KTM 450 SX-F 2012 Owner's manual

OWNER'S MANUAL 2012

450 SX‑F EU

450 SX‑F USA

Art. no. 3211717en

DEAR KTM CUSTOMER 1

DEARKTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.

We wish you 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 specifica­tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain 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 2

TABLEOF CONTENTS

MEANS OF REPRESENTATION ............................................ 4

IMPORTANT INFORMATION ................................................ 5

VIEW OF VEHICLE............................................................... 7

View of the vehicle from the left front (example) ................. 7

View of the vehicle from the right rear (example) ................ 8

SERIAL NUMBERS.............................................................. 9

Chassis number............................................................... 9

Type label....................................................................... 9

Engine number................................................................ 9

Fork part number............................................................. 9

Shock absorber part number ............................................. 9

CONTROLS....................................................................... 10

Clutch lever .................................................................. 10

Hot start lever ............................................................... 10

Hand brake lever ........................................................... 10

Throttle grip.................................................................. 10

Short circuit button ....................................................... 10

Electric starter button .................................................... 11

Opening filler cap.......................................................... 11

Closing filler cap ........................................................... 11

Factory Start (450 SX‑F USA) ......................................... 12

Fuel tap........................................................................ 12

Choke........................................................................... 12

Shift lever..................................................................... 13

Foot brake lever............................................................. 13

Plug-in stand ................................................................ 13

PREPARING FOR USE ....................................................... 14

Advice on first use ......................................................... 14

Running-in the engine ................................................... 15

Preparing vehicle for arduous riding conditions................. 15

Preparing for rides on dry sand ....................................... 15

Preparing for rides on wet sand....................................... 16

Preparing for rides on wet and muddy surfaces................. 16

Preparing for rides at high temperatures and low speeds ... 17

Preparing for rides at low temperatures or in snow ............ 17

RIDING INSTRUCTIONS .................................................... 18

Checks and maintenance before putting into operation...... 18

Starting ........................................................................ 18

Starting up ................................................................... 19

Shifting, riding.............................................................. 19

Braking ........................................................................ 19

Stopping, parking .......................................................... 20

Refueling...................................................................... 20

SERVICE SCHEDULE......................................................... 21

Service schedule ........................................................... 21

Service work (as additional order).................................... 22

TUNING THE CHASSIS...................................................... 23

Checking the basic suspension setting against the rider's

weight .......................................................................... 23

Compression damping of shock absorber.......................... 23

Adjusting the low-speed compression damping of the

shock absorber .............................................................. 23

Adjusting the high-speed compression damping of the

shock absorber .............................................................. 24

Adjusting the rebound damping of the shock absorber....... 24

Measuring rear wheel sag unloaded ................................. 25

Checking the static sag of the shock absorber .................. 25

Checking the riding sag of the shock absorber .................. 26

Adjusting the spring preload of the shock absorber x ...... 26

Adjusting the riding sag x............................................. 27

Checking basic setting of fork ......................................... 27

Adjusting the compression damping of the fork ................ 27

Adjusting the rebound damping of the fork....................... 28

Handlebar position ........................................................ 28

Adjusting handlebar position x...................................... 29

Activating the Factory Start (450 SX‑F USA) .................... 29

SERVICE WORK ON THE CHASSIS ..................................... 30

Raising the motorcycle with the lift stand ........................ 30

Removing the motorcycle from the lift stand .................... 30

Bleeding fork legs.......................................................... 30

Cleaning the dust boots of the fork legs ........................... 30

Loosening the fork protector ........................................... 31

Positioning the fork protection ........................................ 31

Removing the fork legs x.............................................. 31

Installing the fork legs x............................................... 32

Removing the fork protector x....................................... 32

Installing the fork protector x ....................................... 32

Removing the lower triple clamp x ................................ 33

Installing the lower triple clamp x................................. 33

Checking the steering head bearing play .......................... 35

Adjusting play of steering head bearing x....................... 35

Greasing the steering head bearing x............................. 35

Dismount the start number plate..................................... 36

Installing the start number plate ..................................... 36

Removing the front fender .............................................. 36

Installing the front fender............................................... 36

Removing the shock absorber x..................................... 36

Installing the shock absorber x ..................................... 37

Removing the seat ......................................................... 38

Mounting the seat ......................................................... 38

Removing the air filter box lid......................................... 38

Installing the air filter box lid.......................................... 38

Removing the air filter x............................................... 38

Installing the air filter x ............................................... 39

Cleaning the air filter and air filter box x........................ 39

Removing main silencer ................................................. 40

Installing the main silencer ............................................ 40

Changing the glass fiber yarn filling of the main

silencer x ................................................................... 40

Removing the fuel tank x ............................................. 41

Installing the fuel tank x .............................................. 41

Checking for chain dirt accumulation .............................. 42

Cleaning the chain......................................................... 42

Checking the chain tension ............................................ 43

Adjusting the chain tension ............................................ 43

Checking the chain, rear sprocket, engine sprocket and

chain guide................................................................... 44

Adjusting the chain guide x.......................................... 46

Checking the frame x................................................... 46

Checking the swingarm x ............................................. 46

Checking the throttle cable routing.................................. 46

Checking the rubber grip ................................................ 47

Additionally securing the rubber grip ............................... 47

Adjusting the basic position of the clutch lever................. 47

Checking the fluid level of hydraulic clutch...................... 47

Changing the hydraulic clutch fluid x ............................ 48

BRAKES........................................................................... 49

Checking free travel on hand brake lever.......................... 49

Adjusting the basic position of the hand brake lever.......... 49

Checking the brake discs................................................ 49

Checking the brake fluid level of the front brake ............... 50

Adding front brake fluid x ............................................ 50

Checking the front brake linings...................................... 51

TABLE OF CONTENTS 3

Changing the front brake linings x................................. 51

Checking the free travel of the foot brake lever ................. 53

Adjusting the basic position of the foot brake lever x ...... 53

Checking rear brake fluid level ........................................ 54

Adding brake fluid to the rear brake circuit x ................. 54

Checking rear brake linings ............................................ 55

Changing the rear brake linings x.................................. 55

WHEELS, TIRES ............................................................... 57

Removing front wheel x................................................ 57

Installing the front wheel x........................................... 57

Removing the rear wheel x ........................................... 58

Installing the rear wheel x ............................................ 58

Checking the tire condition............................................. 59

Checking tire air pressure ............................................... 60

Checking spoke tension.................................................. 60

ELECTRICAL SYSTEM ....................................................... 61

Removing the battery x ................................................ 61

Installing the battery x................................................. 61

Recharging the battery x .............................................. 61

Removing the main fuse................................................. 62

Installing the main fuse ................................................. 63

COOLING SYSTEM ............................................................ 64

Cooling system .............................................................. 64

Checking the anti-freeze and coolant level ....................... 64

Checking the coolant level.............................................. 64

Draining the coolant x.................................................. 65

Refilling coolant x ....................................................... 65

TUNING THE ENGINE ....................................................... 67

Checking the play in the throttle cable............................. 67

Adjusting the play in the throttle cable x ....................... 67

Carburetor - idle ............................................................ 67

Carburetor - adjusting idle x ......................................... 68

Emptying the carburetor float chamber x ....................... 68

Ignition curve plug connection ........................................ 69

Changing the ignition curve ............................................ 69

Checking the basic position of the shift lever.................... 69

Adjusting the basic position of the shift lever x .............. 70

SERVICE WORK ON THE ENGINE ...................................... 71

Checking engine oil level................................................ 71

Changing the engine oil and oil filter, cleaning the oil

screen x ..................................................................... 71

Adding engine oil .......................................................... 73

CLEANING, CARE ............................................................. 74

Cleaning motorcycle ...................................................... 74

STORAGE ......................................................................... 75

Storage......................................................................... 75

Preparing for use after storage ........................................ 75

TROUBLESHOOTING......................................................... 76

TECHNICAL DATA - ENGINE .............................................. 78

Capacity - engine oil ...................................................... 78

Capacity - coolant.......................................................... 78

TECHNICAL DATA - ENGINE TIGHTENING TORQUES .......... 79

TECHNICAL DATA - CARBURETOR..................................... 81

TECHNICAL DATA - CHASSIS ............................................ 82

Tires ............................................................................ 82

Capacity - fuel............................................................... 83

TECHNICAL DATA - FORK.................................................. 84

450 SX‑F EU ................................................................ 84

450 SX‑F USA .............................................................. 84

TECHNICAL DATA - SHOCK ABSORBER ............................. 85

450 SX‑F EU ................................................................ 85

450 SX‑F USA .............................................................. 85

TECHNICAL DATA - TIGHTENING TORQUES FOR

CHASSIS .......................................................................... 87

SUBSTANCES................................................................... 88

AUXILIARY SUBSTANCES.................................................. 90

STANDARDS..................................................................... 92

INDEX .............................................................................. 93

MEANS OF REPRESENTATION 4

Symbols used

The symbols used are explained in the following.

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 done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.

Identifies a page reference (more information is provided on the specified page).

Formats used

The typographical and other formats used are explained below.

Proprietary name Denotes a proprietary name.

®

Name

Brand™ Denotes a brand available on the open market.

Denotes a protected name.

