pump cover M6 10 Nm (7.4 lbf ft) –
Stud, cylinder head M6 10 Nm (7.4 lbf ft) –
Screw, camshaft bearing bridge M7x1 14 Nm (10.3 lbf ft) Lubricated with engine oil
Screw, clutch cover M7x1 14 Nm (10.3 lbf ft) –
Screw, engine case M7x1 14 Nm (10.3 lbf ft) –
Plug, crankshaft location M8 20 Nm (14.8 lbf ft) –
Screw, engine sprocket M10 60 Nm (44.3 lbf ft) Loctite®2701
Spark plug M10 10… 12 Nm (7.4…
8.9 lbf ft)
–
Plug, cam lever axle M10x1 10 Nm (7.4 lbf ft) –
Plug, oil channel M10x1 10 Nm (7.4 lbf ft) –
Screw, camshaft gear M10x1 50 Nm (36.9 lbf ft) Lubricated with engine oil
Screw, rotor M10x1 80 Nm (59 lbf ft) Lubricated with engine oil
Screw, unlocking of timing chain ten-
sioner
M10x1 10 Nm (7.4 lbf ft) –
TECHNICAL DATA - ENGINE TIGHTENING TORQUES 79
Nut, cylinder head M10x1.25 Tightening sequence:
Tighten in diagonal
sequence.
Tightening stage 1
10 Nm (7.4 lbf ft)
Tightening stage 2
30 Nm (22.1 lbf ft)
Tightening stage 3
50°
Lubricated with engine oil
Stud, cylinder head M10x1.25 20 Nm (14.8 lbf ft) –
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Screw-in fitting, clutch cover M12x1.5 20 Nm (14.8 lbf ft) Loctite®243™
Axle guide rail for timing chain M14x1 15 Nm (11.1 lbf ft) –
Axle tension rail for timing chain M14x1 15 Nm (11.1 lbf ft) –
Nut, compensating sprocket M14x1 20 Nm (14.8 lbf ft) Loctite®243™
Oil suction pipe M14x1 15 Nm (11.1 lbf ft) Loctite®243™
Oil pressure regulator valve plug M14x1.5 18 Nm (13.3 lbf ft) –
Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft) Loctite®243™
Plug, timing chain tensioner M24x1.5 25 Nm (18.4 lbf ft) –
Screw, alternator cover M24x1.5 8 Nm (5.9 lbf ft) –
Nut, freewheel hub M27x1 80 Nm (59 lbf ft) Loctite®243™
Nut, primary gear M27x1 80 Nm (59 lbf ft) Loctite®243™
Plug, oil screen M32x1.5 30 Nm (22.1 lbf ft) Lubricated with engine oil
TECHNICAL DATA - CARBURETOR 80
Carburetor type KEIHIN FCR-MX 41
Carburetor identification number 4125M
Needle position 6th position from top
Idle mixture adjusting screw
Open 1.5 turns
Pump membrane stop 2.15 mm (0.0846 in)
Hot start button
Diameter of bore in carburetor body 2.5 mm (0.098 in)
Main jet 185
Jet needle OBDTQ
Idling jet 42
Idle air jet 100
Cold start jet 85
TECHNICAL DATA - CHASSIS 81
Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Suspension Up Side Down 4860 MXMA CC
Suspension travel
Front 280 mm (11.02 in)
Rear 310 mm (12.2 in)
Fork offset
Front marking 14 mm (0.55 in)
Rear marking 16 mm (0.63 in)
Shock absorber WP Suspension 5018 BAVP DCC
Brake system
Front Single disc brake with radially screwed four-piston fixed caliper,
floating brake disc
Rear Single disc brake with single-piston floating caliper, fixed brake
disc
Brake discs - diameter
Front 310 mm (12.2 in)
Rear 220 mm (8.66 in)
Brake discs - wear limit
Front 4.5 mm (0.177 in)
Rear 3.5 mm (0.138 in)
Tire air pressure off road
Front 1.6 bar (23 psi)
Rear 1.6 bar (23 psi)
Final drive 14:48
Chain 5/8 x 1/4"
Rear sprockets available 38, 40, 42, 45, 48, 49, 50, 51, 52
Steering head angle 63.5°
Wheelbase 1,495±10 mm (58.86±0.39 in)
Seat height unloaded 927 mm (36.5 in)
Ground clearance unloaded 310 mm (12.2 in)
Weight without fuel, approx. 111.5 kg (245.8 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
Maximum permissible overall weight 335 kg (739 lb.)
