KTM 450 XC ATV, 525 XC ATV User Manual

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OWNER'S MANUAL 2008

450 XC ATV

525 XC ATV

ART. NO. 3211251en

DEAR KTM CUSTOMER 1

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

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( P. 12) Dealer's stamp

Engine number ( P. 12)

Key number ( P. 12)

The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing development and design can however not be completely excluded.

All specifications are not binding. KTM Sportmotorcycle AG in particular 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 printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

ISO 9001(12 100 6061) Within the meaning of 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

CONTENTS 2

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

IMPORTANT NOTES............................................................ 5

Overview of warning labels................................................ 8

VIEW OF VEHICLE............................................................. 10

Vehicle view, front left ................................................... 10

View of vehicle, rear right ............................................... 11

LOCATION OF SERIAL NUMBERS ...................................... 12

Chassis number............................................................. 12

Type label..................................................................... 12

Key number .................................................................. 12

Engine number.............................................................. 12

Setting number, front shock absorber .............................. 12

Setting number, rear shock absorber ............................... 13

OPERATING ELEMENTS.................................................... 14

Clutch lever .................................................................. 14

Reverse gear release lever .............................................. 14

Hand brake lever, parking brake...................................... 14

Throttle lever................................................................. 14

Light switch .................................................................. 15

ENG.bSTOPb

Electric starter button .................................................... 15

Ignition switch .............................................................. 15

Indicator lamp overview ................................................. 15

Emergency OFF switch with rip cord................................ 16

Opening filler cap.......................................................... 16

Closing filler cap ........................................................... 16

Fuel tap........................................................................ 16

Choke........................................................................... 17

Hot start button............................................................. 17

Shift lever..................................................................... 17

Foot brake pedal ........................................................... 17

TIPS ON PUTTING INTO OPERATION ................................. 18

Advice on first use ......................................................... 18

Running in the engine.................................................... 19

RIDING INSTRUCTIONS .................................................... 20

Checks before putting into operation ............................... 20

Starting ........................................................................ 20

Starting up ................................................................... 21

Shifting ........................................................................ 21

shifting to reverse gear ................................................... 22

Disengaging reverse gear ................................................ 22

Braking ........................................................................ 22

Riding .......................................................................... 23

Riding in bends............................................................. 23

Riding downhill ............................................................. 24

Riding uphill................................................................. 24

Riding perpendicular to the slope.................................... 25

Turning on slopes .......................................................... 25

Riding through water ..................................................... 25

Switching off the engine ................................................ 26

Stopping, parking .......................................................... 26

Refueling...................................................................... 27

GREASING AND SERVICE TABLE ....................................... 28

Important maintenance work to be carried out by an

authorized KTM workshop. ............................................. 28

Important maintenance work to be carried out by an

authorized KTM workshop. (as additional order)................ 29

Important checks and maintenance work to be carried

out by the rider. ............................................................ 29

MAINTENANCE ON CHASSIS AND ENGINE ........................ 31

Jacking up the vehicle ................................................... 31

Removing the vehicle from the work stand ....................... 31

Switch ........................................................ 15

Basic information on changing the chassis settings........... 31

Adjusting front shock absorber compression damping ....... 31

Adjusting front shock absorber rebound damping.............. 32

Adjusting front shock absorber cross over......................... 33

Adjusting front shock absorber spring preload .................. 33

Adjusting rear shock absorber compression damping......... 34

Adjusting rear shock absorber rebound damping ............... 35

Adjusting rear shock absorber spring preloadb Removing the rear shock absorberb Installing the rear shock absorberb Toe, checkingb Adjusting the toeb Checking/adjusting camberb

Fork offset .................................................................... 41

Adjusting the fork offsetb

Toe width of rear axle..................................................... 41

Adjusting the toe width of rear axleb

Handlebar position ........................................................ 42

Adjusting handlebar positionb

Checking play in gas Bowden cable ................................. 43

Adjusting play in gas Bowden cable................................. 44

Checking the play in the Bowden cable using the reverse

gear release lever........................................................... 44

Adjusting the play in the Bowden cable using the reverse

gear release lever........................................................... 44

Checking chain dirt ....................................................... 45

Cleaning the chain......................................................... 45

Checking the chain tension ............................................ 45

Checking rear sprocket / engine sprocket for wear............. 45

Checking chain wear...................................................... 46

Adjusting chain tension.................................................. 46

Greasing the rear wheel eccentric element ....................... 47

Checking brake discs ..................................................... 47

Checking free play of hand brake lever............................. 48

Adjusting basic position of handbrake lever...................... 48

Checking front brake fluid level....................................... 48

Topping up the front brake fluidb

Checking the front brake linings...................................... 49

Removing front brake liningsb Mounting front brake liningsb Changing the front brake liningsb

Checking free play of foot brake lever .............................. 52

Adjusting basic position of footbrake leverb

Checking rear brake fluid level ........................................ 52

Topping up brake fluid of front brakeb

Checking rear brake linings ............................................ 54

Removing rear brake liningsb Mounting rear brake liningsb Changing rear brake liningsb

Removing wheel/wheels.................................................. 56

Mounting wheel/wheels .................................................. 56

Tire condition checking.................................................. 57

Checking tire air pressure ............................................... 57

Removing the battery ..................................................... 57

Installing the battery...................................................... 58

Recharging the batteryb

changing main fuse ....................................................... 59

Changing the fuses of individual power-consuming

components .................................................................. 59

Ignition curve plug connection ........................................ 60

Changing ignition curve.................................................. 61

x........................................................... 37

x ...................................................... 38

x ............................................ 41

x .............................................. 58

x .............................. 37

x ............................... 37

x ........................................ 40

x............................. 41

x...................................... 43

x................................. 49

x...................................... 50

x ...................................... 50

x................................. 51

x....................................... 54

x ....................................... 55

x........................................ 55

x ............... 36

x................... 52

x.......................... 53

CONTENTS 3

Removing the seat ......................................................... 61

Mounting the seat ......................................................... 61

Removing the radiator spoiler ......................................... 61

Installing the radiator spoiler .......................................... 62

Removing the front cover................................................ 62

Installing the front cover ................................................ 62

Removing the front trim ................................................. 63

Installing the front trim .................................................. 63

Removing the rear fender ............................................... 63

Installing the rear fender ................................................ 64

Removing the engine guard ............................................ 65

Installing the engine guard ............................................. 65

Removing the air filterb Installing the air filterb Cleaning air filterb

Adjusting basic position of clutch lever............................ 66

Checking fluid level of hydraulic clutch ........................... 66

Cooling system .............................................................. 67

Radiator fan.................................................................. 67

Checking antifreeze and coolant level .............................. 67

Checking the coolant level.............................................. 68

Draining coolantb Filling coolant / bleeding cooling systemb

Carburetor - idle ............................................................ 70

Carburetor - adjusting idleb Emptying the carburetor float chamberb

Checking engine oil level................................................ 72

Changing engine oil and oil filter, cleaning oil screensb

Draining engine oil, cleaning oil screensb Removing the oil filterb Mounting oil filterb Filling up with engine oilb

Topping up engine oil .................................................... 76

TROUBLESHOOTING......................................................... 77

CLEANING........................................................................ 79

Cleaning the vehicle ...................................................... 79

STORAGE ......................................................................... 80

Storage......................................................................... 80

Putting the vehicle into operation after storage................. 80

TECHNICAL DATA - ENGINE .............................................. 81

Capacity - engine oil ...................................................... 81

Capacity - cooling liquid................................................. 82

TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 83

TECHNICAL DATA - CARBURETOR..................................... 85

450/525bXCbATV ........................................................... 85

TECHNICAL DATA - CHASSIS ............................................ 86

Lighting equipment ....................................................... 87

Tires ............................................................................ 87

Capacity - fuel............................................................... 87

TECHNICAL DATA - FRONT SHOCK ABSORBER .................. 88

TECHNICAL DATA - REAR SHOCK ABSORBER .................... 89

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 90

WIRING DIAGRAM ............................................................ 92

450/525

SUBSTANCES................................................................... 95

AUXILIARY SUBSTANCES.................................................. 97

STANDARDS..................................................................... 98

INDEX .............................................................................. 99

x.................................................................... 73

bXCbATV ........................................................... 92

x............................................... 65

x ............................................... 66

x...................................................... 66

x ....................................................... 68

x ..................... 69

x ......................................... 71

x ....................... 72

x ..................... 73

x............................................... 74

x ..................................................... 75

x ........................................... 75

MEANS OF REPRESENTATION 4

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Symbols used

The symbols used are explained in the following.

Indicates an expected reaction (e.g. of a work step or a function).

Indicates an unexpected reaction (e.g. of a work step or a function).

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your vehicle 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 in the following.

Specific name Identifies a specific name.

Name

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT NOTES 5

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Use definition

KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid regulations and categories of the top international motorsport organizations.

Warning

Danger of accidentsಘIncorrect assessment of riding situations.

ದ The vehicle may only be ridden by persons over the age of 16.

Info

The ATV must be used only on secluded property remote from public road traffic. The ATV is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components. Using the vehicle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the greasing and service table is reached. Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your vehicle.

Warranty

The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and alterations 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, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss.

Transport

Note

Danger of damageಘDanger of damage from accidental rolling of vehicle.

ದ Park the vehicle on a surface that is as horizontal as possible and activate the parking brake.

Note

Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ದ Do not place the vehicle where there are flammable or explosive substances.

ದ Switch off the engine. ದ Turn the handleb ದ Use straps or other suitable devices to secure the vehicle against accidents or falling over. ದ Pull the hand brake lever, push the locking pawlb

 of the fuel tap to the OFF position. (Figureb100013-10b P. 16)

 down and release the hand brake lever. (Figureb100006-10b P. 14)

Environment

Offroad riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your vehicle responsibly, you can ensure that such problems and conflicts do not have to occur. To protect the future of offroad sport, make sure that you use your ATV legally, display environmental consciousness, and respect the rights of others.

IMPORTANT NOTES 6

Rider training

If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the first time. A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you.

IMPORTANT NOTES 7

IMPORTANT NOTES 8

Overview of warning labels

100106-10

IMPORTANT NOTES 9

Notes/warning notes

Pay attention to the specified notes and warnings.

Info

Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

Grades of risks

Danger

Danger that leads immediately and certainly to severe and permanent injury or death.

Warning

Danger that will probably lead to severe and permanent injury or death.

Note

Danger of serious damage to machine or material.

Warning

Risk of environmental damage.

OWNER'S MANUAL

ದ Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help

you operate and handle your vehicle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury. The owner's manual also contains important information on servicing the vehicle.

ದ The owner's manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.

VIEW OF VEHICLE 10

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Vehicle view, front left



1 Hand brake lever 2 Fuse box 3 Headlight 4 Front shock absorber 5 Right-hand brake caliper 6 Steering damper holder (steering damper is optional) 7 Front left shock absorber 8 Outside brake disk guard 9 Shift lever 10 Left footrest 11 Heel protector 12 Emergency OFF switch with rip cord 13 Clutch lever

600148-10

VIEW OF VEHICLE 11

View of vehicle, rear right

1 Light switch, electric starter button, ENG.bSTOPbswitch 2 Filler cap 3 Main silencer 4 Rear shock absorber 5 Rear sprocket with chain 6 Rear wheel eccentric element 7 Rear brake 8 Foot brake pedal 9 Compensating tank for coolant 10 Manifold 11 Top A-arm 12 Front right fender 13 Throttle lever 14 Ignition switch

600149-10

LOCATION OF SERIAL NUMBERS 12

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Chassis number



The chassis numberb is stamped on the right side of the frame in the vicinity of the upper control arm.

100002-10

Type label

The type labelb is located on the frame tube on the right in front of the radiator.

Key number

Engine number

100034-10

The key numberb is indicated on thebKEYCODECARD.

Info

You need the key number to order a replacement key. Keep thebKEYCODECARD in a safe place.

100089-10

The engine numberb is stamped on the left side of the engine under the engine sprocket.

100001-10

Setting number, front shock absorber

100033-10

The setting numberb is stamped into the top of the shock absorber.

LOCATION OF SERIAL NUMBERS 13

Setting number, rear shock absorber

The setting numberb is stamped into the top of the shock absorber.

100032-10

OPERATING ELEMENTS 14

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Clutch lever



The clutch leverb is fitted on the left side of the handlebar.

Possible states

• Clutch lever in neutral position ದbIn this position, the engine is force-locked with the gear and the starting circuit is interrupted. The electric starter does not turn over when the electric starter button is pressed.

• Clutch lever pulled ದbIn this position, the force lock between the engine and the gear is broken and the starting circuit is closed. The electric starter turns over when the electric starter button is pressed.

100004-10

Reverse gear release lever

The clutch is hydraulically operated and self-adjusting.

The reverse gear release leverb is fitted on the left side of the handlebar. Reverse gear can only be engaged when the reverse gear release lever is activated while the vehicle is at a standstill.

100005-10

Hand brake lever, parking brake

100006-10

The hand brake leverb is located on the right side of the handlebar and operates the front brakes. The hand brake lever is combined with the parking brake, which blocks the front wheels to prevent the vehicle from rolling away. To activate the parking brake, pull the hand brake lever, push the locking pawlb

 down

and release the hand brake lever.

Possible states

• Hand brake lever in basic position ದbFront wheels are not blocked.

• Hand brake lever pulled and locked in position ದbFront wheels are blocked.

Throttle lever

The throttle leverb is fitted on the right side of the handlebar. The throttle lever is used to control the engine speed.