IMPORTANT INFORMATION 5

Use definition

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com­ply 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 KTM dealer.net; otherwise, all warranty claims will be void. No warranty claim can be honored for damage
resulting from manipulation and/or other changes to the vehicle.

Fuel, oils, etc.

You should use the fuels, oils and greases according to specifications as listed in the owner's manual.

Spare parts, accessories

For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise
you.

You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com

Work rules

Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
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 handle  of the fuel tap to the OFF position. (Figure 800189-10 p. 12)
– 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 prob­lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis­play 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 miss­ing, 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

3.1View of the vehicle from the left front (example)

1 Hand brake lever ( p. 10)
2 Clutch lever ( p. 10)
3 Filler cap
4 Air filter box lid
5 Fuel tap ( p. 12)
6 Choke ( p. 12)
7 Chain guide
8 Shift lever ( p. 13)

800180-10

VIEW OF VEHICLE 8

3.2View of the vehicle from the right rear (example)

1 Short circuit button ( p. 10)
2 Electric starter button ( p. 11)
3 Fork compression adjustment
4 Fork rebound adjustment
5 Level viewer, engine oil
6 Foot brake lever ( p. 13)
7 Level viewer for brake fluid, rear
8 Shock absorber rebound adjustment
9 Shock absorber compression adjustment

800183-10

SERIAL NUMBERS 9

4.1Chassis number

The chassis number  is stamped on the steering head on the right.

B00262-10

4.2Type label

The type label  is fixed to the front of the steering head.

4.3Engine number

4.4Fork part number

B00262-20

The engine number  is stamped on the left side of the engine under the engine
sprocket.

B00425-10

The fork part number  is stamped on the inner side of the fork stub.

4.5Shock absorber part number

B00265-01

The shock absorber part number  is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

B00392-10

CONTROLS 10

5.1Clutch lever

The clutch lever  is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.

B00406-10

5.2Hot start lever

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.

5.3Hand brake lever

5.4Throttle grip

B00406-11

Hand brake lever  is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.

400196-10

The throttle grip  is fitted on the right side of the handlebar.

5.5Short circuit button

B00368-10

Short circuit button  is fitted on the left side of the handlebar.

Possible states

• Short circuit button in basic position – In this position, the ignition circuit is
closed, and the engine can be started.

• Short circuit button pressed – In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.

400197-10

CONTROLS 11

5.6Electric starter button

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.

400198-10

5.7Opening 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, con­tact 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.

– Press release button , turn filler cap counterclockwise and lift it upwards and

remove.

B00277-10

5.8Closing filler cap

– Replace the filler cap and turn clockwise until the release button  locks in place.

Info

Route the fuel tank breather hose  without kinking.

B00278-10

CONTROLS 12

5.9Factory Start (450 SX‑F USA)

The Factory Start  is mounted on the right fork protector.

Possible states

•  Factory Start is deactivated – The fork is in the normal operating mode.

•  Factory Start is activated – The fork is compressed and the front of the motor­cycle is lowered.

By activating the Factory Start, the front of the motorcycle is lowered; this causes the
front wheel to rise up off the ground later during acceleration.
When the fork compresses for the first time, the Factory Start lock button is released
automatically. From this point on, the fork operates as if the Factory Start were deacti­vated or not installed.

800182-10

5.10Fuel tap

5.11Choke

The fuel tap is on the left side of the fuel tank.
Using tap handle  on the fuel tap, you can open or close the supply of fuel to the
carburetor.

Possible states

• Fuel supply closed OFF – No fuel can flow from the tank to the carburetor.

• Fuel supply open ON – Fuel can flow from the tank to the carburetor. The fuel tank
empties completely.

800189-10

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.

B00405-10

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.

CONTROLS 13

5.12Shift lever

Shift lever  is mounted on the left side of the engine.

B00426-11

The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.

B00426-10

5.13Foot brake lever

5.14Plug-in stand

Foot brake lever  is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.

800005-10

The holder for the plug-in stand  is the left side of the wheel spindle.
The plug-in stand is used to park the motorcycle.

Info

Remove the plug-in stand before starting on a trip.

B00283-10

PREPARING FOR USE 14

6.1Advice 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. 47)
– Adjust the basic position of the hand brake lever. ( p. 49)

–

Adjust the basic position of the foot brake lever. x ( p. 53)

– 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 transport luggage.
– 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)

6.2Running-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 service hours ≤ 75 %

– Avoid fully opening the throttle!

6.3Preparing vehicle for arduous riding conditions

Info

Using a motorcycle in difficult conditions can lead to excessive wear of components such as the drive train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

–

Seal the air filter box. x

Tip

Seal the air filter box at the edges against dirt.

–

Clean the air filter and air filter box. x ( p. 39)

Info

Check the air filter approx. every 30 minutes.

– Additionally secure the rubber grip. ( p. 47)
– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated.

» If humidity, corrosion, or damage is found:

– Clean and dry the connector, or change it if necessary.

Arduous riding conditions are:

– Rides on dry sand. ( p. 15)
– Rides on wet sand. ( p. 16)
– Rides on wet and muddy surfaces. ( p. 16)
– Rides at high temperatures and low speeds. ( p. 17)
– Rides at low temperatures or in snow. ( p. 17)

6.4Preparing for rides on dry sand

– Fit a dust protection device on the air filter.

B00435-01

Dust protection device for air filter (77206920000)

Info

See the KTM PowerParts fitting instructions.

PREPARING FOR USE 16

– Fit a sand protection device on the air filter.

Sand protection device for air filter (77206922000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and settings.

B00436-01

600868-01

6.5Preparing for rides on wet sand

B00437-01

Info

Your authorized KTM workshop has the recommended carburetor tuning
settings.

– Clean the chain.

Chain cleaner ( p. 90)

– Fit the steel sprocket.

Tip

Do not grease the chain.

– Clean radiator fins.
– Straighten bent radiator fins carefully.

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (77206921000)

Info

See the KTM PowerParts fitting instructions.

– Adjust the carburetor jetting and settings.

Info

Your authorized KTM workshop has the recommended carburetor tuning
settings.

– Clean the chain.

Chain cleaner ( p. 90)

– Fit the steel sprocket.

– Clean radiator fins.

600868-01

6.6Preparing for rides on wet and muddy surfaces

– Straighten bent radiator fins carefully.

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (77206921000)

– Adjust the carburetor jetting and settings.

B00437-01

Tip

Do not grease the chain.

Info

See the KTM PowerParts fitting instructions.

Info

Your authorized KTM workshop has the recommended carburetor tuning
settings.

PREPARING FOR USE 17

– Fit the steel sprocket.
– Clean the motorcycle. ( p. 74)
– Straighten bent radiator fins carefully.

600868-01

6.7Preparing for rides at high temperatures and low speeds

– Adjust the secondary drive to the road conditions.

Info

The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.

– Clean the chain.

Chain cleaner ( p. 90)

600868-01

– Clean radiator fins.
– Straighten bent radiator fins carefully.
– Check the coolant level. ( p. 64)

6.8Preparing for rides at low temperatures or in snow

– Fit a waterproofing device on the air filter.

Waterproofing device for air filter (77206921000)

– Adjust the carburetor jetting and settings.

B00437-01

Info

See the KTM PowerParts fitting instructions.

Info

Your authorized KTM workshop has the recommended carburetor tuning
settings.

RIDING INSTRUCTIONS 18

7.1Checks and maintenance before putting into operation

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. 71)
– Check the brake fluid level of the front brake. ( p. 50)
– Check the rear brake fluid level. ( p. 54)
– Check the front brake linings. ( p. 51)
– Check the rear brake linings. ( p. 55)
– Check that the brake system is functioning properly.
– Check the coolant level. ( p. 64)
– Check for chain dirt accumulation. ( p. 42)
– Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 44)
– Check the chain tension. ( p. 43)
– Check the tire condition. ( p. 59)
– Check the tire air pressure. ( p. 60)
– Check the spoke tension. ( p. 60)
– Clean the dust boots of the fork legs. ( p. 30)
– Bleed fork legs. ( p. 30)
– 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.

7.2Starting

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 at least 5 seconds before trying again.

Engine has been out of use for more than 1 week

–

Empty the carburetor float chamber. x ( p. 68)

– Turn handle  of the fuel tap to the ON position. (Figure 800189-10 p. 12)

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.

400733-01

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 19

The engine is hot and running

– Push back the hot start lever to the stop with the engine running.

7.3Starting up

– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.

7.4Shifting, 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.

7.5Braking

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 20

AA

7.6Stopping, 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 the Press and hold the short circuit button while the engine is idling until the engine stops.
– Turn handle  of the fuel tap to the OFF position. (Figure 800189-10 p. 12)
– Park the motorcycle on firm ground.

7.7Refueling

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)
– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

400382-10

Total fuel tank
capacity, approx.