3Ah battery YTX4L-BS Battery voltage: 12 V
Nominal capacity: 3 Ah
Maintenance-free
Battery YTX5L-BS Battery voltage: 12 V
Nominal capacity: 4 Ah
Maintenance-free
Fuse 58011109110 10 A
23.1
23.1
23.1
23.123.1Tires
Front tire Rear tire
125/80 R 420 TL
Dunlop KR106
170/55 R 17 TL
Dunlop KR108
Additional information is available in the Service section under:
http://www.ktm.com
TECHNICAL DATA - CHASSIS 82
23.2
23.2
23.2
23.223.2Capacity - fuel
Total fuel tank capacity,
approx.
7.5 l (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 87)
TECHNICAL DATA - FORK 83
Fork part number 14.18.7L.08
Fork WP Suspension Up Side Down 4860 MXMA CC
Compression damping
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Rebound damping
Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks
Spring length with preload spacer(s) 484 mm (19.06 in)
Spring rate
Weight of rider: 75… 85 kg (165… 187 lb.) 4.6 N/mm (26.3 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 4.8 N/mm (27.4 lb/in)
Gas pressure 1.2 bar (17 psi)
Fork length 920 mm (36.22 in)
24.1
24.1
24.1
24.124.1Capacity - fork oil
Oil capacity per cartridge 195 ml (6.59 fl. oz.) Fork oil (SAE 5) ( p. 86)
Oil capacity fork leg without
cartridge
400 ml (13.52 fl. oz.) Fork oil (SAE 5) ( p. 86)
TECHNICAL DATA - SHOCK ABSORBER 84
Shock absorber part number 18.18.7L.08
Shock absorber WP Suspension 5018 BAVP DCC
Compression damping, low-speed
Comfort 21 clicks
Standard 18 clicks
Compression damping, high-speed
Comfort 2 turns
Standard 1.5 turns
Rebound damping
Comfort 14 clicks
Standard 12 clicks
Spring preload 19 mm (0.75 in)
Spring rate
Weight of rider: 65… 75 kg (143… 165 lb.) 54 N/mm (308 lb/in)
Weight of rider: 75… 85 kg (165… 187 lb.) 57 N/mm (325 lb/in)
Weight of rider: 85… 95 kg (187… 209 lb.) 60 N/mm (343 lb/in)
Spring length 260 mm (10.24 in)
Gas pressure 10 bar (145 psi)
Static sag 20 mm (0.79 in)
Riding sag 75 mm (2.95 in)
Fitted length 483 mm (19.02 in)
Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 87)
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 85
Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Screw, battery terminal M5 2.5 Nm (1.84 lbf ft) –
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft) –
Spoke nipple, rear wheel M5 5… 6 Nm (3.7… 4.4 lbf ft) –
Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint of push rod on foot
brake cylinder
M6 10 Nm (7.4 lbf ft) Loctite®243™
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft) Loctite®243™
Screw, front brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Screw, rear brake disc M6 14 Nm (10.3 lbf ft) Loctite®243™
Nut, foot brake lever stop M8 20 Nm (14.8 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft) Loctite®2701
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 25 Nm (18.4 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) –
Screw, chain sliding piece M8 15 Nm (11.1 lbf ft) –
Screw, engine brace M8 33 Nm (24.3 lbf ft) –
Screw, fork stub M8 15 Nm (11.1 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®2701
Screw, top steering stem M8 17 Nm (12.5 lbf ft) Loctite®243™
Screw, top triple clamp M8 17 Nm (12.5 lbf ft) –
Engine attachment bolt M10 60 Nm (44.3 lbf ft) –
Remaining nuts, chassis M10 45 Nm (33.2 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701
Screw, handlebar support M10 40 Nm (29.5 lbf ft) Loctite®243™
Screw, top shock absorber M10 60 Nm (44.3 lbf ft) Loctite®2701
Screw, front brake caliper M10x1.25 45 Nm (33.2 lbf ft) Loctite®243™
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, frame on linkage lever M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever on swingarm M14x1.5 80 Nm (59 lbf ft) –
Nut, linkage lever to angle lever M14x1.5 80 Nm (59 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel spindle M20x1.5 80 Nm (59 lbf ft) –
Screw, bottom steering head M20x1.5 60 Nm (44.3 lbf ft) Loctite®243™
Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft) Loctite®243™
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –
SUBSTANCES 86
Brake fluid DOT 4 / DOT 5.1
According to
–DOT
Guideline
–Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends andCastrol Motorex®products.