100007-10

OPERATING ELEMENTS 15

Light switch

The light switchb is fitted on the left side of the handlebar.

Possible states

• High beam on HI ದbLight switch is turned upwards. In this position, the high beam and the tail light are switched on.

• Low beam on LO ದbLight switch is at the middle setting. In this position, the low beam and tail lights are switched on.

• Lights off OFF ದbLight switch has been swiveled down. In this position, all lights are switched off.

100011-10

ENG.bSTOPbSwitch

ThebENG.bSTOPbswitchb is fitted on the left side of the handlebar. Possible states

• Ignition offbOFF ದbIn this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.

• Ignition onbRUN ದbIn this position, the ignition circuit is closed and the engine can be started.

Electric starter button

Ignition switch

100030-10

The STARTb electric starter button is fitted on the left side of the handlebar.

Possible states

• Electric starter button in basic position

• Electric starter button pressed ದbIn this position, the electric starter is actuated.

100029-10

The ignition switchb is located on the instrument support.

Possible states

Ignition off ದbIn this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

Ignition on ದbIn this position, the ignition circuit is closed and the engine can be started.

Indicator lamp overview

100031-10

400288-10

Possible states

Reverse gear indicator lampb

Ignition indicator lampb

 lights up yellow ದbIgnition is switched on.

High beam indicator lampb

Idle speed indicator lampb

 lights up green ದbTransmission is switched

to idle.

 lights up red ದbReverse gear is engaged.

 lights up blue ದbHigh beam is switched on.

OPERATING ELEMENTS 16

Emergency OFF switch with rip cord

The emergency OFF switchb is mounted on the left in front of the fuel tank. A rip

Opening filler cap

100010-10

cord is attached to the clipb of a carabiner

.

The emergency OFF switch shuts the engine off if the rider falls off the vehicle.

Possible states

• Clip is pulled off ದbThe ignition circuit is interrupted, a running engine stops and a non-running engine will not start.

• Clip is mounted ದbThe ignition circuit is closed and the engine can be started.

ದ Press release buttonb, turn filler cap counterclockwise and lift it free.

. It can be attached to the clothing of the rider by means

Closing filler cap

Fuel tap

100012-10

100012-11

ದ Replace the filler cap and turn clockwise until the release buttonb locks in place. ದ Check the fuel tank breatherb

 to ensure it is properly seated.

» If the fuel tank breather is at an angle or loose:

ದ Correctly mount the fuel tank breather.

The fuel tap is located on the right side of the fuel tank. With the tap handleb

 on the fuel tap, you can open or close the supply of fuel to the

carburetor.

Possible states

• Fuel supply closed OFF ದbNo fuel can flow from the tank to the carburetor.

• Fuel supply open ON ದbFuel can flow from the tank to the carburetor. The fuel tank empties down to the reserve.

• Reserve fuel supply open RES ದbFuel can flow from the tank to the carburetor. The fuel tank empties completely.

100013-10

OPERATING ELEMENTS 17

Choke

The choke knobb is fitted on the left side of the carburetor. Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

If the engine is warm, the choke function must be deactivated.

Possible states

100014-10

Hot start button

• Choke function activated ದbThe choke lever is pulled out to the stop.

• Choke function deactivated ದbThe choke lever is pushed in to the stop.

The hot start button (red)b is fitted on the left side of the carburetor. Activating the hot start function frees an opening in the carburetor through which the engine can draw extra air. This gives a leaner fuel-air mixture, which is needed for a hot start.

Info

If the engine is cold, the hot start function must be deactivated.

Shift lever

100015-10

100018-10

Possible states

• Hot start function activated ದbThe hot start button is pulled out to the stop.

• Hot start function deactivated ದbThe hot start button is pushed in as far as possible.

The shift leverb is mounted on the left side of the engine.

The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. Reverse gear can only be engaged with the vehicle at a standstill and the lever pulled.

Foot brake pedal

100017-10

The foot brake pedalb is located in front of the right footrest and operates the rear wheel brake.

100016-10

TIPS ON PUTTING INTO OPERATION 18

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Advice on first use



Danger

Danger of accidentsಘDanger from inadequate traffic experience.

ದ Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.

Warning

Danger of accidentsಘIncorrect assessment of riding situations.

ದ The vehicle may only be ridden by persons over the age of 16.

Warning

Danger of accidentsಘUnaccustomed handling of the ATV.

ದ If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the

vehicle for the first time.

ದ A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your

KTM dealer will be glad to advise you.

Warning

Risk of injuryಘRisk of injury by missing/inadequate protective clothing.

ದ Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle.

Always wear protective clothing, which must be in perfect condition and meet legal requirements.

Warning

Danger of crashingಘImpairment of riding behavior due to different tire tread patterns on front and rear wheels.

ದ 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 accidentsಘCritical riding behavior due to inappropriate riding.

ದ Adapt your riding speed to the road conditoins and your riding ability.

Warning

Danger of accidentsಘAccident risk caused by presence of a passenger.

ದ Your vehicle is not designed to carry passengers. Do not ride with a passenger.

Warning

Danger of accidentsಘBrake system failure.

ದ If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take

your foot off the foot brake pedal if you do not want to brake.

Warning

Danger of accidentsಘUnstable riding behavior.

ದ Do not exceed the maximum permitted weight and axle loads.

Warning

Risk of misappropriationಘUsage by unauthorized persons.

ದ Never leave the vehicle unattended while the engine is running. Secure the vehicle against use by unauthorized persons.

Always remove the ignition key.

Warning

Danger of accidentsಘInstable handling from loaded luggage.

ದ The vehicle is not designed to carry luggage. Do not attach luggage to the vehicle.

Warning

Danger of accidentsಘPoor recognizability of vehicle on hilly terrain and/or sand dunes.

ದ Attach a safety flag to the vehicle.

Info

When using your vehicle, remember that others may feel disturbed by excessive noise.

ದ 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.

ದ Before your first trip, read the entire operating instructions carefully.

TIPS ON PUTTING INTO OPERATION 19

ದ Get to know the operating elements. ದ Adjust the basic position of clutch lever. ( P. 66) ದ Adjust the basic position of the handbrake lever. ( P. 48)

ದ

Adjust the basic position of the footbrake lever.b

ದ Become accustomed to handling the vehicle on a suitable piece of land before making a longer trip.

Info

Offroad, you should be accompanied by another person on another machine so that you can help each other.

ದ Do not make any offroad trips that over-stress your ability and experience. ದ Hold the handlebar firmly with both hands and keep your feet on the footrests when riding. ದ Do not make any changes to the vehicle and use only KTM approved parts. ದ Do not exceed the overall maximum permitted weight and the axle loads.

Specification

Maximum permissible overall weight 293bkg (646blb.) Maximum allowable axle load

Front 144bkg (317blb.) Rear 149bkg (328blb.)

ದ Run the engine in.

x ( P. 52)

Running in the engine

ದ During the running-in phase, do not exceed the specified engine speed and engine performance.

Specification

Maximum engine speed

During the first 3 service hours 7,000brpm

Maximum engine performance during the running-in period

During the first 3 service hours ืb50b% During the next 12 service hours ืb75b%

ದ Avoid fully opening the throttle!

RIDING INSTRUCTIONS 20

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Checks before putting into operation



Info

Make sure that the vehicle is in a perfect technical condition before use.

Info

In the interests of riding safety, make a habit of making a general check before you ride.

ದ Check the engine oil level. ( P. 72) ದ Check the engine for oil loss. ದ Check the fuel supply. ದ Check the chain tension. ( P. 45) ದ Check the chain dirt accumulation. ( P. 45) ದ Check the tire condition. ( P. 57) ದ Checking the tire air pressure. ( P. 57) ದ Check the front brake fluid level. ( P. 48) ದ Check the rear brake fluid level. ( P. 52) ದ Check the front brake linings. ( P. 49) ದ Check the rear brake linings. ( P. 54) ದ Check brake system function. ದ Check that the rear hubs are tight. ದ Check that the footrests are tight. ದ Check the handlebar bridge bearing for excessive play. ದ Check the handlebar for smooth operation and play. ದ Check the coolant level. ( P. 68) ದ Check the cooling system for leakage. ದ Check that all operating elements are correctly adjusted and free to move. ದ Check that the electrical equipment is functioning properly.

Starting

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in unconsciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed

space.

Note

Engine failureಘHigh engine speeds in cold engines have a negative effect on the service life of the engine.

ದ Always warm up the engine at low engine speeds.

Info

If the engine is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing. If the float chamber is filled with fresh fuel, the engine starts immediately. Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.

Conditions

Vehicle has not been operated: ุb1bweek

ದ

Empty the carburetor float chamber.b

ದ Turn the handleb

Fuel can flow from the tank to the carburetor.

ದ Mount the vehicle. ದ Insert the clipb ದ Press thebENG.bSTOPbswitch into thebRUN position.

 of the fuel tap to the ON position. (Figureb100013-10b P. 16)

 into the emergency OFF switch and fasten the rip cord to the clothing of the rider. (Figureb100010-10b P. 16)

x ( P. 72)

RIDING INSTRUCTIONS 21

ದ Turn the key in the ignition switch to thebpositionb .

The yellow ignition indicator lampbON lights up.

Info

Under no circumstances should you open the throttle when switching on the ignition! The vehicle is equipped with a safety system that switches off the engine in case of a malfunction in the throttle lever, Bowden cable or carburetor. When the ignition is switched on, a system check is performed during which the throttle lever must be in its basic position. If not, the safety system detects a malfunction and blocks the ignition current. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark.

ದ Shift gear to neutral.

The green idling speed indicator lampbN light up.

Conditions

Engine cold ದ Pull choke lever out as far as possible.

Conditions

Engine is hot

ದ Pull the hot start button (red) all the way out. ದ Pull the clutch lever. ದ Press the electric starter button.

Info

When the clutch lever is not pulled, the starting circuit is not closed. The electric starter does not turn over when the electric starter button is pressed. Don't open the throttle.

ದ Release the clutch lever.

Conditions

Engine hot and running

ದ Push the hot start button in as far as possible when the engine is running.

Starting up

Info

Switch your lights on before leaving. You will then be seen earlier by other motorists.

ದ Pull the hand brake lever and release it again.

Locking pawl moves into its basic position, parking brake is deactivated.

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

Shifting

Warning

Danger of accidentsಘIf you change down at high engine speed, the rear wheels can block.

ದ Do not change into a low gear at high engine speed. The engine races and the rear wheels can block.

100017-10

Conditions

When conditions allow (incline, road situation, etc.), you can shift into a higher gear.

ದ Release the throttle while simultaneously pulling the clutch lever, shift into the

next gear, release the clutch and open the throttle.

Info

The position of the 5 forward gears can be seen in the illustration. First gear is used for starting off or for steep inclines.

ದ To shift down, brake if necessary and close the throttle at the same time. ದ Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and

open the throttle or shift again.

RIDING INSTRUCTIONS 22

shifting to reverse gear

Warning

Danger of accidentsಘDanger of accidents from blocked rear wheels if reverse gear is engaged while the vehicle is rolling.

ದ To engage reverse gear, it is important to stop the vehicle first and have the engine at idle speed.

Note

Transmission damageಘDanger of transmission damage when engaging reverse gear while the vehicle is rolling.

ದ To engage reverse gear, it is important to stop the vehicle first and have the engine at idle speed.

ದ Stop the vehicle and run the engine at idling speed. ದ Activate the clutch and engage 1st gear. ದ Apply light pressure to the shift lever and activate the reverse gear release lever. Press the shift lever all the way down with your

foot to engage reverse gear.

ದ Release the reverse gear release lever. ದ Look toward the rear and slowly release the clutch lever while depressing the accelerator carefully.

Info

The engine speed is limited when reverse gear is engaged.

Disengaging reverse gear

Warning

Danger of rolloversಘThe vehicle can roll over if the clutch lever is released with the forward gear engaged while the vehicle is

rolling backward.

ದ To disengage reverse gear, it is important that you stop the vehicle first.

Warning

Danger of accidentsಘDanger of accidents from blocked rear wheels if reverse gear is disengaged while the vehicle is rolling.

ದ To disengage reverse gear, it is important that you stop the vehicle first.

Note

Transmission damageಘDanger of transmission damage when disengaging reverse gear while the vehicle is rolling.

ದ To disengage reverse gear, it is important that you stop the vehicle first.

ದ Activate the clutch, stop the vehicle and let the engine run at idling speed. ದ Press the shift lever up until 1st gear engages.

Info

The reverse gear release lever no longer needs to be activated.

ದ Slowly release the clutch lever while carefully depressing the accelerator or shifting into neutral.

Braking

Warning

Danger of accidentsಘIf you brake too hard, the wheels can lock. When the front wheels lock, the vehicle can no longer be

steered.

ದ Adapt your braking to the traffic situation and the road conditions.

Warning

Danger of accidentsಘReduced braking caused by spongy pressure point of front or rear brake.

ದ Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘReduced braking due to wet or dirty brakes.

ದ Clean or dry dirty or wet brakes by riding and braking gently.

ದ Use the hand brake lever to activate the front brakes and the foot brake pedal to activate the rear brakes. ದ When braking, release the throttle and apply the front and rear brakes at the same time.

RIDING INSTRUCTIONS 23

ದ Shift the transmission to lower gears according to the vehicle's speed. ದ Braking should always be completed before you go into a bend. ದ 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

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. If the vehicle goes out of control and you fall off the vehicle, the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing. This short-circuits the ignition circuit and the engine switches off.