– Close the filler cap. ( p. 11)

7.5 l
(1.98 US gal)

Super unleaded (ROZ 95/RON 95/PON

91) ( p. 89)

SERVICE SCHEDULE 21

8.1Service schedule

S1N S10A S20A S30A

Check and charge the battery. x
Change the engine oil and oil filter, clean the oil screen. x ( p. 71)

Check the front brake linings. ( p. 51) • • •
Check the rear brake linings. ( p. 55) • • •
Check the brake discs. ( p. 49) • • •
Check the brake lines for damage and leakage. • • •
Check the rear brake fluid level. ( p. 54) • • •
Check the free travel of the foot brake lever. ( p. 53) • • •

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. 59) • • • •
Check the tire air pressure. ( p. 60) • • • •

Check the wheel bearing for play. x
Check the wheel hubs. x
Check the rim run-out. x

Check the spoke tension. ( p. 60) • • • •
Check the chain, rear sprocket, engine sprocket and chain guide. ( p. 44) • • •
Check the chain tension. ( p. 43) • • • •

Lubricate all moving parts (e.g., hand lever, chain, ...) and check for smooth operation. x

Check the fluid level of the hydraulic clutch. ( p. 47) • • •
Check the brake fluid level of the front brake. ( p. 50) • • •
Check the free travel on the hand brake lever. ( p. 49) • • •
Check the steering head bearing play. ( p. 35) • • • •

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. 64) • • • •

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. x ( p. 39)
Change the glass fiber yarn filling of the main silencer. x ( p. 40)
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 KTM DEALER.NET and in the service record. x

• • • •

• • • •

• •

• • • •

• • • •

• • • •

• • • •

• • •

• • •

•

• • •

• • •

•

• • •

• • •

• • •

•

• • •

• • •

• • •

S1N: Once after 1 service hour - corresponds to about 7 liters of fuel (1.8 US gal)
S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race
S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal)

SERVICE SCHEDULE 22

8.2Service 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. x ( p. 48)
Grease the steering head bearing. x ( p. 35)

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 service hours - corresponds to about 140 liters of fuel (37 US gal)
S20A: Every 20 service hours - corresponds to about 140 liters of fuel (37 US gal)
S40A: Every 40 service hours - corresponds to about 280 liters of fuel (74 US gal)
S80A: Every 80 service hours - corresponds to about 560 liters of fuel (148 US gal)
J1A: Annually

TUNING THE CHASSIS 23

9.1Checking 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.

– 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.

401030-01

9.2Compression 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.

9.3Adjusting 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.

– Turn adjusting screw  clockwise with a screwdriver up to the last perceptible

click.

B00290-10

Info

Do not loosen nut !

– Turn back counterclockwise by the number of clicks corresponding to the shock

absorber type.

TUNING THE CHASSIS 24

Guideline

Compression damping, low-speed (450 SX‑F EU)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Compression damping, low-speed (450 SX‑F USA)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

9.4Adjusting 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.

– 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 (450 SX‑F EU)

B00289-10

Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns

Compression damping, high-speed (450 SX‑F USA)

Comfort 2.5 turns
Standard 2 turns
Sport 1.5 turns

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

9.5Adjusting 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.)

TUNING THE CHASSIS 25

00AA

00AA

0

0

BB

– 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 (450 SX‑F EU)

Comfort 17 clicks
Standard 15 clicks

B00291-10

9.6Measuring rear wheel sag unloaded

– Raise the motorcycle with the lift stand. ( p. 30)
– Measure the distance – as vertically as possible – between the rear axle and a fixed

– Make note of the value as measurement .
– Remove the motorcycle from the lift stand. ( p. 30)

Sport 13 clicks

Rebound damping (450 SX‑F USA)

Comfort 17 clicks
Standard 15 clicks
Sport 13 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

point, such as a mark on the side cover.

400988-10

9.7Checking the static sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 25)
– Hold the motorcycle upright with the aid of an assistant.
– Measure the distance between the rear axle and the fixed point again.
– Note down the value as dimension .

– Check the static sag.

» If the static sag is less or more than the specified value:

400989-10

Info

The static sag is the difference between measurements  and .

Static sag (450 SX‑F EU) 30 mm (1.18 in)

Static sag (450 SX‑F USA) 34 mm (1.34 in)

–

Adjust the spring preload of the shock absorber. x ( p. 26)

TUNING THE CHASSIS 26

00AA

0

0

CC

9.8Checking the riding sag of the shock absorber

– Measure distance  of rear wheel unloaded. ( p. 25)
– With another person holding the motorcycle, the rider, wearing full protective cloth-

ing, sits on the seat in a normal sitting position (feet on footrests) and bounces up
and down a few times.

The rear wheel suspension levels out.

– Another person now measures the distance between the rear axle and a fixed point.
– Note down the value as dimension .

Info

The riding sag is the difference between measurements  and .

– Check the riding sag.

Riding sag (450 SX‑F EU) 90 mm (3.54 in)

Riding sag (450 SX‑F USA) 100 mm (3.94 in)

» If the riding sag differs from the specified measurement:

–

Adjust the riding sag. x ( p. 27)

400990-10

9.9Adjusting 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. x ( p. 36)

– After removing the shock absorber, clean it thoroughly.
– Loosen screw .
– Turn adjusting ring  until the spring is no longer under tension.

Hook wrench (T106S)

– Measure the overall spring length while the spring is not under tension.
– Tighten the spring by turning adjusting ring  to measurement .

Guideline

Spring preload (450 SX‑F EU) 15 mm (0.59 in)
Spring preload (450 SX‑F USA) 12 mm (0.47 in)

401025-10

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
(450 SX‑F EU)

Screw, shock absorber adjusting ring
(450 SX‑F USA)

–

Install the shock absorber. x ( p. 37)

M5 5 Nm (3.7 lbf ft)

M5 5 Nm (3.7 lbf ft)

TUNING THE CHASSIS 27

9.10Adjusting the riding sag x

–

Remove the shock absorber. x ( p. 36)

– After removing the shock absorber, clean it thoroughly.
– Choose and mount a suitable spring.

Guideline

Spring rate (450 SX‑F EU)

B00292-10

Weight of rider: 65… 75 kg (143…
165 lb.)

Weight of rider: 75… 85 kg (165…
187 lb.)

Weight of rider: 85… 95 kg (187…
209 lb.)

Spring rate (450 SX‑F USA)

Weight of rider: 65… 75 kg (143…
165 lb.)

Weight of rider: 75… 85 kg (165…
187 lb.)

Weight of rider: 85… 95 kg (187…
209 lb.)

54 N/mm (308 lb/in)

57 N/mm (325 lb/in)

60 N/mm (343 lb/in)

54 N/mm (308 lb/in)

57 N/mm (325 lb/in)

60 N/mm (343 lb/in)

Info

The spring rate is shown on the outside of the spring.

–

Install the shock absorber. x ( p. 37)

– Check the static sag of the shock absorber. ( p. 25)
– Check the riding sag of the shock absorber. ( p. 26)
– Adjust the rebound damping of the shock absorber. ( p. 24)

9.11Checking basic setting of fork

Info

For various reasons, no exact riding sag can be determined for the forks.

– 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.

401000-01

9.12Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

– 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.

101275-10

TUNING THE CHASSIS 28

00BB

0

0

AA

Guideline

Compression damping (450 SX‑F EU)

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

Compression damping (450 SX‑F USA)

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

9.13Adjusting the rebound damping of the fork

Info

The hydraulic rebound damping determines the fork suspension behavior.

– Remove protection caps .
– Turn adjusting screws  clockwise all the way.

9.14Handlebar position

B00295-10

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 (450 SX‑F EU)

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

Rebound damping (450 SX‑F USA)

Comfort 14 clicks
Standard 12 clicks
Sport 10 clicks

Info

Turn clockwise to increase damping; turn counterclockwise to reduce damp­ing.

– Mount protection covers .

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.

800116-10

TUNING THE CHASSIS 29

0022

0

0

11

0

0

22

11

9.15Adjusting handlebar position x

– 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 .

B00375-10

Guideline

Screw, handlebar support M10 40 Nm

Info

Position the left and right handlebar supports evenly.

– Position the handlebar.

Info

Make sure cables and wiring are positioned correctly.

Loctite®243™

(29.5 lbf ft)

– Position the handlebar clamp. Fit and evenly tighten the four screws .

Guideline

Screw, handlebar clamp M8 20 Nm

9.16Activating the Factory Start (450 SX‑F USA)

Info

In cold weather, the lock button may freeze up, preventing it from being released during compression.

– Check lock button  to ensure it can move easily.
– Bend over the handlebars while sitting on the motorcycle. Grip the rim and com-

press the fork. Press lock button  and decompress slowly until the lock button
engages in lock ring .

When the fork compresses for the first time, the lock button is released auto­matically.

800181-10

(14.8 lbf ft)

SERVICE WORK ON THE CHASSIS 30

10.1Raising the motorcycle with 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.

– Raise the motorcycle at the frame underneath the engine.

Lift stand (54829055000)

The wheels should no longer touch the ground.

B00393-01

10.2Removing 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.

– Secure the motorcycle against falling over.

– 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.

B00283-10

10.3Bleeding fork legs

101276-10

10.4Cleaning the dust boots of the fork legs

Info

Remove the plug-in stand before starting on a trip.

– Raise the motorcycle with the lift stand. ( p. 30)
– 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. 30)

– Raise the motorcycle with the lift stand. ( p. 30)
– Loosen the fork protector. ( p. 31)
– Push dust boots  of both fork legs downwards.