Supplier
Castrol
–RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
–Brake Fluid DOT 5.1
Coolant
Guideline
–Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-
ing. KTM recommends Motorex®products.
Mixture ratio
Antifreeze protection: 25… 45 °C ( 13…− − −
−49 °F)
50 % corrosion inhibitor/antifreeze
50 % distilled water
Coolant (mixed ready to use)
Antifreeze 40 °C ( 40 °F)− −
Supplier
Motorex®
–Anti Freeze
Engine oil (SAE 10W/50)
According to
–JASO T903 MA ( p. 90)
–SAE ( p. 90) (SAE 10W/50)
Guideline
–Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex®products.
Synthetic engine oil
Supplier
Motorex®
–Cross Power 4T
Fork oil (SAE 5)
According to
–SAE ( p. 90) (SAE 5)
Guideline
–Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex®products.
Supplier
Motorex®
–Racing Fork Oil
Hydraulic fluid (15)
According to
–ISO VG (15)
Guideline
–Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Motorex®products.
Supplier
Motorex®
–Hydraulic Fluid 75
SUBSTANCES 87
Shock absorber oil (SAE 2.5) (50180342S1)
According to
–SAE ( p. 90) (SAE 2.5)
Guideline
–Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.
Super unleaded (ROZ 95/RON 95/PON 91)
According to
–DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
–Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).not
Product specificaties
| Merk: | KTM |
| Categorie: | Motor |
| Model: | 450 SMR (2012) |
Heb je hulp nodig?
Als je hulp nodig hebt met KTM 450 SMR (2012) stel dan hieronder een vraag en andere gebruikers zullen je antwoorden
Handleiding Motor KTM
28 Januari 2023
28 Januari 2023
7 Juli 2023
28 Januari 2023
19 Juni 2023
16 Juni 2023
16 Juni 2023
12 Juni 2023
10 Juni 2023
4 Juni 2023
Handleiding Motor
- Motor Yamaha
- Motor Aprilia
- Motor Benelli
- Motor BMW
- Motor BodyCraft
- Motor Danfoss
- Motor Derbi
- Motor Ducati
- Motor Elac
- Motor Emco
- Motor Harley Davidson
- Motor Honda
- Motor Husqvarna
- Motor Kawasaki
- Motor Kettler
- Motor Mercedes-Benz
- Motor Metabo
- Motor Milwaukee
- Motor Mitsubishi
- Motor Moto Guzzi
- Motor MV Agusta
- Motor Nautilus
- Motor Piaggio
- Motor Reebok
- Motor SMC
- Motor Suzuki
- Motor Texas
- Motor Victory
- Motor Zero
- Motor Joy-it
- Motor Juki
- Motor Mahindra
- Motor Beta
- Motor Triumph
- Motor Hyosung
- Motor TVS
- Motor GasGas
- Motor Indian
- Motor Bajaj
- Motor Mash
- Motor Hero
- Motor Cagiva
- Motor Chang Jiang
- Motor Ridley
- Motor Sherco
- Motor Royal Enfield
- Motor Anova
- Motor CRRCpro
Nieuwste handleidingen voor Motor
2 Februari 2025
8 Januari 2025
8 Januari 2025
27 December 2024
14 December 2024
14 December 2024
14 December 2024
3 December 2024
26 November 2024
16 November 2024