ದ During normal operation, you sit erect on the vehicle with both hands on the handlebar and both feet on the footrests. ದ If the choke function was activated, deactivate it after the engine has warmed up. ದ After reaching maximum speed by fully opening the throttle, close the throttle so it is 3/4 open.

This barely reduces vehicle speed but lowers fuel consumption considerably.

ದ Always open the throttle only as much as the engine can handle ದ abrupt pressure on the throttle increases fuel consumption. ದ Switch off the engine if you expect to be standing for a long time.

Specification

ุb2bmin

ದ Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system. ದ Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.

Riding in bends

Info

When riding in bends, the outer wheels cover a greater distance than the inner wheels. Because the rear axle of the ATV is rigid in design, the rear wheels turn at the same speed. The difference in distance is compensated by slippage of the tires.

Warning

Danger of accidentsಘExcessive speed and turning at sharp angles can cause

the vehicle to roll over.

ದ Decrease your speed before entering into bends.

ದ Handling of the ATV is strongly influenced by shifts in the position of your body

weight. Always shift your body weight toward the inside of the bend and forward.

ದ The faster you ride and the tighter the bend, the more you need to shift your body

400300-01

weight.

ದ Always exert pressure on the footrest on the inside of the bend. ದ Look in the direction of the bend while you are riding. ದ The farther back you are sitting, the more the vehicle has the tendency to move

straight ahead. The farther forward you shift your weight, the more pressure is applied to the front axle and the more easily the vehicle can take the bend.

RIDING INSTRUCTIONS 24

Riding downhill

Warning

Danger of accidentsಘDanger of accidents when riding on slopes.

ದ Always check the terrain before riding onto a slope. ದ Never ride on a slope with an inclination of more than 25°. ದ Never ride on a slope that exceeds your driving skills. ದ Never ride down a slope backward. If you activate the rear brake, the

vehicle will roll over.

400297-01

ದ Always ride straight up or down a slope and never at a slant. ದ Engage a gear with which you can ride all the way down the slope. ದ Shift your body weight to the rear and ride cautiously without opening the throttle. ದ Keep your vehicle speed and engine speed as constant as possible. ದ Always be prepared to jump sideways off the vehicle should it go out of control. ದ Brake by mainly applying the rear brake; the rear wheels should not become

ದ When you come to a standstill, always dismount from the vehicle and

turn it.

ದ Never ride on a slope with a slippery surface. The vehicle can easily go

out of control and roll over.

Note

Material damageಘDamage to vehicle after fall or rollover.

ದ Perform a vehicle check as is done everytime before you start to ride.

blocked.

Riding uphill

400295-01

Warning

Danger of accidentsಘDanger of accidents when riding on slopes.

vehicle will roll over.

ದ When you come to a standstill, always dismount from the vehicle and

turn it.

ದ Never ride on a slope with a slippery surface. The vehicle can easily go

out of control and roll over.

ದ Always ride straight up or down a slope and never at a slant. ದ Engage a gear with which you can ride all the way up the slope. Shifting on the

slope can cause the vehicle to roll over.

ದ Shift your body weight to the front and ride cautiously. ದ Keep your vehicle speed and engine speed as constant as possible. ದ Always be prepared to jump sideways off the vehicle should it go out of control. ದ Drive slowly over hilltops to give yourself the opportunity to react to obstacles and

changes in terrain.

ದ If the vehicle comes to a stop, immediately activate both brakes to prevent the

vehicle from rolling backward. Dismount from the vehicle and turn it.

RIDING INSTRUCTIONS 25

Riding perpendicular to the slope

Warning

Danger of accidentsಘWhen riding perpendicular to a slope, the vehicle can

tip easily and roll over.

ದ Avoid riding perpendicular to the slope if possible. ದ Ride slowly and shift you weight toward the slope.

ದ If the vehicle starts to tip over, steer it downhill and dismount immediately to the

uphill side.

400299-01

Turning on slopes

Warning

Danger of accidentsಘDanger of accidents from turning the vehicle on a slope.

ದ Never ride down a slope backward. The vehicle can roll over easily. ದ Always position yourself next to the vehicle in a location where you cannot be caught by a wheel. ದ When turning on a slope, always stand on the uphill side of the vehicle to avoid injury should the vehicle tip. ದ If the slope is too steep or slippery to turn the vehicle, you should leave it where it is and get assistance in retrieving it.

Riding through water

400298-01

ದ If you come to a stop on a slope with your vehicle, dismount from the vehicle and

turn it.

ದ Switch off the engine and activate the parking brake. ದ Dismount from the vehicle on the uphill side. ದ Switch the transmission to neutral and stand next to the vehicle. ದ Grasp the handlebar with both hands, release the parking brake and carefully

release the front brake.

ದ Let the vehicle roll downhill carefully until you reach a location where you can turn

it. Control its speed using the front brake.

ದ To turn the vehicle, steer it to the side. When doing so, you should always stand on

the uphill side and apply pressure to the footrest on the uphill side.

ದ When the vehicle is standing perpendicular to the slope or slightly downhill, acti-

vate the parking brake.

ದ Mount the vehicle, start the engine, pull the clutch lever and engage 1st gear. Cau-

tiously release the parking brake and ride down the hill in 1st gear.

ದ Riding downhill. ( P. 24) ದ If you lose control over the vehicle, you should get away from the vehicle as fast as

possible.

Warning

Danger of accidentsಘThe vehicle can roll over when riding through deep

water with a strong current.

ದ Avoid riding through deep water with a strong current.

400302-01

Warning

Danger of accidentsಘReduced braking due to wet or dirty brakes.

ದ Clean or dry dirty or wet brakes by riding and braking gently.

Note

Engine failureಘWhen riding through deep water, water can enter into the engine

through the air filter and cause engine damage.

ದ Only ride through water if it reaches no higher than the upper edge of the

footrest.

ದ Before riding through water, determine the depth and current of the water. ದ Ride slowly and negotiate around obstacles.

RIDING INSTRUCTIONS 26

ದ After riding through water, dry the brakes by lightly activating both brakes until nor-

mal braking power is available again.

ದ If the vehicle becomes submerged, an authorized KTM workshop must perform a

thorough check and comprehensive service.. Do not start the engine.

Switching off the engine

Info

There are three ways to switch off the engine.

Alternativeb1

Switch off the engine using the ignition key.

ದ Turn the key in the ignition switch to thebpositionb .

Info

All power-consuming components are switched off.

Alternativeb2

Switch off the engine using the ENG.bSTOPbswitch.

ದ Press thebENG.bSTOPbswitch into thebOFF position.

Info

All power-consuming components are switched off.

Alternativeb3

Switch off the engine using the emergency OFF switch with a rip cord.

ದ Pull off the clipb

. (Figureb100010-10b P. 16)

Info

When the engine is switched off using the emergency OFF switch, the power-consuming components are not switched off. All power-consuming components that are switched on (head lights, tail light, CDI, etc.) continue consuming electricity. This uses battery power and causes it to discharge.

Stopping, parking

Warning

Danger of burnsಘSome vehicle components get very hot when the machine is driven.

ದ 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 damageಘDanger of damage from accidental rolling of vehicle.

ದ Park the vehicle on a surface that is as horizontal as possible and activate the parking brake.

Note

Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.

ದ Do not place the vehicle where there are flammable or explosive substances.

400296-01

ದ Stop the vehicle and park it on a surface that is as horizontal as possible. ದ Shift gear to neutral.

The green idling speed indicator lamp N lights up.

ದ Switch off the engine. ( P. 26) ದ Remove the ignition key and the clip from the emergency OFF switch. ದ Pull the hand brake lever, push the locking pawlb

brake lever. (Figureb100006-10b P. 14)

The front wheels are blocked.

ದ Turn the handleb

(Figureb100013-10b P. 16)

No more fuel flows from the tank to the carburetor.

ದ If the vehicle must be parked on an incline, additionally secure the rear wheels

against rolling (see illustration).

 of the fuel tap to the OFF position.

 down and release the hand

RIDING INSTRUCTIONS 27

Refueling

Danger

Fire hazardಘFuel can easily catch fire.

ದ Never fill up 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.

ದ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

ದ Avoid contact between fuel and 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 hazardಘImproper handling of fuel is a danger to the environment.

ದ Do not allow fuel to get into the ground water, the ground, or the sewage system.

ದ Open the filler cap. ( P. 16) ದ Switch off the engine. ದ Fill the fuel tank with fuel up to measurementb

Specification

Measurement ofb

 35bmm (1.38bin)

.

400287-10

Tank capacity 13.4bl

(3.54bUSbgal)

ದ Close the filler cap. ( P. 16)

Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 95)

GREASING AND SERVICE TABLE 28

*5($6,1*$1'6(59,&( 7$%/(

Important maintenance work to be carried out by an authorized KTM workshop.



S3N S15A S30A

Engine

Carburetor Check carburetor connection boots for cracks and leakage. • •

Attachments Check the cooling system for leakage. • • •

Brakes Check the front brake linings. ( P. 49) • • •

Chassis Check shock absorbers for cracks and proper functioning. • • •

Wheels Check rim run-out. • • •

Change the engine oil and oil filter, clean the oil screens.b Replace spark plug. • Check and adjust valve clearance. • • • Check engine mounting screws for tightness. • • • Clean spark plug connectors and check for tightness. • • • Check shift lever screw for tightness. • • •

Check vent hoses for damage and routing without sharp bends. • • • Check idle. •••

Check the antifreeze and coolant level. ( P. 67) • • • Check the exhaust system for leakage and looseness. • • Check Bowden cables for damage, smooth operation and routing without sharp

bends. Check the fluid level of the hydraulic clutch. ( P. 66) • • • Clean the air filter.b Check cables for damage and routing without sharp bends. • • Check that the electrical equipment is functioning properly. • • • Check the headlamp setting. • • Check speed limitation in reverse gear. • • •

Check the rear brake linings. ( P. 54) • • • Check the brake discs. ( P. 47) • • • Check the front brake fluid level. ( P. 48) • • • Check the rear brake fluid level. ( P. 52) • • • Check brake lines for damage and leakage. • • • Check the free play of the hand brake lever. ( P. 48) • • • Check the free play of the foot brake lever. ( P. 52) • • • Check brake system function. • • • Check screws and guide bolts of brake system for tightness. • • •

Check the steering column bearing for wear and smooth operation. • • • Clean and grease bearing and sealing elements of steering column. • • • Check steering for smooth operation and play. • • • Check the bearing of the handlebar bridge of excessive play. • • • Check tie rods and tie rod ends for damage and play. • • • Check front wheel suspension for wear and tightness. • • • Check that front and rear wheel hubs are tight. • • • Check swingarm bearing. •• Check the bearing of the rear axle for play. • • • Grease the rear wheel eccentric element. ( P. 47) • • Check all screws to see if they are tight. • • •

Check the tire condition. ( P. 57) • • • Checking the tire air pressure. ( P. 57) • • • Check the chain wear. ( P. 46) • • • Check the chain tension. ( P. 45) • • • Clean the chain. ( P. 45) • • • Check front wheel bearing for play. • • •

x ( P. 66)

x ( P. 73)

•••

S3N: After 3 service hours - corresponds to about 21 liters of fuel

GREASING AND SERVICE TABLE 29

S15A: Every 15 service hours - corresponds to about 105 liters of fuel / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel

Important maintenance work to be carried out by an authorized KTM workshop. (as additional order)

Competition use Hobby use J1A J2A

S15A S30A S45A S30A S60A S90A

Carry out a complete shock absorber service. • Clean and adjust carburetor. •• Treat electric contacts with contact spray. •• Change hydraulic clutch fluid. •• Change brake fluid. •• Clean spark arrestor. •• Check wear of clutch discs. • • • • • • Check long clutch springs. • • Check clutch slave cylinder for dents. • • Check outer clutch hub for dents. • • Check cylinder and piston wear. • • Check camshaft wear. (visual check) • • Change the camshaft bearing support. • • Check wear of valve spring seat. • • Check wear of valve guides. • • Check valves. • • Check valve springs. • • Check the radial clearance of the rocker arm rollers. • • Measure length of timing chain. • • Check the timing-chain tensioner function. • • Check crankshaft and crankshaft journal for run-out. • • Change conrod bearing. • • Change the crankshaft main bearing. • • Change the balancer bearing. • • Check wear of all transmission components including

shafts and bearings. Check long bypass valve spring. • • Change glass fiber yarn filling of main silencer. • • Replace foot brake cylinder seals. • • Check carburetor components. • •

••

S15A: Every 15 service hours - corresponds to about 105 liters of fuel / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel S45A: Every 45 service hours - corresponds to about 315 liters of fuel S60A: Every 60 service hours - corresponds to about 420 liters of fuel S90A: Every 90 service hours - corresponds to about 630 liters of fuel J1A: annually J2A: every 2 years

Important checks and maintenance work to be carried out by the rider.

Check the engine oil level. ( P. 72) • Check the front brake fluid level. ( P. 48) • Check the rear brake fluid level. ( P. 52) • Check the front brake linings. ( P. 49) • Check the rear brake linings. ( P. 54) • Check and adjust Bowden cables. • Clean the chain. ( P. 45) • Check the chain tension. ( P. 45) •

NB1A

GREASING AND SERVICE TABLE 30

NB1A

Check the chain wear. ( P. 46) • Check rear sprocket / engine sprocket for wear. ( P. 45) • Clean the air filter.b Checking the tire air pressure. ( P. 57) • Check the tire condition. ( P. 57) • Check the coolant level. ( P. 68) • Check that all operating elements for smooth operation. • Check braking force (incl. parking brake). • Check all screws, nuts and hose clamps regularly for tightness. •

NB1A: Depending on conditions of use according to requirements.

x ( P. 66)

•

MAINTENANCE ON CHASSIS AND ENGINE 31

0$,17(1$1&(21&+$66,6 $1'(1*,1(

Jacking up the vehicle



Note

Danger of damageಘDanger of damage from tipping of vehicle.