B00297-10

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. 91)

SERVICE WORK ON THE CHASSIS 31

– Press the dust boots back into their normal position.
– Remove excess oil.
– Position the fork protection. ( p. 31)
– Remove the motorcycle from the lift stand. ( p. 30)

10.5Loosening the fork protector

– Remove screws  and remove the clamp.
– Remove screws  on the left fork leg. Push the fork protector downwards.
– Remove the screws on the right fork leg. Push the fork protector downwards.

B00298-10

10.6Positioning the fork protection

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

10.7Removing the fork legs x

B00298-20

B00300-10

– Position brake line. Put the clamp on, mount and tighten screws .
– Position the fork protection on the right fork leg. Mount and tighten screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–

Remove front wheel. x ( p. 57)

– Remove screws  and take off clamp.
– Remove screws  and take off brake caliper.
– Hang the brake caliper and the brake line loosely to the side.

– Loosen screw . Remove the fork leg on the left.
– Loosen screw . Remove the fork leg on the right.

B00339-10

SERVICE WORK ON THE CHASSIS 32

10.8Installing the fork legs x

– Position the fork legs.

Info

The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws  toward the front.

101276-10

– 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)

B00339-11

– Position the brake caliper. Mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

Loctite®243™

B00300-11

10.9Removing the fork protector x

B00306-10

10.10Installing the fork protector x

– Position the brake line and clamp. Mount and tighten screws .

–

Install the front wheel. x ( p. 57)

–

Remove the fork legs. x ( p. 31)

– Remove screws  on the left fork leg. Remove the fork protector upwards.
– Remove the screws on the right fork leg. Remove the fork protector upwards.

– Position the fork protection on the left fork leg. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B00306-10

– Position the fork protection on the right fork leg. Mount and tighten the screws.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

–

Install the fork legs. x ( p. 32)

SERVICE WORK ON THE CHASSIS 33

0011

0

0

22

0

0

33

10.11Removing the lower triple clamp x

–

Remove the fork legs. x ( p. 31)

– Dismount the start number plate ( p. 36)
– Remove the front fender. ( p. 36)
– Remove the handlebar cushion.
– Remove screw .
– Remove screw .
– Take off the top triple clamp with the handlebar and set it aside.

Info

Protect the motorcycle and its attachments against damage by covering
them.
Do not bend the cables and lines.

B00309-10

– Remove O-ring . Remove protective ring .
– Take out the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

B00310-10

10.12Installing the lower triple clamp x

800115-10

– Clean the bearing and sealing elements, check for damage, and grease.

High viscosity grease ( p. 90)

– 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 .

– Position the upper triple clamp with the steering.
– Mount screw  but do not tighten yet.

B00376-10

SERVICE WORK ON THE CHASSIS 34

– Position the fork legs.

Info

The upper milled groove in the fork leg must be flush with the top edge of
the upper triple clamp.
Position bleeder screws  toward the front.

B00407-10

– Fully tighten screws .

Guideline

Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft)

B00378-10

– Tighten screw .

Guideline

Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

B00380-10

B00380-11

B00378-11

– Mount and tighten screw .

Guideline

Screw, top steering stem M8 17 Nm

(12.5 lbf ft)

– Fully tighten screws .

Guideline

Screw, top triple clamp M8 17 Nm

– Position the brake caliper. Mount and tighten screws .

Guideline

Screw, front brake caliper M8 25 Nm

(18.4 lbf ft)

Loctite®243™

(12.5 lbf ft)

Loctite®243™

B00379-10

– Position the brake line and clamp. Mount and tighten screws .
– Install the front fender. ( p. 36)
– Mount the handlebar cushion.
– Install the start number plate. ( p. 36)
– Check that the wiring harness, cables, and brake and clutch lines can move freely

and are routed correctly.

–

Install the front wheel. x ( p. 57)

SERVICE WORK ON THE CHASSIS 35

– Check the steering head bearing play. ( p. 35)

10.13Checking the 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 dam­aged over time.

– Raise the motorcycle with the lift stand. ( p. 30)
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

–

Adjust play of the steering head bearing x ( p. 35)

– Move the handlebar to and fro over the entire steering range.

400738-11

– Remove the motorcycle from the lift stand. ( p. 30)

10.14Adjusting play of steering head bearing x

– Raise the motorcycle with the lift stand. ( p. 30)
– Loosen screw . Remove screw .
– Loosen and retighten screw .

– Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
– Fully tighten screw .

101277-10

– Mount and tighten screw .

The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.

» If click positions are noticeable:

–

Adjust play of the steering head bearing x ( p. 35)

– Check the steering head bearing and replace if required.

Guideline

Screw, top steering head M20x1.5 12 Nm (8.9 lbf ft)

Guideline

Screw, top triple clamp M8 17 Nm

(12.5 lbf ft)

Guideline

Screw, top steering stem M8 17 Nm

Loctite®243™

(12.5 lbf ft)

10.15Greasing the steering head bearing x

800010-10

– Check the steering head bearing play. ( p. 35)

–

Remove the lower triple clamp. x ( p. 33)

–

Install the lower triple clamp. x ( p. 33)

SERVICE WORK ON THE CHASSIS 36

10.16Dismount the start number plate

– Remove screw  and take off clamp.
– Remove screw . Remove the start number plate.

101278-10

10.17Installing the start number plate

– Position the start number plate. Mount and tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

Info

Ensure that the retaining lugs engage in the fender.

– Position the brake line. Put the clamp on, and mount and tighten screw .

10.18Removing the front fender

10.19Installing the front fender

101278-11

– Remove screws . Remove the front fender.
– Make sure the spacers remain in place.

B00307-10

– 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.

B00307-10

10.20Removing the shock absorber x

B00408-10

– Raise the motorcycle with the lift stand. ( p. 30)
– Remove the main silencer. ( p. 40)
– Remove screw .
– Remove screw cap .

SERVICE WORK ON THE CHASSIS 37

– Press angle lever  toward the rear.
– Press linkage lever  downward.

B00268-10

– Detach springs .

Spring hooks (50305017000)

– Remove screw .

B00409-10

– Remove screw .
– Turn the shock absorber toward the rear and remove the exhaust manifold.
– Remove the shock absorber from the top.

B00270-10

10.21Installing the shock absorber x

B00272-10

B00409-11

– 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

Loctite®2701

(44.3 lbf ft)

– Mount and tighten screw .

Guideline

Remaining screws, chassis M8 25 Nm

(18.4 lbf ft)

– Attach springs .

Spring hooks (50305017000)

– 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)

B00408-11

– Mount and tighten screw .

Guideline

Screw, bottom shock

M10 60 Nm

absorber

– Install the main silencer. ( p. 40)

Loctite®2701

(44.3 lbf ft)

SERVICE WORK ON THE CHASSIS 38

– Remove the motorcycle from the lift stand. ( p. 30)

10.22Removing the seat

– Remove screw .
– Lift up the seat at the rear, pull it back and then remove it from above.

101279-10

10.23Mounting the seat

– Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear

and simultaneously push it forward.

– Make sure that the seat is correctly locked in.
– Mount and tighten the screw of the seat fixing.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

10.24Removing the air filter box lid

10.25Installing the air filter box lid

B00410-01

– Pull off the air filter box lid in area  to the side and remove to the front.

B00411-10

– Insert the air filter box lid into the rear area  and clip it into the front area .

B00411-11

10.26Removing 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.

SERVICE WORK ON THE CHASSIS 39

– Remove the air filter box lid. ( p. 38)
– 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.

B00412-10

10.27Installing the air filter x

– Mount the clean air filter onto the air filter support.
– Apply grease to the section  of the air filter.

Long-life grease ( p. 90)

301262-10

– Put in both parts together, position them and fix them with air filter holder .

Info

If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.

– Install the air filter box lid. ( p. 38)

B00412-10

10.28Cleaning the air filter and air filter box 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.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

–

Remove the air filter. x ( p. 38)

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

B00325-01

Air filter cleaner ( p. 90)

Info

Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high quality filter oil.

Oil for foam air filter ( p. 90)

– Clean the air filter box.
– Check the carburetor connection boot for damage and firm seating.

–

Install the air filter. x ( p. 39)

SERVICE WORK ON THE CHASSIS 40

0033

0

0

44

0022

0

0

11

10.29Removing main silencer

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.

– Disconnect spring .
– Remove screws  and take off main silencer.

101280-10

10.30Installing the main silencer

– Mount the main silencer. Mount and tighten screws .

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

– Reconnect spring .

101280-11

10.31Changing 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. 40)
– 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. 40)

B00420-10

SERVICE WORK ON THE CHASSIS 41

10.32Removing 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, con­tact 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. 38)
– Turn handle  of the fuel tap to the OFF position. (Figure 800189-10 p. 12)
– Pull off the fuel hose.

Info

Remaining fuel may flow out of the fuel hose.

B00415-11

B00316-12

B00414-01

– Remove screws  with the collar sleeve.

– Remove screw  with the rubber bushing.
– Remove the tube from the fuel tank breather.

– Pull both spoilers off of the sides of the radiator bracket and lift off the fuel tank.

10.33Installing 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.

SERVICE WORK ON THE CHASSIS 42

– Check the throttle cable routing. ( p. 46)
– 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.

B00414-01

– Mount the fuel tank vent hose.
– Mount and tighten screw  with the rubber bushing.

Guideline

Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

B00316-11

– 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. 38)

B00315-11

10.34Checking for chain dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 42)

400678-01

10.35Cleaning 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 43

– Clean the chain regularly and then treat with chain spray.

Chain cleaner ( p. 90)
Off-road chain spray ( p. 90)

400725-01

10.36Checking 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 neces­sary.

– Raise the motorcycle with the lift stand. ( p. 30)
– 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 55… 58 mm (2.17… 2.28 in)

B00421-10

» If the chain tension does not meet specifications:

– Adjust the chain tension. ( p. 43)

– Remove the motorcycle from the lift stand. ( p. 30)

10.37Adjusting 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 neces­sary.

– Raise the motorcycle with the lift stand. ( p. 30)
– Check the chain tension. ( p. 43)

SERVICE WORK ON THE CHASSIS 44

1 2 3 16 17 18

00

0

BB

0

0

AA

– Loosen nut .
– Loosen nuts .
– Adjust the chain tension by turning the adjusting screws  left and right.

Guideline

Chain tension 55… 58 mm (2.17… 2.28 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 (1.18 in))
enables different secondary ratios with the same chain length.

B00343-11

– Remove the motorcycle from the lift stand. ( p. 30)

Chain adjusters  can be turned by 180°.

10.38Checking the chain, rear sprocket, engine sprocket and chain guide

– Raise the motorcycle with the lift stand. ( p. 30)
– 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.

400227-01

– 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)

400987-10

» 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 45

– 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

B00346-01

Screw, chain sliding
guard

– 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

M6 6 Nm

(4.4 lbf ft)

Loctite®243™

(11.1 lbf ft)

B00345-01

400984-10

B00347-01

– Measure material thickness  at the bottom of the chain guide.

Minimum distance  at the lowest
point

» If distance  is less than the specified measurement:

–

Change the chain guide. x

– 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

– Remove the motorcycle from the lift stand. ( p. 30)

12 mm (0.47 in)

(7.4 lbf ft)

SERVICE WORK ON THE CHASSIS 46

10.39Adjusting the chain guide x

– Loosen screw . Remove screw . Push the chain guide down.

Condition

Number of teeth: ≤ 44 teeth
– Insert collar sleeve  in hole . Position the chain guide.
– Mount and tighten screw . Tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

Condition

Number of teeth: ≥ 45 teeth
– Insert collar sleeve  in hole . Position the chain guide.
– Mount and tighten screw . Tighten screw .

Guideline

Remaining screws, chassis M6 10 Nm

(7.4 lbf ft)

B00348-10

10.40Checking the frame x

10.41Checking the swingarm x

800188-10

500285-01

– 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.

– 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.

10.42Checking the throttle cable routing

B00416-10

–

Remove the fuel tank. x ( p. 41)

– 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. x ( p. 41)

SERVICE WORK ON THE CHASSIS 47

10.43Checking the rubber grip

– 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.

Rubber grip adhesive (00062030051) ( p. 91)

401197-01

10.44Additionally securing the rubber grip

– Check the rubber grip. ( p. 47)
– 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 rub­ber grip.

401198-01

10.45Adjusting the basic position of the clutch lever

– Adjust the basic setting of the clutch lever to your hand size by turning adjusting

screw .

B00406-12

10.46Checking the fluid level of hydraulic clutch

Info

The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Check the fluid level.

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

400245-10

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. 88)

– Position the cover with the membrane. Mount and tighten the screws.

SERVICE WORK ON THE CHASSIS 48

10.47Changing 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.

– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .

400245-10

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Hydraulic fluid (15) ( p. 88)

– On the slave cylinder, remove bleeder screw  and mount bleeding syringe .

500224-10

400247-10

– 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 49

A

A

11.1Checking 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.

– 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. 49)

400196-11

11.2Adjusting the basic position of the hand brake lever

– Check the free travel on the hand brake lever. ( p. 49)
– Adjust the basic setting of the hand brake lever to your hand size by turning adjust-

ing screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the hand brake lever and the handlebar.

400196-12

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!

11.3Checking 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.)

– 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 2.5 mm (0.098 in)

400257-10

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 50

11.4Checking the brake fluid level of the front brake

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking effect caused by 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.)

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in viewer .

» If the brake fluid is below the MIN mark:

–

Add front brake fluid. x ( p. 50)

400231-10

11.5Adding front brake fluid x

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Skin 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 effect caused by 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.

BRAKES 51

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .
– Add brake fluid to level .

Guideline

Dimension  (brake fluid level below
top edge of container)

Brake fluid DOT 4 / DOT 5.1 ( p. 88)

– Position the cover with the membrane. Mount and tighten the screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

11.6Checking the front brake linings

5 mm (0.2 in)

Warning

Danger of accidents Reduced braking efficiency caused by worn brake linings.

– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings. x ( p. 51)

– Check the brake linings for damage and cracking.

» If damage or cracking is visible:

–

Change the front brake linings. x ( p. 51)

B00350-10

11.7Changing 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 effect caused by 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.

BRAKES 52

0

0

77

0

0

66

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 origi­nal 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.

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with membrane .

B00353-10

B00351-10

100397-01

– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons. Ensure that brake fluid does not overflow from the brake fluid reser­voir, using suction to remove it if it does.

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

– Remove the locking split pins , pull out the pin  and remove the brake linings.
– Clean the brake caliper and brake caliper support.

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

– Insert the brake linings, insert pin , and mount locking split pins .
– Operate the hand brake lever repeatedly until the brake linings are in contact with

the brake disc and there is a pressure point.

B00351-11

BRAKES 53

– Correct the brake fluid quantity to level .

Guideline

Dimension  (brake fluid level below
top edge of container)

Brake fluid DOT 4 / DOT 5.1 ( p. 88)

– Position cover  with membrane .
– Mount and tighten screws .

Info

Clean up overflowed or spilt brake fluid immediately with water.

600706-10

11.8Checking the free travel of the foot brake lever

5 mm (0.2 in)

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.

– Disconnect spring .
– Move the foot brake lever backwards and forwards between the end stop and the

foot brake cylinder piston bracket and check free travel .
Guideline

Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)

» If the free travel does not meet specifications:

–

Adjust the basic position of the foot brake lever. x ( p. 53)

800005-11

11.9Adjusting the basic position of the foot brake lever x

– Reconnect spring .

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.

– 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.

800006-10

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)

BRAKES 54

– Hold screw  and tighten nut .

Guideline

Nut, foot brake lever stop M8 30 Nm

(22.1 lbf ft)

– Hold push rod  and tighten nut .

Guideline

Remaining nuts, chassis M6 10 Nm (7.4 lbf ft)

– Reconnect spring .

11.10Checking rear brake fluid level

Warning

Danger of accidents Failure of the brake system.

– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Danger of accidents Reduced braking effect caused by 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.)

– 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. x ( p. 54)

800187-10

11.11Adding 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 MIN mark, this indicates a leakage in the brake system or worn-out brake linings.

Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.

Warning

Danger of accidents Reduced braking effect caused by 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.

BRAKES 55

– 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. 88)

– Mount the screw cap with the membrane and the O-ring.

Info

B00360-10

11.12Checking 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.)

– Check the brake linings for minimum thickness .

– Check the brake linings for damage and cracking.

B00355-10

Clean up overflowed or spilt brake fluid immediately with water.

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings. x ( p. 55)

» If damage or cracking is visible:

–

Change the rear brake linings. x ( p. 55)

11.13Changing 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 effect caused by 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.

B00356-10

– Stand the vehicle upright.
– Remove screw cap  with membrane  and the O-ring.

BRAKES 56

– Press the brake caliper toward the brake disc to push back the brake piston and

ensure that no brake fluid runs out of the brake fluid reservoir, sucking it off if it
does.

Info

Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.

– Remove locking split pins , withdraw pin , and take out the brake linings.

B00357-10

B00358-10

– Clean the brake caliper and brake caliper support.

– Check that leaf spring  in the brake caliper and sliding plate  in the brake

caliper support are seated correctly.

Info

The arrow on the leaf spring points in the rotation direction of the brake
disc.

– Insert the brake linings, insert pin , and mount locking split pins .

B00359-10

B00360-10

Info

Make sure that the decoupling plate  is mounted on the piston side of the
brake lining.

– Operate the foot brake lever repeatedly until the brake linings are in contact with

the brake disc and there is a pressure point.

– Add brake fluid to level .

Brake fluid DOT 4 / DOT 5.1 ( p. 88)

– Mount and tighten screw cap  with membrane  and the O-ring.

Info

Clean up overflowed or spilt brake fluid immediately with water.

WHEELS, TIRES 57

12.1Removing front wheel x

– Raise the motorcycle with the lift stand. ( p. 30)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake pistons.

Info

Make sure when pushing back the brake pistons that you do not press the
brake caliper against the spokes.

B00301-10

– Remove screw .
– Loosen screw .

B00302-10

– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of

the fork.

Info

Do not operate the hand brake lever when the front wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam­aged.

B00303-10

– Remove spacers .

B00304-10

12.2Installing 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.

B00304-11

– 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. 90)

– Insert the spacers.