ದ Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand.

ದ Jack up the vehicle on the frame underneath the engine. The wheels must no

longer touch the ground.

ದ Secure the vehicle.

100054-10

Removing the vehicle from the work stand

Note

Danger of damageಘDanger of damage by the vehicle running away or falling over.

ದ Always place the vehicle on a firm and even surface.

ದ Lower the vehicle. ದ Remove the work stand.

Basic information on changing the chassis settings

The standard setting of the chassis is the result of many fine tuning tests. It is laid out for the weight of the average rider (with a full set of protective clothing) and for a sporty driving style.

Standard rider weight 70… 80bkg (154… 176blb.)

By making a variety of adjustments to the chassis, you can set it to better match your body weight and riding style. The left and right front shock absorbers should have the same settings. If your weight is above or below the range, you have to adjust the standard setting of the suspension components 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.

Tip

When changing the chassis settings, always start with the standard setting. Between test rides, always change only one setting. This will enable you to better assess the effect of the setting on vehicle handling. Do not make radical changes to the settings; proceed in small steps instead. Even small changes can have a large impact on vehicle handling.

Adjusting front shock absorber compression damping

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Warning

Danger of accidentsಘDo not make any radical changes to the adjustment of the shock absorbers.

ದ Only make adjustments within the recommended range.

Info

The compression damping setting has an impact on the compression of the shock absorber.

MAINTENANCE ON CHASSIS AND ENGINE 32

ದ Turn the adjusting wheelb clockwise until it stops. ದ Turn back counterclockwise the number of clicks corresponding to the shock

absorber type. Specification

Compression damping

Standard 14bclicks Maximum deviation from standard

value

100027-10

Tip

Experience has shown that settings outside of this range are detrimental to vehicle handling. When changing the chassis settings, always start with the standard setting.

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. The left and right shock absorbers should have the same settings.

Adjusting front shock absorber rebound damping

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

෥5… 5bclicks

Warning

Danger of accidentsಘDo not make any radical changes to the adjustment of the shock absorbers.

ದ Only make adjustments within the recommended range.

Info

The rebound damping setting has an impact on the compression of the shock absorber.

ದ Turn the adjusting screwb clockwise until it stops. ದ Turn back counterclockwise the number of clicks corresponding to the shock

absorber type. Specification

Rebound damping

Standard 20bclicks Maximum deviation from standard

value

100028-10

෥5… 5bclicks

Tip

Experience has shown that settings outside of this range are detrimental to vehicle handling. When changing the chassis settings, always start with the standard setting.

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping. The left and right shock absorbers should have the same settings.

MAINTENANCE ON CHASSIS AND ENGINE 33

Adjusting front shock absorber cross over

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Info

The cross over setting is used to adjust the suspension travel of the short (soft) spring. Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower. The suspension travel and the progressive part of the long (hard) spring is not fully utilized. Less cross over makes the spring action at the front harder and the front of the vehicle lies higher.

ದ Jack up the vehicle. ( P. 31) ದ Clean the shock absorber thoroughly. ದ Loosen the adjusting ringb. Suitable toolsb are available from an authorized

KTM workshop.

Hook wrench, Öhlins (83019001000)

100084-10

ದ The cross over settingb is measured between the sliding bushingb and the collar

of the spring retainerb

Specification

ದ Change the settings accordingly and lock the adjusting ring.

Adjusting front shock absorber spring preload

400348-11

ದ Remove the vehicle from the work stand. ( P. 31)

Cross over 17±1.5bmm (0.67±0.059bin)

Info

The sliding bushing is made of plastic. Therefore, do not lock it too tightly to avoid damaging the thread. The left and right shock absorbers should have the same settings.

.

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Warning

Danger of accidentsಘDo not make any radical changes to the adjustment of the shock absorbers.

ದ Make adjustments in small steps only.

Info

Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.

Tip

Before you change the spring preload, make a note of the groove in which the securing clip is positioned. When making adjustments, always start from the standard setting.

ದ Jack up the vehicle. ( P. 31) ದ Clean the shock absorber thoroughly.

MAINTENANCE ON CHASSIS AND ENGINE 34

ದ Press the spring pack and the spring retainerb down to make the securing clipb

accessible.

ದ Using pliers, position the securing clip in one of the upper grooves. Do not over-

strain the securing clip.

ದ Release the spring pack and measure the length of the unloaded spring pack.

100083-10

ದ Press together the spring pack, position the securing clip in the corresponding

groove and release the spring pack. Specification

00AA

Clip position, spring preload

Standard 7 th position from top Corresponds to a spring preload of 5bmm (0.2bin)

Info

The spring preloadb is the difference in length between the spring pack when it is unloaded and when it is installed. The securing clip must be positioned entirely within the cut-out of the spring retainer. The spring pack should never be installed loosely (without preload). The standard setting is the lowest permissible spring preload. Therefore, you can only increase the spring preload. If you increase the spring preload, you should also slightly increase the rebound damping. The left and right shock absorbers should have the same settings.

400347-10

Adjusting rear shock absorber compression damping

ದ Remove the vehicle from the work stand. ( P. 31)

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Warning

Danger of accidentsಘDo not make any radical changes to the adjustment of the shock absorbers.

ದ Only make adjustments within the recommended range.

Info

The compression damping setting has an impact on the compression of the shock absorber.

ದ Turn the adjusting wheelb clockwise until it stops.

100080-10

MAINTENANCE ON CHASSIS AND ENGINE 35

ದ Turn back counterclockwise the number of clicks corresponding to the shock

absorber type. Specification

Compression damping

Standard 15bclicks Maximum deviation from standard

value

Tip

Experience has shown that settings outside of this range are detrimental to vehicle handling. When changing the chassis settings, always start with the standard setting.

Info

Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

Adjusting rear shock absorber rebound damping

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

෥5… 5bclicks

Warning

Danger of accidentsಘDo not make any radical changes to the adjustment of the shock absorbers.

ದ Only make adjustments within the recommended range.

Info

The rebound damping setting has an impact on the compression of the shock absorber.

ದ Turn the adjusting wheelb to the right until it stops. ದ Turn back to the left the number of clicks corresponding to the shock absorber

type. Specification

Rebound damping

Standard 15bclicks Maximum deviation from standard

value

100081-10

෥5… 5bclicks

Tip

Experience has shown that settings outside of this range are detrimental to vehicle handling. When changing the chassis settings, always start with the standard setting.

Info

Turning to the right increases damping, while turning to the left lessens damping.

MAINTENANCE ON CHASSIS AND ENGINE 36

Adjusting rear shock absorber spring preloadbx

Danger

Danger of accidentsಘThe shock absorber is under high pressure.

ದ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-

tenance on it yourself.

Warning

Danger of accidentsಘDo not make any radical changes to the adjustment of the shock absorbers.

ದ Make adjustments in small steps only.

Info

Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.

Tip

Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

100082-10

ದ

Remove the rear shock absorber.b ದ After removing the shock absorber, clean it thoroughly. ದ Loosen the lock nutb. Hold adjusting ringb while doing so. Suitable toolsb are

available from an authorized KTM workshop.

Hook wrench (83019002000)

x ( P. 37)

Info

Do not loosen the lock nutb at the top of the shock absorber.

ದ Turn adjusting ring until the spring is no longer under tension.

ದ Measure the overall spring length when not under tension.

Info

The spring preloadb is the difference in length between the spring when it is unloaded and when it is installed.

ದ Tighten the spring by turning adjusting ring to measurement .

Specification

Spring preload

Standard 3bmm (0.12bin)

ದ Tighten the lock nut and the adjusting ring.

400363-11

Info

The adjusting ringb is made of plastic. Therefore, do not lock the adjusting ring too tightly to avoid damaging the thread. If you increase the spring preload, you should also slightly increase the rebound damping.

ದ

Install the rear shock absorber.b

x ( P. 37)

MAINTENANCE ON CHASSIS AND ENGINE 37

Removing the rear shock absorberbx

ದ Jack up the vehicle. ( P. 31) ದ Remove the rear fender. ( P. 63)

Note

Danger of damageಘThe chain sliding piece and frame can be damaged from incor-

rect handling.

ದ When removing the rear shock absorber, secure the swingarm with a tension

belt to prevent it from swinging down further.

100078-10

Installing the rear shock absorberbx

ದ Attach the swingarm to the subframe with a tension beltb

 to relieve the shock

absorber. ದ Remove the bottom screw of the shock absorber.

Tip

Press the screw out of the swingarm with a screw driver while moving the tension belt.

ದ Remove the top screwb

absorber out of the vehicle toward the rear.

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the shock absorber in the vehicle with the reservoir on the right. Mount

and tighten the top screwb

Specification

Screw, rear top shock absorber M12 60bNm

ದ Position the shock absorber in the swingarm. Mount and tighten the bottom screw.

Specification

Screw, rear bottom shock absorber M12 70bNm

 of the shock absorber and carefully remove the shock

.

(44.3blbfbft)

(51.6blbfbft)

Toe, checkingbx

ದ Remove the tension belt. ದ Install the rear fender. ( P. 64) ದ Remove the vehicle from the work stand. ( P. 31)

100079-10

ದ Park the vehicle on a horizontal surface. ದ Check the tire condition. ( P. 57) ದ Checking the tire air pressure. ( P. 57) ದ Check the chassis parts for damage, play and wear.

MAINTENANCE ON CHASSIS AND ENGINE 38

ದ Load the vehicle with the specified weight.

Specification

Standard rider weight 70… 80bkg (154… 176blb.)

ದ Turn the steering to the straight-ahead position and fix it.

Steering fixing for straight-ahead position (83019015000)

500228-01

ದ Measure distancesb andb.

» If distancesb

ದ

Adjust the toe.b

ದ Measure distancesb

Specification

Toe

Front 0bmm (0bin)

 andb are not equal:

x ( P. 38)

 andb.

Info

The toe is the difference in length between distancesb andb by which the wheels are spaced at the front or rear when driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange.

» If the toe does not meet specifications:

ದ

Adjust the toe.b

Adjusting the toebx

x ( P. 38)

400333-10

ದ Park the vehicle on a horizontal surface. ದ Check the tire condition. ( P. 57) ದ Checking the tire air pressure. ( P. 57) ದ Check the chassis parts for damage, play and wear. Replace damaged or worn

parts.

MAINTENANCE ON CHASSIS AND ENGINE 39

ದ Load the vehicle with the specified weight.

Specification

Standard rider weight 70… 80bkg (154… 176blb.)

ದ Turn the steering to the straight-ahead position and fix it.

Steering fixing for straight-ahead position (83019015000)

500228-01

400333-11

ದ Loosen nutsb andb. ದ Adjust the distancesb ದ Adjust the distancesb

Specification

Toe

Front 0bmm (0bin)

 andb to the same value by rotating the tie rodsb.  andb to the specified value by evenly rotating the tie rodsb.

Info

ದ Tighten nutsb

Specification

Lock nut, tie rod, outside M12x1,25 20bNm (14.8blbfbft) Lock nut, tie rod, inside M12LHx1,25 20bNm (14.8blbfbft)

 andb.

Info

The tie rodsb must still be freely movable.

MAINTENANCE ON CHASSIS AND ENGINE 40

Checking/adjusting camberbx

Info

The left and right camber should have the same settings. The operations are the same on the left and right.

ದ Jack up the vehicle. ( P. 31) ದ Loosen nutsb.

600128-10

ದ Remove screwsb with bushingsb. ದ Check parts for damage and wear. Replace damaged or worn parts.

600126-10

600127-10

600126-10

ದ Insert the toolb in the heim joint and clip onto the A-arm.

Camber gauge (83019014000)

ದ Check the camber on both heim joints.

» If the markingb

ದ Turn the toolb

 is not aligned with the top edge of the A-arm:

 with the heim joint in steps of 180° until the marking is in

line with the top edge of the A-arm.

ದ Remove the toolb

.

ದ Position the A-arm with the bushingsb. Mount and tighten screwsb.

Specification

Screw, A-arm top M10x52 45bNm

(33.2blbfbft)

ದ Align the heim joint at right angles to the screwsb and tighten the nutb.

Specification

Nut, A-arm top M12x1,25 30bNm

(22.1blbfbft)

600128-10

Info

All four heim joints must be checked and adjusted if necessary.

ದ Remove the vehicle from the work stand. ( P. 31)

MAINTENANCE ON CHASSIS AND ENGINE 41

Fork offset

The fork offset has an impact on the handling of the vehicle. The fork offset can optionally be adjusted. Fork offset is defined as the slanted position of the swivel axis in the direction of the longitudinal axis of the vehicle in relation to a vertical line to the driving surface. When both sleeves are installed in front of the A-arms, the fork offset increases. This enhances driving stability on fast raceways. When both bushings are installed behind the A-arms, the fork offset decreases. This improves handling in bends. Upon delivery one bushing is installed in front of the A-arm and one behind it.

Adjusting the fork offsetbx

Info

The left and right fork offset should have the same settings. The operations are the same on the left and right.

ದ Jack up the vehicle. ( P. 31) ದ Remove screwsb with bushingsb. ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Place the A-arm with the bushingsb

screwsb

.

Specification

Screw, A-arm top M10x52 45bNm

 in the desired position. Mount and tighten

(33.2blbfbft)

600126-11

Toe width of rear axle

The toe widthb can be adjusted by installed the spacing sleeve in various ways.

ದ Remove the vehicle from the work stand. ( P. 31)

Difference between nar-

76bmm (2.99bin)

row/wide toe

100101-10

Adjusting the toe width of rear axlebx

Warning

Danger of accidentsಘChanges to the chassis can strongly influence how the vehicle handles.

ದ After making changes, always ride slowly to allow yourself to respond to vehicle handling.

ದ Engage 1st gear. ದ Loosen nutsb of the wheel hubs on both sides. ದ Jack up the vehicle. ( P. 31) ದ Remove the nutsb ದ Check parts for damage and wear. Replace damaged or worn parts.

 on both sides and take all parts off of the rear axle.

100102-10

Info

The left and right toe width should have the same settings.

MAINTENANCE ON CHASSIS AND ENGINE 42

Setting a narrow toe width:

22 0033

0022

0033

100103-10

100104-10

ದ Mount the wheel hubb

ದ Mount the conical ringb

ದ Mount the spacing sleeveb

ದ Mount the washer and the new self-locking nut.

Setting a wide toe width:

ದ Mount the spacing sleeveb

ದ Mount the conical ringb

ದ Mount the wheel hubb

ದ Mount the washer and the new self-locking nut.

ದ Remove the vehicle from the work stand. ( P. 31) ದ Tighten nutsb

Specification

Nut, rear wheel hub M18x1,5 130bNm

 on both sides.

.

 with the cone facing outward.

 with the cone facing inward.

 with the cone facing outward.

.

(95.9blbfbft)

Handlebar position

100102-10

ದ Shift gear to neutral.

The handlebar position can be adjusted 4-fold by turning the handlebar supportb and the handlebar supportb The holes on the handlebar support are placed at a distance ofb

Distanceb

The holes on the handlebar bridge are placed at a distance ofb

Distanceb

 between holes 3.5bmm (0.138bin)

 between holes 7.5bmm (0.295bin)

.

 from the center.

 from the center.

100098-10

MAINTENANCE ON CHASSIS AND ENGINE 43

Adjusting handlebar positionbx

ದ Pull the instrument support off the handlebar and swing it to the side.

Info

Protect the vehicle and its attachments from damage by covering them. Do not bend the cables and lines.

100100-10

ದ Remove the four screwsb. Remove the handlebar clampsb, swing the handlebar

forward and set it down.

ದ Remove the nutsb ದ Remove screwsb ದ Remove screwsb ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Place the handlebar bridgeb

Mount and tighten screwb

Specification

Screw, steering bridge M8 20bNm

 and remove the handlebar supportb with the screws.  andb. . Remove the handlebar bridgeb.

 onto the steering column in the desired position.

.

(14.8blbfbft)

100099-10

ದ Mount and tighten screwb

Specification

Screw, steering column, top M20x1,5 25bNm

ದ Mount and tighten screwsb

Specification

Screw, steering bridge M8 20bNm

ದ Mount the handlebar supportb

new self-locking nutsb Specification

Nut, handlebar support M10 45bNm

ದ Position the handlebar and fix it with the handlebar clampsb

screwsb

.

Specification

Screw, handlebar clamp M8 20bNm

.

.

 in the desired position using the screws. Mount

 and tighten.

Info

Make sure cables and wiring are positioned correctly.

ದ Position the instrument support on the handlebar.

(18.4blbfbft)

(14.8blbfbft)

(33.2blbfbft)

. Mount and tighten

(14.8blbfbft)

Checking play in gas Bowden cable

600142-10

ದ Move the handlebar to the straight-ahead position. Move the throttle lever back and

forth slightly to ascertain the play in the gas Bowden cableb Specification

Play in gas Bowden cable 3… 5bmm (0.12… 0.2bin)

» If the gas Bowden cable play does not meet specifications:

ದ Adjust the play in the gas Bowden cable. ( P. 44)

.

MAINTENANCE ON CHASSIS AND ENGINE 44

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

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

steering range.

The idle speed must not change.

» If the idle speed changes:

ದ Adjust the play in the gas Bowden cable. ( P. 44)

Adjusting play in gas Bowden cable

ದ Check gas Bowden cable route. ದ Move the handlebar to the straight-ahead position. ದ Loosen the nutb

cableb

.

Specification

Play in gas Bowden cable 3… 5bmm (0.12… 0.2bin)

 and use the screwb to adjust the play in the gas Bowden

ದ Tighten nutb

600142-11

Checking the play in the Bowden cable using the reverse gear release lever

.

ದ Move the handlebar to the straight-ahead position. Move the reverse gear release

lever back and forth slightly to ascertain the play in the Bowden cableb Specification

Play in the Bowden cable on the reverse gear release lever

» If the Bowden cable play on the reverse gear release lever does not agree with

the specifications: ದ Adjust the play in the Bowden cable using the reverse gear release lever.

600141-10

Adjusting the play in the Bowden cable using the reverse gear release lever

( P. 44)

ದ Check that the Bowden cable is correctly laid from the reverse gear release lever. ದ Move the handlebar to the straight-ahead position. ದ Release the nutb

 and using the screwb, adjust the play of the Bowden cableb

on the reverse gear release lever. Specification

Play in the Bowden cable on the reverse gear release lever

.

10bmm (0.39bin)

600141-11

ದ Tighten nutb

.

MAINTENANCE ON CHASSIS AND ENGINE 45

Checking chain dirt

ದ Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

ದ Clean the chain. ( P. 45)

Cleaning the chain

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

The service life of the chain depends largely on its maintenance.

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

Chain cleaner ( P. 97) Offroad chain spray ( P. 97)

Checking the chain tension

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ 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 eccentric element) 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 wheels or damage the engine. Check for correct chain tension and adjust if necessary.

ದ Park the vehicle on a horizontal surface and shift gears to neutral. ದ Push the upper chain section at the end of the chain sliding component upwards to

measure the chain tensionb

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 140… 145bmm (5.51… 5.71bin)

100093-10

Checking rear sprocket / engine sprocket for wear

» If the chain tension does not meet specifications:

ದ Adjust the chain tension. ( P. 46)

ದ Check rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

ದ Replace the rear sprocket / engine sprocket.

400227-01

Info

When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction). The engine sprocket, rear sprocket and chain should always be replaced together.

ದ Check that the chain guides are tight.

MAINTENANCE ON CHASSIS AND ENGINE 46

Checking chain wear

ದ Park the vehicle on a horizontal surface and shift gears to neutral. ದ Pull the lower chain section with the specified weightb.

Specification

Chain-wear measuring weight 10… 15bkg (22… 33blb.)

ದ Measure the distanceb

 of 18 chain links in the upper chain section.

Info

Chain wear is not always even, so you should repeat this measurement at different chain positions.

Maximum distanceb

 at the longest

272bmm (10.71bin)

chain section

» If the distanceb

 is greater than the specified measurement:

ದ Replace the chain.

Info

When you replace the chain, you should also replace the rear sprocket and engine sprocket. New chains wear out faster on old, worn sprockets.

100096-10

Adjusting chain tension

Warning

Danger of accidentsಘDanger caused by incorrect chain tension.

ದ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

100093-10

ದ Park the vehicle on a horizontal surface and shift gears to neutral. ದ Push the upper chain section at the end of the chain sliding component upwards to

measure the chain tensionb

Info

The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

MAINTENANCE ON CHASSIS AND ENGINE 47

ದ Loosen the screwsb by four turns. Alternativeb1

ದ Insert the toolb

element.

Alternativeb2

ದ Use a special tool on the rear wheel eccentric.

Hook wrench (83019011000)

 from the tool set into the holeb of the rear wheel eccentric

ದ To adjust the chain tensionb

100094-10

ದ Fully tighten screwsb

ದ Remove toolb

Greasing the rear wheel eccentric element

ದ Use a grease gun to fill the rear wheel eccentric element via the grease nippleb

$, use the special tool to slowly turn at the rear wheel

to rotate the rear wheel eccentric element forward or backward. Specification

Chain tension 140… 145bmm (5.51… 5.71bin)

Info

Rotating the rear wheel eccentric element forward increases chain tension. Rotating the rear wheel eccentric element backward reduces chain tension. The rear wheel eccentric element should always be positioned such that the grease nippleb

 is visible. This ensures that the vehicle has the greatest

ground clearance.

.

Specification

Screw, rear wheel eccentric element M8 20bNm

(14.8blbfbft)

.

until grease emerges from the left shaft seal ringb.

Long-life grease ( P. 95)

100092-10

Checking brake discs

Warning

Danger of accidentsಘReduced braking due to worn brake discs.

ದ Worn brake discs should be replaced immediately in an authorized KTM workshop.

ದ Check the thickness of the front and rear brake discs at several places on the disc

to see if it conforms to measurementb

Info

Wear reduces the thickness of the brake disc around the area used by the brake linings.

Wear limit of brake discs

Front 3.5bmm (0.138bin)

400362-10

Rear 3.5bmm (0.138bin)

» If the brake disc thickness is less than the specified value.

ದ Change the brake disc.

.

MAINTENANCE ON CHASSIS AND ENGINE 48

Checking free play of hand brake lever

Warning

Danger of accidentsಘBrake system failure.

ದ If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake

can fail due to overheating. Adjust free travel on hand brake lever according to specifications.

ದ Push the hand brake lever forwards and check free play.b.

Free play of hand brake lever ุb3bmm (ุb0.12bin)

» If the free travel does not meet the specifications:

ದ Adjust the basic position of the handbrake lever. ( P. 48)

100088-10

Adjusting basic position of handbrake lever

ದ Adjust the basic setting of the handbrake lever to your hand size by turning adjust-

ing screwb

.

Info

Pull the brake lever forward and turn the adjusting screw. Turn the adjusting screw clockwise to increase the distance between the handbrake lever and the handlebar. Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar.

100052-10

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!

ದ Check the free play of the hand brake lever. ( P. 48)

Checking front brake fluid level

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake

linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

ದ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ದ Check the brake fluid level in the viewerb

» When the brake fluid level has dropped below the bottom of the viewer:

ದ

Top up the brake fluid of the front brake.bx ( P. 49)

.

100035-10

MAINTENANCE ON CHASSIS AND ENGINE 49

Topping up the front brake fluidbx

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake

linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Never user DOTb5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for DOTb5 brake fluid. Avoid contact between brake fluid and painted parts. Brake fluid attacks paint! Use only clean brake fluid from a sealed container!

ದ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ದ Remove screwsb ದ Remove coverb ದ Top up brake fluid to levelb

Specification

Measurement ofb

Brake fluid DOTb4b/bDOTb5.1 ( P. 95)

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the cover with the membrane. Mount and tighten screws.

.

 with membraneb.

.

 5bmm (0.2bin)

Info

Clean up overflowed or spilt brake fluid immediately with water.

100036-10

Checking the front brake linings

Warning

Danger of accidentsಘReduced braking due to worn brake linings.

ದ Worn brake linings should be replaced immediately in an authorized KTM workshop.

ದ Remove the wheel/wheels. ( P. 56)

MAINTENANCE ON CHASSIS AND ENGINE 50

ದ Check the brake linings of both front brake calipers for minimum thicknessb.

100074-10

Removing front brake liningsbx

Minimum thicknessb

» If the minimum thickness is less than specified:

ದ

Change the front brake linings.b

ದ Mount the wheel/wheels. ( P. 56)

 ุb1bmm (ุb0.04bin)

Warning

Danger of accidentsಘImproper brake maintenance and repair.

ದ Always have your brake system maintained and repaired in an authorized KTM workshop.

Info

The operations are the same on the left and right.

ದ Remove the wheel/wheels. ( P. 56) ದ Pull the hand brake lever and release it again.

Locking pawl moves into its basic position, parking brake is deactivated.

ದ Push the brake piston back to release pressure on the brake linings. ದ Remove the locking split pinsb ದ Clean the brake caliper and bolts.

, withdraw the bolt, and take out the brake pads.

x ( P. 51)

100071-10

Mounting front brake liningsbx

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

ದ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidentsಘReduced braking due to use of non-approved brake linings.

ದ 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.

Info

The operations are the same on the left and right.

ದ Check the brake discs. ( P. 47)

MAINTENANCE ON CHASSIS AND ENGINE 51

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Insert the inside brake lining into the brake caliper and fix with boltb ದ Insert the external brake lining into the brake caliper and slide the bolts in all the

way.

100072-10

ದ Mount the locking split pinsb. ದ Operate the hand brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

ದ Mount the wheel/wheels. ( P. 56)

100073-10

Changing the front brake liningsbx

.

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

ದ

Remove the front brake linings.b ದ Move the brake fluid reservoir mounted on the handlebar to a horizontal position. ದ Remove screwsb ದ Remove coverb ದ Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

ದ

Mount the front brake linings.b ದ Top up brake fluid to levelb

Specification

Measurement ofb

.

 with membraneb.

 5bmm (0.2bin)

x ( P. 50)

.

100036-10

Brake fluid DOTb4b/bDOTb5.1 ( P. 95)

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the cover with the membrane. Mount and tighten screws.

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE ON CHASSIS AND ENGINE 52

Checking free play of foot brake lever

Warning

Danger of accidentsಘBrake system failure.

ದ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

ದ Disconnect springb. ದ Move the foot brake lever backwards and forwards between the end stop and the

foot brake cylinder piston bracket and check free playb

Specification

Free play at foot brake lever 3… 5bmm (0.12… 0.2bin)

» If the free travel does not meet specifications:

ದ

Adjust the basic position of the footbrake lever.b

100085-10

Adjusting basic position of footbrake leverbx

ದ Reconnect springb

.