WHEELS, TIRES 58

– 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)

– Activate the hand brake lever multiple times until the brake linings are in contact

with the brake disc.

B00302-11

12.3Removing the rear wheel x

– Remove the motorcycle from the lift stand. ( p. 30)
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Fully tighten screw .

Guideline

Screw, fork stub M8 15 Nm

(11.1 lbf ft)

– Raise the motorcycle with the lift stand. ( p. 30)
– Press the brake caliper by hand on to the brake disc in order to press back the

brake piston.

B00340-10

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 dam­aged.

– Remove spacers .

B00341-10

12.4Installing 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.

WHEELS, TIRES 59

– 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. 90)

– Insert the spacers.

B00341-11

– Lift the rear wheel into the swing arm, position it, and insert the wheel spindle .
– Put the chain on.

B00342-10

– 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. 43)
– 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 (1.18 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. 30)

B00343-10

12.5Checking the tire condition

Info

Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be mounted with tires with similar profiles.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

– Check the front and rear tires for cuts, run-in objects and other damage.

» If you find cuts, foreign bodies or other damage on a tire:

– Change the tire.

– Check the depth of the tread.

400602-10

Info

Note local national regulations concerning the minimum tread depth.

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

» If the tread depth is less than the minimum allowable depth:

WHEELS, TIRES 60

– Change the tire.

– Check the tire age.

Info

The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits indi­cate the week of manufacture and the last two digits the year of manufac­ture.
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.

12.6Checking tire air pressure

Info

Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.

– Remove the dust cap.
– Check tire air pressure when tires are cold.

Tire air pressure off road

Front 1.0 bar (15 psi)
Rear 1.0 bar (15 psi)

» If the tire pressure does not meet specifications:

– Correct the tire air pressure.

400695-01

12.7Checking spoke tension

– Fit the dust cap.

Warning

Danger of accidents Instable handling due to incorrect spoke tension.

– Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)

Info

A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.

– Tap each spoke with a screwdriver.

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.

400694-01

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 M4.5 5… 6 Nm (3.7…

4.4 lbf ft)

Torque wrench with various accessories in set (58429094000)

ELECTRICAL SYSTEM 61

13.1Removing 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. 38)
– 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.

B00361-10

13.2Installing the battery x

– Place the battery in the battery holder.

External temperature ≥ 10 °C (≥ 50 °F)
Battery (YTX4L-BS) ( p. 82)
External temperature ≤ 10 °C (≤ 50 °F)
Battery (YTX5L-BS) ( p. 82)

– Reconnect the rubber band .
– Attach the plus cable and replace the plus pole cover .

B00361-11

– Attach the minus cable .
– Mount the seat. ( p. 38)

13.3Recharging 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.

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.

ELECTRICAL SYSTEM 62

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. 38)
– Disconnect the negative cable of the battery to avoid damage to the onboard elec-

tronics.

– 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 over­charge the battery.

13.4Removing the main fuse

400240-10

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

3 months

motorcycle is not in use

– Mount the seat. ( p. 38)

– Switch off all power consumers and switch off the engine.
– Remove the air filter box lid. ( p. 38)
– Pull starter relay  off of the holder.

Info

The main fuse is located in the starter relay under the air filter box lid.

B00362-10

B00363-10

– Remove protective cover .
– Remove main fuse.

ELECTRICAL SYSTEM 63

13.5Installing 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.

– Insert the main fuse.

Fuse (58011109110) ( p. 82)

Info

A reserve fuse  is located in the starter relay.
Replace a faulty fuse  by an equivalent fuse only.

– Replace the protective cover.

B00363-11

– Mount the starter relay on the holder.
– Install the air filter box lid. ( p. 38)

COOLING SYSTEM 64

14.1Cooling system

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 tem­perature will not result in a risk of malfunctions.

120 °C (248 °F)

Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool­ing effect.

B00422-10

14.2Checking 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 immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition

Engine is cold.

– Stand the motorcycle upright on a horizontal surface.
– Remove radiator cap.
– Check the anti-freeze of the coolant.

−25… −45 °C (−13… −49 °F)

» If the anti-freeze of the coolant does not meet specifications:

– Correct the anti-freeze of the coolant.

– Check the coolant level in the radiator.

400243-10

Coolant level  above radiator fins. 10 mm (0.39 in)

» If the level of the coolant does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 88)

Alternative 2

Coolant (mixed ready to use) ( p. 88)

– Refit the radiator cap.

14.3Checking 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 immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

COOLING SYSTEM 65

Condition

The engine is cold.

– Stand the motorcycle upright on a horizontal surface.
– Remove radiator cap.
– Check the coolant level in the radiator.

Coolant level  above the radiator fins. 10 mm (0.39 in)

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

400243-10

– Mount the radiator cap.

14.4Draining 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.

Coolant ( p. 88)

Alternative 2

Coolant (mixed ready to use) ( p. 88)

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 immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

Condition

The engine is cold.

– Stand the motorcycle upright.
– 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)

800184-10

14.5Refilling 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 immedi­ately. Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.

800003-10

– 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. 88)

Coolant (mixed ready to use) ( p. 88)

COOLING SYSTEM 66

– Refit the radiator cap.
– Make a short test ride.
– Check the coolant level. ( p. 64)

TUNING THE ENGINE 67

15.1Checking the play in the throttle cable

– 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. x ( p. 67)

Danger

400192-10

– Start the engine and let it run idle. Move the handlebar to and fro over the entire

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.

steering range.

The idle speed must not change.

» If the idle speed changes:

–

Adjust the play in the throttle cable. x ( p. 67)

15.2Adjusting the play in the throttle cable x

800185-10

15.3Carburetor - idle

–

Remove the fuel tank. x ( p. 41)

– Check the throttle cable routing. ( p. 46)
– 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. x ( p. 41)

– Check the play in the throttle cable. ( p. 67)

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.

400266-10

Info

The carburetor and its components are subject to increased wear caused by
engine vibration. Wear can result in malfunctioning.

The idle speed is adjusted with the adjustment screw .
The idle mixture is adjusted with the idle mixture adjustment screw .

TUNING THE ENGINE 68

15.4Carburetor - adjusting idle x

– Screw in idle adjusting screw  until it stops and then to the prescribed basic set-

ting.
Guideline

Idle mixture adjusting screw

Open 1.5 turns

Adjustment tool for mixture control screw (77329034000)

– Run the engine until warm.

400266-10

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 adjusting screw  slowly clockwise until the idle speed begins to fall.
– Note the position and turn the idle adjusting screw slowly counterclockwise until

the idle speed falls.

– Adjust to the point between these two positions with the highest idle speed.

15.5Emptying the carburetor float chamber x

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 adjusting screw to the end without any change of
engine speed, you have to fit a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.

– Adjust the idle speed with adjusting screw .

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.

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, con­tact 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 69

000AA

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 handle  of the fuel tap to the OFF position. (Figure 800189-10 p. 12)

No more fuel flows from the tank to the carburetor.

– Guide the hose coming down behind the engine into a suitable container.

Info

Water in the float chamber results in malfunctioning.

– Undo screw  (turn it counterclockwise) a few turns and drain the fuel from the

float chamber.

– Tighten screw .

800186-10

15.6Ignition curve plug connection

The plug connection  is located under the seat near the upper shock absorber fixa­tion.

Possible states

• Soft – The plug connection is disconnected to achieve better driveability.

• Performance – The plug connection is connected to achieve better performance.

B00424-10

15.7Changing the ignition curve

Change the ignition curve from Performance to Soft.

– Disconnect plug connection . (Figure B00424-10 p. 69)

Soft – better driveability

Change the ignition curve from Soft to Performance.

– Connect plug connection . (Figure B00424-10 p. 69)

Performance – higher performance

15.8Checking the basic position of the shift lever

– 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

» If the distance does not meet the specifications:

–

Adjust the basic position of the shift lever. x ( p. 70)

400692-10

10… 20 mm (0.39… 0.79 in)

TUNING THE ENGINE 70

15.9Adjusting the basic position of the shift lever x

– Remove screw  and take off shift lever .

B00427-10

– 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 compo­nents during the shift procedure.

B00428-10

– Mount and tighten screw.

Guideline

Screw, shift lever M6 14 Nm

Loctite®243™

(10.3 lbf ft)

SERVICE WORK ON THE ENGINE 71

16.1Checking 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.

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. 73)

Condition

400212-10

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. 73)

16.2Changing 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.
– Place a suitable container under the engine.
– Remove oil drain plug  with the seal ring.

800011-10

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 72

– Mount and tighten oil drain plug  with the seal ring.

Guideline

Oil drain plug with magnet M12x1.5 20 Nm

(14.8 lbf ft)

800011-10

– Remove screws . Remove the oil filter cover with the O-ring.

B00430-10

– Pull oil filter  out of the oil filter housing.

Circlip pliers reverse (51012011000)

B00431-10

B00432-10

– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.

– Lay the motorcycle on its side and fill the oil filter housing to about ⅓ full with

engine oil.

– Fill 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.

– 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. 88)

Info

Too little engine oil or poor-quality engine oil results in premature wear to
the engine.

B00433-11

– 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. 71)

SERVICE WORK ON THE ENGINE 73

16.3Adding engine oil

Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

– Remove the oil filler plug  on the clutch cover and fill up with engine oil.