Warning

Danger of accidentsಘBrake system failure.

ದ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake

can fail due to overheating. Adjust free travel on foot brake pedal according to specifications.

.

x ( P. 52)

100061-10

Checking rear brake fluid level

ದ Disconnect springb. ದ Loosen nutb ದ To adjust the basic position of the footbrake lever individually, loosen nutb

turn screwb

 and with push rodb, turn it back until you have maximum free play.

 accordingly.

Info

The range of adjustment is limited.

ದ Turn push rodb

basic position of the footbrake lever.

Specification

Free play at foot brake lever 3… 5bmm (0.12… 0.2bin)

ದ Hold screwb

Specification

Remaining nuts, chassis M8 30bNm

ದ Hold push rodb

Specification

Remaining nuts, chassis M6 15bNm

ದ Reconnect springb

 accordingly until you have free playb. If necessary, adjust the

 and tighten nutb.

(22.1blbfbft)

 and tighten nutb.

(11.1blbfbft)

.

 and

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake

linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

MAINTENANCE ON CHASSIS AND ENGINE 53

ದ Park the vehicle on a horizontal surface. ದ Check the brake fluid level in the viewerb

» When the brake fluid level has dropped to the bottom of the viewerb

ದ

Top up the brake fluid of the rear brake.b

100040-10

Topping up brake fluid of front brakebx

Warning

Danger of accidentsಘBrake system failure.

ದ If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake

linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

.

:

x ( P. 53)

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

ದ Remove screwb with membraneb.

100049-10

ದ Top up the brake fluid to levelb.

100050-10

Brake fluid DOTb4b/bDOTb5.1 ( P. 95)

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Refit screwb

 with membraneb.

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE ON CHASSIS AND ENGINE 54

Checking rear brake linings

Warning

Danger of accidentsಘReduced braking due to worn brake linings.

ದ Worn brake linings should be replaced immediately in an authorized KTM workshop.

ದ Check the brake linings for minimum thicknessb.

100038-10

Removing rear brake liningsbx

Minimum thicknessb

» If the minimum thickness is less than specified:

ದ

Change the rear brake linings.b

 ุb1bmm (ุb0.04bin)

Warning

Danger of accidentsಘImproper brake maintenance and repair.

ದ Always have your brake system maintained and repaired in an authorized KTM workshop.

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

brake piston.

x ( P. 55)

100063-10

100064-10

100066-10

ದ Loosen the screwb while holding the hexagonal headb of the bearing bolt.

Unscrew the screw by approx. 10 turns and use the screw to press the bearing bolt

out of the brake caliper. Remove screw.

Note

Danger of damageಘKinking of brake line.

ದ Position and handle the brake line without straining it. The brake line must be

replaced if it is kinked.

ದ Swing the brake caliper up, unhook it from the brake caliper supportb

down.

ದ Remove the brake liningsb ದ Clean brake caliper and brake caliper support.

.

 and set it

MAINTENANCE ON CHASSIS AND ENGINE 55

Mounting rear brake liningsbx

Warning

Danger of accidentsಘReduced braking due to oil or grease on the brake discs.

ದ Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.

Warning

Danger of accidentsಘReduced braking due to use of non-approved brake linings.

ದ Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc-

ದ Check the brake discs. ( P. 47) ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Check that the sliding plateb

insert the brake linings.

Info

Make sure that the decoupling plateb is mounted on the piston side of the brake pad.

 is seated correctly in the brake caliper support and

100067-10

ದ Grease the bearing boltb and insert the brake caliper with the bearing bolt into

the brake caliper supportb

100068-10

.

ದ Swing the brake caliper downwards. Mount and tighten screw .

Specification

Screw, rear brake caliper M6 10bNm

ದ Operate the foot brake lever repeatedly until the brake linings lie on the brake disc

and there is a tight spot.

100069-10

Changing rear brake liningsbx

Warning

Skin irritationsಘBrake fluid can cause skin irritation on contact.

ದ Avoid contact with skin and eyes, and keep out of the reach of children. ದ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

(7.4blbfbft)

Loctite

243™

Warning

Danger of accidentsಘReduced braking due to old brake fluid.

ದ Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

MAINTENANCE ON CHASSIS AND ENGINE 56

Info

ದ

Remove the rear brake linings.b ದ Remove screwb ದ Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

ದ

Mount the rear brake linings.b ದ Top up the brake fluid to levelb

Brake fluid DOTb4b/bDOTb5.1 ( P. 95)

 with membraneb.

x ( P. 54)

x ( P. 55)

.

100070-10

Removing wheel/wheels

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Refit screwb

Info

Proceed in the same way on the other wheels if necessary.

ದ Pull the hand brake lever, push the locking pawlb

ದ Loosen the wheel nutsb. ದ Jack up the vehicle. ( P. 31) ದ Remove the wheel nuts. Remove the wheel.

700001-01

 with membraneb.

Info

Clean up overflowed or spilt brake fluid immediately with water.

 down and release the hand

brake lever. (Figureb100006-10b P. 14)

Info

Carefully remove the wheel, making sure it does not become jammed with the threads of the screws.

Mounting wheel/wheels

Note

Material damageಘDamage and destruction of components from incorrect positioning and mounting.

ದ Do not swap the wheels; the tire valves must always be on the outside when the wheels are positioned and mounted.

Info

Proceed in the same way on the other wheels if necessary.

ದ Position the wheel on the hub.

Info

Carefully position the wheel on the hub, being careful not to damage the threads of the screws.

ದ Mount the wheel nuts but do not tighten. ದ Remove the vehicle from the work stand. ( P. 31)

700002-01

ದ Pull the hand brake lever, push the locking pawlb

brake lever. (Figureb100006-10b P. 14)

 down and release the hand

MAINTENANCE ON CHASSIS AND ENGINE 57

ದ Tighten the wheel nuts crosswise.

Specification

Wheel nut M10x1,25 45bNm

(33.2blbfbft)

Tire condition checking

Info

Fit only tires approved 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 vehicle. The front and rear wheels must be fitted with tires with similar profiles. Worn tires have a negative effect on riding behavior, especially on wet surfaces.

ದ Examine the tires for cuts, foreign bodies and other damage. ದ Check the depth of the tread.

Minimum tread depth ุb2bmm (ุb0.08bin)

» If the minimum tread depth is insufficient:

ದ Change the tire.

Checking 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. The tire pressure must be checked and corrected on all wheels.

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

Tire air pressure off road 0.3bbar (4bpsi)

» If the tire pressure does not meet specifications:

ದ Correct tire pressure.

ದ Mount dust cap.

100044-10

Removing the battery

Warning

Risk of injuryಘBattery acid and battery gases cause serious cauterization.

ದ Keep batteries out of the reach of children. ದ Wear suitable protective clothing and goggles. ದ Avoid contact with battery acid and battery gases. ದ Keep the battery away from sparks or open fire. Charge only in well ventilated rooms. ದ In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least

15 minutes and contact a doctor.

ದ Switch off all power-consuming components and switch off the engine. ದ Remove the rear fender. ( P. 63)

MAINTENANCE ON CHASSIS AND ENGINE 58

ದ Disconnect the negative (minus) cableb of the battery.

Installing the battery

200150-10

ದ Pull back the plus pole cover and disconnect the positive (plus) cableb

tery. ದ Loosen the rubber bandb

.

ದ Remove the battery.

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Place the battery in the battery holder.

4Ah batteryb(YTX5L-BS) ( P. 86)

 of the bat-

ದ Reconnect the rubber bandb ದ Attach the plus cable and replace the plus pole coverb ದ Connect the negative (minus) cableb

.

.

 of the battery.

ದ Install the rear fender. ( P. 64)

200150-11

Recharging the batterybx

Warning

Risk of injuryಘBattery acid and battery gases cause serious cauterization.

15 minutes and contact a doctor.

Warning

Environmental hazardಘComponents and battery acid are a danger to the environment.

ದ Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery. Fast recharging with a high charge current shortens the battery's service life. If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes. The battery capacity is then reduced. If the battery is discharged from starting, it must be recharged immediately. If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed. The battery is maintenance-free, i.e., the acid level does not have to be checked.

ದ Switch off all power-consuming components and switch off the engine. ದ Remove the rear fender. ( P. 63) ದ Disconnect the minus (negative) cable of the battery to avoid damage to the vehi-

cle's electronics.

MAINTENANCE ON CHASSIS AND ENGINE 59

ದ Connect the battery charger to the battery. Switch on the battery charger.

Battery chargerb(58429074000)

You can also use the battery charger to test rest potential and start potential of the

battery, and to test the generator. With this device, you cannot overcharge the bat-

tery.

Info

Never remove the lidb.

changing main fuse

100087-10

Charge the battery according to the instructionsb

ದ Switch off the charger after charging. Disconnect the battery.

Specification

The charge current, charge voltage and charge time must not be exceeded. Charge the battery regularly when the

3bmonths

vehicle is not in use.

ದ Install the rear fender. ( P. 64)

ದ Switch off all power-consuming components and switch off the engine. ದ The main fuseb is located in the starter relayb in front of the battery. ದ Remove protection coversb

.

ದ Remove the faulty main fuse.

 on the battery casing.

Info

You can recognize a blown fuse by its broken filamentb.

Warning

Fire hazardಘThe electrical system can be overloaded by the use of incorrect

fuses.

ದ Use only fuses with the prescribed amperage. Never by-pass or repair

fuses.

ದ Insert a new fuse.

Fuseb(58011109120)

Info

If the new fuse burns out, contact an authorized KTM workshop.

100091-10

ದ Replace the protection covers.

Changing the fuses of individual power-consuming components

ದ Remove the front cover. ( P. 62) ದ Switch off all power-consuming components and switch off the engine.

Tip

The spare fuseb should always be present in the starter relay so that it is available if needed.

MAINTENANCE ON CHASSIS AND ENGINE 60

ದ Open the coverb of the fuse boxb.

Info

The designation of the fuses is located on the inside cover of the fuse boxb

.

ದ Remove the faulty fuse.

Specification

Fuseb1 - 10A - ignition, CDI controller, indicator lamps ON, N, R Fuseb2 - 15A - high beam, low beam, parking light, tail light, brake light, high

beam indicator lamp Fuseb3 - 10A - radiator fan Fuseb4 - 10A - for auxiliary devices (permanent positive) Fuseb5 - 10A - for auxiliary devices (plus switched on with ignition switch) Fusebres. - 10A/15A - replacement fuses

Info

You can recognize a blown fuse by its broken filamentb.

100090-10

Warning

Fire hazardಘThe electrical system can be overloaded by the use of incorrect

fuses.

ದ Use only fuses with the prescribed amperage. Never by-pass or repair

fuses.

Ignition curve plug connection

ದ Insert new fuse of suitable specification.

Fuseb(58011109110) Fuseb(58011109115)

Info

If the new fuse burns out, contact an authorized KTM workshop.

Tip

The spare fuses should always be present in the fuse box so that thez are available if needed.

ದ Close the cover of the fuse box. ದ Install the front cover. ( P. 62)

The plug-in connectorb is located under the trim at the front on the frame tube.

Possible states

• Soft ದbThe plug-in connector is connected for better driveability.

• Performance ದbThe plug-in connector is disconnected for better performance.

100105-10

MAINTENANCE ON CHASSIS AND ENGINE 61

Changing ignition curve

ದ Remove the front trim. ( P. 63)

Changing the ignition curve from Performance to Soft.

ದ Connect the plug-in connectorb

Soft ದbThe plug-in connector is connected for better driveability. ( P. 60)

Change the ignition curve from Performance to Soft.

ದ Disconnect the plug-in connectorb

Performance ದbThe plug-in connector is disconnected for better performance. ( P. 60)

ದ Install the front trim. ( P. 63)

Removing the seat

. (Figureb100105-10b P. 60)

ದ Pull the release hookb back. Lift up the seat at the rear, pull it back and then

remove from above.

100041-10

Mounting the seat

100046-10

100043-10

Removing the radiator spoiler

Info

The operations are the same on the left and right.

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Hook the slotb

of the seat and slide the tabb

 on the seat into the collar sleeveb of the fuel tank, lower the rear

 under the fuel tankb.

ದ Push down the rear of the seat until the release hookb engages. ದ Make sure that the seat is correctly locked in.

100056-10

ದ Remove the seat ( P. 61) ದ Remove the screwsb on the fuel tank.

MAINTENANCE ON CHASSIS AND ENGINE 62

ದ Remove the screwsb on the radiator. ದ Unhinge and remove the radiator spoiler and the fuel tank.

100057-10

Installing the radiator spoiler

Info

The operations are the same on the left and right.

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Hook the catchb

position it on the radiator.

 of the radiator spoiler into the holderb of the fuel tank and

Removing the front cover

100058-10

100059-10

100053-10

ದ Fit and tighten screwsb on the radiator.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Fit and tighten screwsb

 on the fuel tank.

Specification

Screw on fuel tank M6 6bNm (4.4blbfbft)

ದ Mount the seat ( P. 61)

ದ Remove screwb. ದ Slide the front cover up and remove it.

Installing the front cover

100055-10

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the front cover in the slotsb

 on both sides of the front trim.

ದ Mount and tighten screw .

MAINTENANCE ON CHASSIS AND ENGINE 63

Removing the front trim

ದ Remove the front cover. ( P. 62) ದ Remove screwsb. ದ Raise the front trim and disconnect the plug-in connectors from the head light and

the emergency OFF switch with the rip cord.

ದ Remove the front trim.

Installing the front trim

100075-10

100076-10

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Connect the plug-in connectors of the head light and the emergency OFF switch

with the rip cord and position the front trim.

ದ Mount all screws. ದ Fully tighten screwsb

.

Specification

Screw on fuel tank M6 6bNm (4.4blbfbft)

ದ Fully tighten screwsb

.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Install the front cover. ( P. 62)

Removing the rear fender

ದ Remove the seat ( P. 61)

MAINTENANCE ON CHASSIS AND ENGINE 64

ದ Remove screwsb. Remove the collar sleeves.

200149-10

ದ Raise the rear of the air filter box lidb. At the same time, use your other hand to

press on the carburetor connection boot to kink it at that location. This prevents the

carburetor connection boot from disconnecting from the carburetor. ದ Raise the fenderb

 at the rear and remove it.

Installing the rear fender

200148-10

200148-11

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Raise the rear of the air filter box lidb

. At the same time, use your other hand to

press on the carburetor connection boot to kink it at that location. This prevents the

carburetor connection boot from disconnecting from the carburetor. ದ Position the front fenderb

.

ದ Fix the air filter box lid in the fender.

ದ Fit and tighten screwsb with collar sleeves.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

ದ Mount the seat ( P. 61)

200149-11

MAINTENANCE ON CHASSIS AND ENGINE 65

Removing the engine guard

ದ Remove screwsb andb. Remove the engine guard.

600133-10

Installing the engine guard

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the engine guard on the frame bearer. Mount and tighten screwsb

andb.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft) Remaining screws, chassis M8 25bNm

(18.4blbfbft)



600133-10

Removing the air filterbx

Note

Engine failureಘUnfiltered intake air has a negative effect on the service life of the engine.

ದ Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

ದ Remove the seat ( P. 61) ದ Raise the rear of the air filter box lidb. At the same time, use your other hand to

press on the carburetor connection bootb

the carburetor connection boot from disconnecting from the carburetor. ದ Unhook the air filter holderb

 and swing it to the side. Remove the air filterb with

the air filter support. ದ Remove the air filter from the air filter support.

 to kink it at that location. This prevents

100077-10

MAINTENANCE ON CHASSIS AND ENGINE 66

Installing the air filterbx

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Mount the clean air filter onto the air filter support. ದ Put in both parts together, position them and fix them with the air filter supportb

Info

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

ದ Mount the air filter box lid.

100086-10

Cleaning air filterbx

ದ Mount the seat ( P. 61)

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

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

.

ದ

Remove the air filter.b

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

Air filter cleaner ( P. 97)

x ( P. 65)

Info

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

ದ Oil the dry air filter with a high/quality filter oil.

Oil for foam air filter ( P. 97)

ದ Clean the air filter box. ದ Check carburetor connection boot for damage and tightness.

ದ

Install the air filterb

Adjusting basic position of clutch lever

x ( P. 66)

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

screwb

.

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.

100039-10

Turn the adjusting screw by hand only, and do not apply any force. Do not make any adjustments while riding!

Checking fluid level of hydraulic clutch

Info

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

MAINTENANCE ON CHASSIS AND ENGINE 67

ದ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. ದ Remove screwsb ದ Remove coverb ದ Check the fluid level.

Fluid level under top level of container. 4bmm (0.16bin)

» If the level of the cooling liquid does not meet specifications:

ದ Correct the fluid level of the hydraulic clutch.

100037-10

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the cover with the membrane. Mount and tighten screws.

Cooling system

The water pumpb in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . The specified coolant temperature is therefore permissible without danger of function problems.

120b°C (248b°F)

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

600130-10

.

 with membraneb.

Hydraulic fluid (15) ( P. 95)

Radiator fan

The radiator fanb is located on the radiator under the fuel tank.

Working range within which radiator fan is switched on and off.

Thermoswitch

Switch-off temperature 80b°C (176b°F) Switch-on temperature 85b°C (185b°F)

600117-10

Checking antifreeze and coolant level

Warning

Danger of scaldingಘThe coolant gets very hot and is under high pressure when the vehicle is driven.

ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

contact 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 coolants out of the reach of children.

600123-12

ದ Remove the front trim. ( P. 63) ದ Remove the radiator capb. ದ Check antifreeze of coolant.

෥25… ෥45b°C (෥13… ෥49b°F)

» If the antifreeze of the cooling liquid does not meet specifications:

ದ Correct antifreeze of coolant.

ದ Completely fill the radiator with coolant and close theb

 radiator cap.

MAINTENANCE ON CHASSIS AND ENGINE 68

ದ Open the compensating tank coverb. ದ Check antifreeze of coolant.

෥25… ෥45b°C (෥13… ෥49b°F)

» If the antifreeze of the cooling liquid does not meet specifications:

ದ Correct antifreeze of coolant.

600125-12

ದ The coolant levelb

» If the level of the cooling liquid does not meet specifications:

ದ Correct the coolant level.

Alternative 1

Alternative 2

 must be between MIN andbMAX.

Coolant ( P. 95)

Coolant (mixed ready to use) ( P. 95)

ದ Mount the compensating tank coverb

.

ದ Install the front trim. ( P. 63)

Checking the coolant level

Warning

Danger of scaldingಘThe coolant gets very hot and is under high pressure when the vehicle is driven.

ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

Condition

The radiator must be completely full.

ದ The coolant levelb

» If the level of the cooling liquid does not meet specifications:

ದ Open the compensating tank coverb

Alternative 1

 must be between MIN andbMAX.

 and correct the coolant level.

Coolant ( P. 95)

600125-11

Alternative 2

Coolant (mixed ready to use) ( P. 95)

ದ Mount the compensating tank coverb

Draining coolantbx

.

Warning

Danger of scaldingಘThe coolant gets very hot and is under high pressure when the vehicle is driven.

ದ Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and

cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

ದ Remove the front trim. ( P. 63) ದ Place a suitable container under the vehicle.

MAINTENANCE ON CHASSIS AND ENGINE 69

ದ Remove screwb.

600118-10

ದ Remove screwb.

600119-10

ದ Remove the radiator capb. Completely drain the coolant.

600123-11

ದ Open the plug of the compensation tankb. ದ Remove the screwsb ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Position the compensating tankb

ದ Move the ventilation hoseb

600124-10

Filling coolant / bleeding cooling systembx

ದ Mount and tighten the screwsb

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

 and empty the compensating tankb.

. Mount and tighten screwsb.

 up.

 andb with new seal rings.

Warning

Danger of poisoningಘCoolants are poisonous and a health hazard.

ದ Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and

ದ Position the vehicle as shown and secure it against rolling away. The height differ-

enceb

 must be achieved.

Specification

Height differenceb

 50bcm (19.7bin)

00AA

400360-10

ದ Pull the hand brake lever, push the locking pawlb

brake lever. (Figureb100006-10b P. 14)

The front wheels are blocked.

 down and release the hand

MAINTENANCE ON CHASSIS AND ENGINE 70

ದ Fill the coolant into the radiatorb.

Coolant

With compensating tank

Without compensating tank

600120-10

ದ Open the screwb to bleed the cylinder head. Tighten the screwb when coolant

emerges from the opening.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

Info

Ensure that the radiator is always filled with a sufficient amount of coolant.

600121-10

ದ Open the screwb to bleed the radiator. Tighten the screwb when coolant

emerges from the opening.

Specification

Remaining screws, chassis M6 10bNm (7.4blbfbft)

1.50bl (1.59bqt.) Coolant ( P. 95) Coolant (mixed ready to use) ( P. 95)

1.30bl (1.37bqt.) Coolant ( P. 95) Coolant (mixed ready to use) ( P. 95)

Carburetor - idle

600122-10

ದ Completely fill the radiator and close the radiator capb.

600123-10

ದ Top up the compensating tank to levelb. Mount the capb. ದ Install the front trim. ( P. 63) ದ Make a short test ride. ದ Check the coolant level. ( P. 68)

600125-10

The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. An engine with a correctly set idle speed is easier to start than if the idle is set wrongly.

600145-10

Info

The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning. If the idle speed is set significantly higher, the engine does not start. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark.

MAINTENANCE ON CHASSIS AND ENGINE 71

Carburetor - adjusting idlebx

600145-10

The idle speed is adjusted with the adjustment screwb The idle mixture is adjusted with the idle mixture adjustment screwb

ದ Screw in the idle adjusting screwb until it stops and then to the prescribed basic

setting. Specification

Idle mixture adjusting screw

Open 1.0bturn

Adjustment tool for mixture control screw (59029034000)

ದ Run the engine until warm.

Specification

Warm-up time ุb5bmin

ದ Adjust the idle speed with the adjusting screwb

Specification

Choke function deactivated ದbThe choke lever is pushed in to the stop. ( P. 17) Idle speed 1,500… 1,600brpm

.

.

.

Info

If the idle speed is set significantly higher, the engine does not start. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark.

ದ Turn the idle adjusting screwb ದ Note the position and turn the idle adjusting screw slowly counterclockwise until

the idle speed falls.

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

 slowly until the idle speed begins to fall.

Info

If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extremely sporty rider 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.

ದ Adjust the idle speed with the adjusting screwb

Specification

Choke function deactivated ದbThe choke lever is pushed in to the stop. ( P. 17) Idle speed 1,500… 1,600brpm

.

Info

Following extreme air temperature or altitude changes, adjust the idle speed again.

MAINTENANCE ON CHASSIS AND ENGINE 72

Emptying the carburetor float chamberbx

Danger

Fire hazardಘFuel can easily catch fire.

ದ Never fill up 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.

ದ Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.

Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

ದ 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 hazardಘImproper handling of fuel is a danger to the environment.

ದ 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.

ದ Turn the handleb

(Figureb100013-10b P. 16)

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

ದ Undo the screwb

the float chamber.

ದ Tighten screwb

100051-10

Checking engine oil level

Info

The engine oil level can be checked on a cold or hot engine.

ದ Park the vehicle on a horizontal surface.

Condition

The engine is at operating temperature. ದ Check the engine oil level.

 of the fuel tap to the OFF position.

No more fuel flows from the tank to the carburetor.

Info

Water in the float chamber results in malfunctioning.

 (turn it counterclockwise) a few turns and drain the fuel from

.

600131-10

Info

After switching off the engine, wait one minute before checking the level.

The engine oil reaches the middle of the viewerb

» When the engine oil does not reach the middle of the viewerb

ದ Top up the engine oil. ( P. 76)

.

:

MAINTENANCE ON CHASSIS AND ENGINE 73

Condition

Engine is cold. ದ Check the engine oil level.

The engine oil reaches the bottom of the viewerb

» When the engine oil does not reach the bottom of the viewerb

ದ Top up the engine oil. ( P. 76)

600131-11

Changing engine oil and oil filter, cleaning oil screensbx

ದ

Drain engine oil, clean oil screens.b

ದ

Remove the oil filter.b

ದ

Mount the oil filter.b

ದ

Fill up with engine oil.b

Draining engine oil, cleaning oil screensbx

Warning

Danger of scaldingಘEngine oil and gear oil get very hot when the vehicle is driven.

ದ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

x ( P. 74)

x ( P. 75)

x ( P. 73)

.

:

Info

Drain the engine oil only when the engine is warm.

ದ Park the vehicle on a horizontal surface. ದ Remove the engine guard. ( P. 65) ದ Place a suitable container under the engine. ದ Remove the oil drain plugb

600134-10

ದ Remove the plug screw b and small oil screen with both O-rings.

.

600135-10

MAINTENANCE ON CHASSIS AND ENGINE 74

ದ Remove the plug screwb and large oil screen with both O-rings. ದ Completely drain the engine oil.

600136-10

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Thoroughly clean parts and sealing area. ದ Oil the O-ringsb

insert them until the O-ring is seated in the housingb

ದ Fit the plug screwb

Specification

Locking screw, oil sieve, long M20x1,5 15bNm

, mount them on the oil screenb and using a long hexagon key

 with the oil screen.

 with seal ring and tighten it.

(11.1blbfbft)

600144-10

ದ Insert the oil screenb with the O-ringsb into the plug screwb(1 and tighten.

Specification

Locking screw, oil sieve, short

600140-10

M16x1,5 10bNm

(7.4blbfbft)

Engine oil (any)

ದ Fit oil drain plugb(2 with seal ring and tighten it.

Specification

Oil drain plug with magnet M12x1,5 20bNm

(14.8blbfbft)

ದ Install the engine guard. ( P. 65)

600134-11

Removing the oil filterbx

Warning

Danger of scaldingಘEngine oil and gear oil get very hot when the vehicle is driven.

ದ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

ದ Place a suitable container under the engine.

MAINTENANCE ON CHASSIS AND ENGINE 75

ದ Disconnect the ground cableb from the engine. ದ Remove screwsb

600137-10

ದ Pull the oil filtersb andb out of the engine housing.

Circlip pliers reverse (51012011000)

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

600138-10

Mounting oil filterbx

ದ Check parts for damage and wear. Replace damaged or worn parts. ದ Fill the oil filtersb

 andb. Take off the oil filter cover with the O-ring.

 andb with engine oil and place in the oil filter container.

600147-10

ದ Oil the O-rings of the oil filter covers and mount them with the oil filter covers.

Mount and tighten screwsb

 andb.

Specification

Screw, oil filter cover M5 6bNm (4.4blbfbft)

ದ Connect the ground cableb

 on the engine and tighten the screw.

Specification

Screw, starter engine M6 10bNm (7.4blbfbft)

600137-10

Filling up with engine oilbx

Info

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

ದ Remove the screw capb on the clutch cover and fill up with engine oil.