Engine oil (SAE 10W/50) ( p. 88)

– 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-

400265-10

– Start the engine and check that it is oil-tight.

tion, and do not start or run the engine in an enclosed space without an
effective exhaust extraction system.

CLEANING, CARE 74

17.1Cleaning 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.

– 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. 90)

401061-01

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. x ( p. 68)

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. 42)
– 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. 90)

– 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. 91)

STORAGE 75

18.1Storage

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, con­tact 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.

– Clean the motorcycle. ( p. 74)

–

Change the engine oil and oil filter, clean the oil screen. x ( p. 71)

– Check the anti-freeze and coolant level. ( p. 64)
– Drain the fuel from the tanks into a suitable container.

–

Empty the carburetor float chamber. x ( p. 68)

– Check the tire air pressure. ( p. 60)

–

Remove the battery. x ( p. 61)

–

401058-01

Recharge the battery. x ( p. 61)

Guideline

Storage temperature of battery without
direct sunlight.

0… 35 °C (32… 95 °F)

18.2Preparing for use after storage

– 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. 30)
– 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.

– Remove the motorcycle from the lift stand. ( p. 30)

–

Install the battery. x ( p. 61)

– Refuel. ( p. 20)
– Perform checks and maintenance steps before putting into operation. ( p. 18)
– Take a test ride.

401059-01

TROUBLESHOOTING 76

Faults Possible cause Action

The engine cannot be cranked (elec­tric starter)

Engine turns but does not start Operating error – Carry out the start procedure. ( p. 18)

Engine has no idle Idling jet blocked –

Engine does not speed up Carburetor running over because float

Engine has a lack of power Fuel feed interrupted – Check the fuel tank breather.

Engine stalls or pops back into the
carburetor

Operating error – Carry out the start procedure. ( p. 18)
Battery discharged –

Main fuse blown – Remove the main fuse. ( p. 62)

Low external temperature – Use the battery supplied in the accessory pack-

Starter relay defective –
Starter motor defective –

Motorcycle was out of use for a long
time and there is old fuel in the float
chamber

Fuel feed interrupted – Check the fuel tank breather.

Spark plug oily or wet – Clean and dry the spark plug or replace if nec-

Electrode distance (plug gap) of spark
plug too wide

Ignition system defective –
Short-circuit cable in wiring harness

frayed, short-circuit button defective

Plug connector of CDI control device,
pulse generator or ignition coil oxi­dized.

Water in carburetor or jets blocked –

Adjusting screws on carburetor dis­torted

Spark plug defective – Change spark plug.
Ignition system defective –

needle dirty or worn.
Loose carburetor jets –
Ignition system defective –

Air filter heavily contaminated –

Exhaust system leaky, deformed or
too little glass fiber yarn filling in
main silencer

Valve clearance too little –
Ignition system defective –
Lack of fuel – Turn handle  of the fuel tap to the ON posi-

Recharge the battery. x ( p. 61)

–

Check the charging voltage. x

–

Check the closed current. x

–

Check the stator winding of the alternator. x

– Install the main fuse. ( p. 63)

age.
Battery (YTX5L-BS) ( p. 82)

Check the starter relay. x
Check the starter motor. x

–

Empty the carburetor float chamber. x

( p. 68)

– Clean the fuel tap.

–

Check/adjust the carburetor components. x

essary.

– Adjust the plug gap.

Guideline
Spark plug electrode gap

0.7 mm (0.028 in)

Check the ignition system. x

– Check the wiring harness. (visual check)
– Check the electrical system.
– Clean the plug connector and treat it with con-

tact spray.

Check/adjust the carburetor components. x
Check/adjust the carburetor components. x

–

Carburetor - adjust the idle speed. x

( p. 68)

Check the ignition system. x

–

Check/adjust the carburetor components. x
Check/adjust the carburetor components. x

Check the ignition system. x

– Clean the fuel tap.

–

Check/adjust the carburetor components. x
Clean the air filter and air filter box. x

( p. 39)

– Check exhaust system for damage.
– Change the glass fiber yarn filling of the main

silencer. x ( p. 40)
Set the valve clearance. x
Check the ignition system. x

tion. (Figure 800189-10 p. 12)

– Refuel. ( p. 20)

TROUBLESHOOTING 77

Faults Possible cause Action

Engine stalls or pops back into the
carburetor

Engine overheats Too little coolant in cooling system – Check the cooling system for leakage.

High oil consumption Engine vent hose bent – Route the vent hose without bends or replace it

Battery discharged Battery is not charged by alternator –

The intake system has an air leak – Check rubber sleeves and carburetor for tight-

ness.

– Check the coolant level. ( p. 64)
Insufficient airflow – Switch off engine when stationary.
Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system –

Bent radiator hose –

Engine oil level too high – Check the engine oil level. ( p. 71)
Engine oil too thin (low viscosity) – Change the engine oil and oil filter, clean the

Piston and cylinder worn – Piston/cylinder - determine the mounting clear-

Unwanted power consumer –

Drain the coolant. x ( p. 65)

–

Refill the coolant. x ( p. 65)
Change the radiator hose. x

if necessary.

oil screen. x ( p. 71)
ance x

Check the charging voltage. x

–

Check the stator winding of the alternator. x
Check the closed current. x

TECHNICAL DATA - ENGINE 78

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 Multidisc clutch in oil bath/hydraulically activated
Transmission ratio

1st gear 16:34
2nd gear 19:31
3rd gear 20:26
4th gear 23:25

5th gear 26:24
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

20.1Capacity - engine oil

Engine oil 1.35 l (1.43 qt.) Engine oil (SAE 10W/50) ( p. 88)

20.2Capacity - coolant

Coolant 1.2 l (1.3 qt.) Coolant ( p. 88)

Coolant (mixed ready to use) ( p. 88)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 79

Jet, engine case breather M4 On block

Oil jet, cam lever lubrication M4 6 Nm (4.4 lbf ft)
Oil jet, piston cooling M4 4 Nm (3 lbf ft)
Locking screw for bearing M5 6 Nm (4.4 lbf ft)
Oil jet, clutch oil supply M5 6 Nm (4.4 lbf ft)
Screw, bearing bolt of oil pump idler

shaft
Screw, camshaft bearing retaining

bracket
Screw, clutch spring M5 6 Nm (4.4 lbf ft) –
Screw, ignition pulse generator M5 6 Nm (4.4 lbf ft)
Screw, ignition pulse generator adapter M5 6 Nm (4.4 lbf ft)
Screw, locking lever M5 6 Nm (4.4 lbf ft)
Screw, oil filter cover M5 6 Nm (4.4 lbf ft) –
Screw, oil pump cover M5 6 Nm (4.4 lbf ft)
Screw, stator bracket M5 6 Nm (4.4 lbf ft)
Screw, stator cable holder M5 6 Nm (4.4 lbf ft)
Screw, timing train axle retaining

bracket
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)
Oil jet, timing chain tensioner M6 6 Nm (4.4 lbf ft)
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)
Screw, ignition pulse generator cable

holder
Screw, oil pump casing M6 10 Nm (7.4 lbf ft)
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Screw, shift lever M6 14 Nm (10.3 lbf ft)
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)
Spark plug M10 10… 12 Nm (7.4…

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

M5 6 Nm (4.4 lbf ft)

M5 6 Nm (4.4 lbf ft)

M5 6 Nm (4.4 lbf ft)

M6 10 Nm (7.4 lbf ft)

8.9 lbf ft)

M10x1 10 Nm (7.4 lbf ft) –

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®2701

–

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 80

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°
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 studs for clutch cover M12x1.5 20 Nm (14.8 lbf ft) –
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)
Oil suction pipe M14x1 15 Nm (11.1 lbf ft)
Oil pressure regulator valve plug M14x1.5 18 Nm (13.3 lbf ft) –
Nut, inner clutch hub M18x1.5 80 Nm (59 lbf ft)
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)
Nut, primary gear M27x1 80 Nm (59 lbf ft)
Plug, oil screen M32x1.5 30 Nm (22.1 lbf ft) Lubricated with engine oil

Lubricated with engine oil

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

TECHNICAL DATA - CARBURETOR 81

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 82

Frame Central tube frame made of chrome molybdenum steel tubing
Fork WP Suspension Up Side Down 4860 MXMA CC
Suspension travel

Front 300 mm (11.81 in)
Suspension travel (450 SX‑F EU)

Rear 330 mm (12.99 in)
Suspension travel (450 SX‑F USA)

Rear 317 mm (12.48 in)
Fork offset 22 mm (0.87 in)
Shock absorber WP Suspension 5018 BAVP DCC
Brake system Disc brakes, brake calipers on floating bearings
Brake discs - diameter

Front 260 mm (10.24 in)

Rear 220 mm (8.66 in)
Brake discs - wear limit

Front 2.5 mm (0.098 in)

Rear 3.5 mm (0.138 in)
Tire air pressure off road

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)
Final drive 14:52
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 992 mm (39.06 in)
Ground clearance unloaded 371 mm (14.61 in)
Weight without fuel, approx. (450 SX‑F EU) 107.8 kg (237.7 lb.)
Weight without fuel, approx. (450 SX‑F USA) 108.4 kg (239 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.)

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

23.1Tires

Validity Front tire Rear tire

(450 SX‑F EU) 80/100 - 21 M/C 51M TT

Pirelli SCORPION MX Midsoft 32

(450 SX‑F USA) 80/100 - 21 51M TT

Dunlop GEOMAX MX51F

Additional information is available in the Service section under:
http://www.ktm.com

110/90 - 19 62M TT

Pirelli SCORPION MX Midsoft 32

110/90 - 19 62M TT

Dunlop GEOMAX MX51

TECHNICAL DATA - CHASSIS 83

23.2Capacity - fuel

Total fuel tank capacity,
approx.

7.5 l (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 89)

TECHNICAL DATA - FORK 84

24.1450 SX‑F EU

Fork part number 14.18.7L.09
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) 494 mm (19.45 in)
Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 4.6 N/mm (26.3 lb/in)

Weight of rider: 75… 85 kg (165… 187 lb.) 4.8 N/mm (27.4 lb/in)

Weight of rider: 85… 95 kg (187… 209 lb.) 5.0 N/mm (28.6 lb/in)
Gas pressure 1.2 bar (17 psi)
Fork length 940 mm (37.01 in)

Oil capacity per cartridge 195 ml (6.59 fl. oz.) Fork oil (SAE 5) ( p. 88)
Oil capacity fork leg without

390 ml (13.19 fl. oz.) Fork oil (SAE 5) ( p. 88)

cartridge

24.2450 SX‑F USA

Fork part number 14.18.7L.59
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) 494 mm (19.45 in)
Spring rate

Weight of rider: 65… 75 kg (143… 165 lb.) 4.8 N/mm (27.4 lb/in)

Weight of rider: 75… 85 kg (165… 187 lb.) 5.0 N/mm (28.6 lb/in)

Weight of rider: 85… 95 kg (187… 209 lb.) 5.2 N/mm (29.7 lb/in)
Gas pressure 1.2 bar (17 psi)
Fork length 940 mm (37.01 in)

Oil capacity per cartridge 195 ml (6.59 fl. oz.) Fork oil (SAE 5) ( p. 88)
Oil capacity fork leg without

375 ml (12.68 fl. oz.) Fork oil (SAE 5) ( p. 88)

cartridge

TECHNICAL DATA - SHOCK ABSORBER 85

25.1450 SX‑F EU

Shock absorber part number 18.18.7L.09
Shock absorber WP Suspension 5018 BAVP DCC
Compression damping, low-speed

Comfort 17 clicks

Standard 15 clicks

Sport 13 clicks
Compression damping, high-speed

Comfort 2.5 turns

Standard 2 turns

Sport 1.5 turns
Rebound damping

Comfort 17 clicks

Standard 15 clicks

Sport 13 clicks
Spring preload 15 mm (0.59 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 30 mm (1.18 in)
Riding sag 90 mm (3.54 in)
Fitted length 490 mm (19.29 in)

Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 89)

25.2450 SX‑F USA

Shock absorber part number 18.18.7L.57
Shock absorber WP Suspension 5018 BAVP DCC
Compression damping, low-speed

Comfort 17 clicks

Standard 15 clicks

Sport 13 clicks
Compression damping, high-speed

Comfort 2.5 turns

Standard 2 turns

Sport 1.5 turns
Rebound damping

Comfort 17 clicks

Standard 15 clicks

Sport 13 clicks
Spring preload 12 mm (0.47 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 34 mm (1.34 in)
Riding sag 100 mm (3.94 in)

TECHNICAL DATA - SHOCK ABSORBER 86

Fitted length 486 mm (19.13 in)

Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 89)

TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS 87

Spoke nipple, front wheel M4.5 5… 6 Nm (3.7… 4.4 lbf ft) –
Spoke nipple, rear wheel M4.5 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
Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)
Screw, front brake disc M6 14 Nm (10.3 lbf ft)
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Nut, foot brake lever stop M8 30 Nm (22.1 lbf ft) –
Nut, rear sprocket screw M8 35 Nm (25.8 lbf ft)
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, front brake caliper M8 25 Nm (18.4 lbf ft)
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, subframe M8 35 Nm (25.8 lbf ft)
Screw, top steering stem M8 17 Nm (12.5 lbf ft)
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)
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Screw, top shock absorber M10 60 Nm (44.3 lbf ft)
Nut, seat fixing M12x1 20 Nm (14.8 lbf ft) –
Nut, frame to 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, top steering head M20x1.5 12 Nm (8.9 lbf ft) –
Screw-in nozzles, cooling system M20x1.5 12 Nm (8.9 lbf ft)
Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) –

M6 10 Nm (7.4 lbf ft) –

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®2701

Loctite®243™

Loctite®2701

Loctite®243™

Loctite®2701

Loctite®243™

Loctite®2701

Loctite®243™

SUBSTANCES 88

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 Castrol and Motorex®products.

Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4

®

Motorex
– Brake Fluid DOT 5.1

Coolant

Guideline

– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foam-

ing. KTM recommends Motorex®products.

Mixture ratio

Antifreeze protection: −25… −45 °C (−13…

−49 °F)

Coolant (mixed ready to use)

50 % corrosion inhibitor/antifreeze
50 % distilled water

Antifreeze −40 °C (−40 °F)

Supplier

®

Motorex
– Anti Freeze

Engine oil (SAE 10W/50)

According to

– JASO T903 MA ( p. 92)
– SAE ( p. 92) (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. 92) (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 89

Shock absorber oil (SAE 2.5) (50180342S1)

According to

– SAE ( p. 92) (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 not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

AUXILIARY SUBSTANCES 90

Air filter cleaner

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Twin Air Dirt Bio Remover

Chain cleaner

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Chain Clean

Cleaning and preserving materials for metal, rubber and plastic

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Protect & Shine

High viscosity grease

Guideline

–

KTM recommends SKF®products.

Supplier

®

SKF
– LGHB 2

Long-life grease

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Bike Grease 2000

Motorcycle cleaner

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Moto Clean 900

Off-road chain spray

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Chainlube Offroad

Oil for foam air filter

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Twin Air Liquid Bio Power

AUXILIARY SUBSTANCES 91

Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Clean & Polish

Rubber grip adhesive (00062030051)

Supplier

KTM-Sportmotorcycle AG

– GRIP GLUE

Universal oil spray

Guideline

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Joker 440 Synthetic

STANDARDS 92

JASO T903 MA

Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear­lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi­cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore­ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The
JASO MA Standard meets these special requirements.

SAE

The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis­cosity. The viscosity describes only one property of oil and says nothing about quality.

INDEX 93

INDEX

A

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Air filter

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Air filter box

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Air filter box lid

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Anti-freeze

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Arduous riding conditions . . . . . . . . . . . . . . . . . . . . . . . . . 15

B

Basic suspension setting

checking against the rider's weight . . . . . . . . . . . . . . . 23

Battery

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 50

rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 50

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 54

Brake linings

front brake, changing . . . . . . . . . . . . . . . . . . . . . . . . 51

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 51

rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 55

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 55

C

Carburetor

adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

float chamber, emptying . . . . . . . . . . . . . . . . . . . . . . 68

idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Chain

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chain guide

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Clutch

fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 47

fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 47

Compression damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Compression damping, high-speed

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 24

Compression damping, low-speed

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 23

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

D

Difficult operating conditions

high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . 17

low speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

low temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

muddy surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

wet surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Difficult riding conditions

dry sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

wet sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

E

Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine

running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engine oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Engine sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

F

Factory Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

activating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Filler cap

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Filling up

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 53

free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 53

Fork legs

basic setting, checking . . . . . . . . . . . . . . . . . . . . . . . 27

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 30

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fork protector

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

INDEX 94

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Frame

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Front fender

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fuel tank

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuse

main fuse, installing . . . . . . . . . . . . . . . . . . . . . . . . . 63

main fuse, removing . . . . . . . . . . . . . . . . . . . . . . . . . 62

H

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 49

free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 49

Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Hot start lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

I

Ignition curve

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

L

Lower triple clamp

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

M

Main fuse

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Main silencer

glass fiber yarn filling, changing . . . . . . . . . . . . . . . . . 40

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

raising with lift stand . . . . . . . . . . . . . . . . . . . . . . . . 30

removing from lift stand . . . . . . . . . . . . . . . . . . . . . . 30

O

Oil filter

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Oil screen

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Owner's manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P

Play in throttle cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Preparing for use

advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 14

after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

checks and maintenance before putting into operation . . 18

R

Rear sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Rear wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Rebound damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 24

Riding sag

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Rubber grip

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

S

Seat

mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22

Shift lever

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 70

basic position, checking . . . . . . . . . . . . . . . . . . . . . . 69

Shock absorber

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 26

spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . 26

static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 25

Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Spoke tension

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Start number plate

dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Steering head bearing

greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Steering head bearing play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Swingarm

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

T

Technical data

carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-83

chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 87

INDEX 95

engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

engine tightening torques . . . . . . . . . . . . . . . . . . . 79-80

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-86

Throttle cable routing

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Tire air pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Tire condition

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-77

Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

U

Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V

View of vehicle

left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

W

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

*3211717en*

3211717en

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

03/2011

Photo: Mitterbauer