Engine oil 2.00bl (2.11bqt.) External tem-

perature: ุb0b°C (ุb32b°F)

External temperature: <b0b°C (<b32b°F)

Engine oil (SAE 10W/50)

( P. 95)

Engine oil (SAE 5W/40) ( P. 96)

600132-10

ದ Mount and tighten screw capb

.

MAINTENANCE ON CHASSIS AND ENGINE 76

Danger

Danger of poisoningಘExhaust gases are poisonous and can result in uncon-

sciousness and/or death.

ದ When running the engine, always make sure there is sufficient ventila-

tion, and do not start or run the engine in a closed space.

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

Specification

Switch off the engine when the radiator fan switches on.

ದ Check the engine oil level. ( P. 72)

Topping up engine oil

Info

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

ದ Check the engine for leakage. ದ Remove the screw capb

Condition

External temperature: ุb0b°C (ุb32b°F)

 on the clutch cover and fill up with engine oil.

600132-10

Engine oil (SAE 10W/50) ( P. 95)

Condition

External temperature: <b0b°C (<b32b°F)

Engine oil (SAE 5W/40) ( P. 96)

Info

To ensure optimal engine oil performance, it is advisable to not use different engine oils. We recommend making an oil change in this case.

ದ Mount and tighten screw capb

.

TROUBLESHOOTING 77

7528%/(6+227,1*

Faults Possible cause Measure

Engine turns but does not start. Operating error ದ Follow the instructions on starting the

engine. ( P. 20)

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

Fuel feed interrupted ದ Check the tank breather.

Engine flooded ದ Clean and dry spark plug or replace if

Spark plug oily or wet ದ Clean and dry spark plug or replace if

Electrode distance (plug gap) of spark plug too wide

Spark plug connector or spark plug defective

ದ

Empty the carburetor float chamber.b

( P. 72)

ದ Clean fuel tap. ದ Clean carburetor.

necessary.

ದ Adjust plug gap.

Specification Spark plug electrode gap

0.6bmm (0.024bin)

Warning

Risk of injuryಘThe ignition sys-

tem is under high voltage.

ದ Do not touch parts of the

ignition system. Have work on the ignition system carried out in an authorized KTM workshop.

ದ Remove spark plug, connect ignition

cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.

Specification You should see a strong spark on the spark plug.

ದ If there is no spark, change the spark

plug.

ದ If there is still no spark, remove the

spark plug cap from the ignition cable, hold it at the specified distance from the ground contact, and try to start the engine.

Specification 5bmm (0.2bin)

ದ If you now have a spark, replace the

spark plug connector.

ದ If there is no spark, have the ignition

system checked.

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

Water in carburetor or jets blocked ದ Clean carburetor. Idle speed is set too high ದ

Emergency OFF switch with rip cord faulty

Throttle lever activated ದ Do not activate the throttle lever.

Switch for throttle lever faulty ದ Check wiring harness. (visual check)

Throttle valve sensor TPS incorrectly set or faulty

ದ Clean socket connector and treat it

with contact spray.

Carburetor - adjust the idle speed.b

( P. 71)

ದ Check wiring harness. (visual check) ದ Check electrical system.

ದ See instructions on starting.

ದ Check electrical system. ದ Have the throttle valve sensor TPS

checked or adjusted.

TROUBLESHOOTING 78

Faults Possible cause Measure

The engine cannot be cranked (electric starter).

Engine does not speed up. Carburetor running over because float

Engine has no idle. Idling jet blocked ದ Clean carburetor.

Engine stalls or is popping into the carburetor.

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

Engine has too little power. Fuel feed interrupted ದ Check the tank breather.

High oil consumption Engine vent hose bent ದ Route the vent hose without bends or

Parts of the electrical system are not functional.

Battery discharged Battery is not charged by generator ದ Check electrical system.

Operating error ದ Follow the instructions on starting the

engine. ( P. 20)

Battery discharged ದ

Main fuse burned out ದ Change the main fuse. ( P. 59)

Low external temperature ದ Recharge the battery. Establish the

needle dirty or worn Loose carburetor jets ದ Have carburetor checked. Electronic ignition adjustment defective ದ Have ignition system checked.

Adjusting screws on carburetor distorted ದ Have the carburetor adjusted. Spark plug defective ದ Change spark plug. Ignition system defective ದ Have ignition system checked. Lack of fuel ದ Clean and check the fuel system and

Engine takes in bad air ದ Check rubber sleeves and carburetor

Loose contact or oxidized connector ದ Check electrical system.

Radiator fins very dirty ದ Clean radiator fins. Foam formation in cooling system ದ

Bent radiator hose ದ Replace the radiator hose. Thermostat defective ದ Have thermostat removed and checked.

Defect in radiator fan system ದ Have the radiator fan system checked.

Air filter very dirty ದ Exhaust system leaky, deformed or too

little glass fiber yarn filling in main silencer.

Valve clearance too little ದ Have valve clearance adjusted. Electronic ignition adjustment defective ದ Have ignition system checked.

Engine oil level too high ದ Check the engine oil level. ( P. 72) Engine oil too thin (low viscosity) ದ Change the engine oil and oil filter,

Fault in the electrical system ದ Change the fuses of individual power-

Recharge the battery.b

ದ Check the cause of discharging.

ದ Check electrical system.

reason for discharging or have it checked in a KTM workshop.

ದ Have carburetor checked.

carburetor.

for tightness.

ದ Clean socket connector and treat it

with contact spray.

ದ Check the coolant level. ( P. 68)

Drain the coolant.b

ದ

Fill coolant / bleed cooling system.b

( P. 69)

Specification Opening temperature: 70b°C (158b°F)

ದ Clean fuel tap. ದ Clean carburetor.

Clean the air filter.b

ದ Check exhaust system for damage.

replace it if necessary.

clean the oil screens.b

consuming components. ( P. 59)

ದ Check electrical system.

x ( P. 58)

x ( P. 68)

x ( P. 66)

x ( P. 73)

CLEANING 79

&/($1,1*

Cleaning the vehicle



Note

Material damageಘDamage and destruction of components by high-pressure cleaning equipment.

ದ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-

cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazardಘProblem materials cause environmental damage.

ದ Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.

Info

If you clean the vehicle regularly, its value and appearance are maintained over a long period. Avoid direct sunshine on the vehicle during cleaning.

Info

Do not place the vehicle onto the rear frame bracket to clean it since it could fall over. Never raise the vehicle on your own, even if a gear is engaged. Fuel can leak out of the fuel tank.

ದ Before you clean the vehicle, seal the exhaust system to prevent penetration by water. ದ First remove coarse dirt particles with a gentle water spray. ದ Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.

Motorcycle cleaner ( P. 97)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

ದ After rinsing the vehicle with a gentle water spray, allow it to dry thoroughly. ದ Clean and dry the air filter box.

ದ

Empty the carburetor float chamber.b

x ( P. 72)

Warning

Danger of accidentsಘReduced braking due to wet or dirty brakes.

ದ Clean or dry dirty or wet brakes by riding and braking gently.

ದ After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

ದ Push back the protection covers on the handlebar instruments to allow water to evaporate. ದ After the vehicle has cooled off, oil or grease all moving parts and bearings. ದ Clean the chain. ( P. 45) ದ Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( P. 97)

ದ Treat all painted parts with a mild paint polish.

High-luster polish for paint ( P. 97)

ದ To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( P. 97)

STORAGE 80

6725$*(

Storage



Warning

Danger of poisoningಘFuel is poisonous and a health hazard.

ದ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

Info

If you want to store the vehicle for a longer period, take the following actions.

Info

Before storing the vehicle, 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.

ದ Clean the vehicle. ( P. 79)

ದ

Change the engine oil and oil filter, clean the oil screens.b ದ Check the antifreeze and coolant level. ( P. 67) ದ Drain the fuel from the tank into a suitable container.

ದ

Empty the carburetor float chamber.b ದ Checking the tire air pressure. ( P. 57) ದ Remove the battery. ( P. 57)

ದ

Recharge the battery.b

Specification

Storage temperature of battery without direct sunshine. 0… 35b°C (32… 95b°F)

x ( P. 58)

x ( P. 72)

x ( P. 73)

ದ The storage place should be dry and not subject to large temperature differences. ದ Cover the vehicle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus

causing corrosion.

Info

Avoid running the engine of a vehicle in storage 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.

Putting the vehicle into operation after storage

ದ Install the battery. ( P. 58) ದ Fill up with fuel. ( P. 27) ದ Checks before putting into operation ( P. 20) ದ Make a cautious test ride.

TECHNICAL DATA - ENGINE 81

7(&+1,&$/'$7$ (1*,1(

Design 1-cylinder 4-stroke engine with balancer, water-cooled Displacement (450 XC ATV) 448bcm³ (27.34bcubin) Displacement (525 XC ATV) 510bcm³ (31.12bcubin) Stroke 72bmm (2.83bin) Bore (450 XC ATV) 89bmm (3.5bin) Bore (525 XC ATV) 95bmm (3.74bin) Compression ratio 11:1 Idle speed 1,500… 1,600brpm Control 4 valves controlled via rocker arm and overhead camshaft,

camshaft drive via simplex chain Valve diameter, intake 35bmm (1.38bin) Valve diameter, exhaust 30bmm (1.18bin) Valve clearance, cold, intake 0.10… 0.15bmm (0.0039… 0.0059bin) Valve clearance, cold, exhaust 0.10… 0.15bmm (0.0039… 0.0059bin) Crankshaft bearing 2 cylinder roller bearing Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons (450 XC ATV) Cast light alloy Pistons (525 XC ATV) Forged light alloy Piston rings 1 compression ring, 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 rotor pumps Primary transmission 31:78 straight tooth spur gears Clutch Multidisc clutch in oil bath / hydraulically activated Transmission ratio

1st gear 14:35 2nd gear 17:33 3rd gear 19:30 4th gear 21:28 5th gear 23:26

Reverse gear 14:19:34 Generator 12bV, 200bW Ignition Contactless controlled fully electronic ignition with digital igni-

tion adjustment, type Kokusan Spark plug NGK DCPRb8bE Spark plug electrode gap 0.6bmm (0.024bin) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter

Capacity - engine oil

Engine oil 2.00bl (2.11bqt.) External temperature: ุb0b°C

(ุb32b°F)

External temperature: <b0b°C

(<b32b°F)

Engine oil (SAE 10W/50)

( P. 95)

Engine oil (SAE 5W/40)

( P. 96)

TECHNICAL DATA - ENGINE 82

Capacity - cooling liquid

Coolant

With compensating tank 1.50bl (1.59bqt.) Coolant ( P. 95)

Coolant (mixed ready to use) ( P. 95)

Without compensating tank 1.30bl (1.37bqt.) Coolant ( P. 95)

Coolant (mixed ready to use) ( P. 95)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 83

7(&+1,&$/'$7$ (1*,1(7,*+7(1,1* 72548(6

Screw, cable holder in generator cover M4 Screw, timing chain securing guide M5 6bNm (4.4blbfbft) Screw, locking lever M5 6bNm (4.4blbfbft) Screw, ignition pulse generator M5 6bNm (4.4blbfbft) Screw, gear sensor M5 6bNm (4.4blbfbft) Screw, rocker arm shaft M5 6bNm (4.4blbfbft) ದ Locking screw for bearing M5 6bNm (4.4blbfbft) Screw, oil pump cover M5 6bNm (4.4blbfbft) Screw, oil filter cover M5 6bNm (4.4blbfbft) ದ Screw, locking shaft lever M5 6bNm (4.4blbfbft) Screw, stator bracket M5 6bNm (4.4blbfbft) Nut, adjusting screw, valve clearance M6x0,75 11bNm (8.1blbfbft) ದ Oil jet, piston cooling M6x0,75 4bNm (3blbfbft) Screw, drive wheel for balancer M6 10bNm (7.4blbfbft) Screw, exhaust flange M6 10bNm (7.4blbfbft) Screw, vent hose bracket M6 10bNm (7.4blbfbft) Screw, timing chain guide rail M6 6bNm (4.4blbfbft) Screw, clutch cover M6 10bNm (7.4blbfbft) ದ Screw, clutch spring M6 8bNm (5.9blbfbft) Screw, bearing stud, starter engine M6 10bNm (7.4blbfbft) Screw, engine housing M6x30 10bNm (7.4blbfbft) ದ Screw, engine housing M6x45 10bNm (7.4blbfbft) ದ Screw, engine housing M6x60 10bNm (7.4blbfbft) ದ Screw, engine housing M6x65 10bNm (7.4blbfbft) ದ Screw, engine housing M6x75 10bNm (7.4blbfbft) ದ Screw, shift drum locating M6 10bNm (7.4blbfbft) Screw, shift lever M6 10bNm (7.4blbfbft) Screw, timing chain tensioning rail M6 6bNm (4.4blbfbft) Screw, starter engine M6 10bNm (7.4blbfbft) ದ Screw, timing-chain tensioner M6 10bNm (7.4blbfbft) ದ Plug, timing chain tensioner M8 10bNm (7.4blbfbft) ದ Screw, cylinder head top section M6x30 10bNm (7.4blbfbft) ದ Screw on cylinder head top section M6x45 10bNm (7.4blbfbft) ದ Screw on cylinder head top section M6x50 10bNm (7.4blbfbft) ದ Screw on cylinder head top section M6x55 ದ 10.9 10bNm (7.4blbfbft) ದ Screw on cylinder head top section M6x75 10bNm (7.4blbfbft) ದ Screw, water pump cover M6 10bNm (7.4blbfbft) ದ Screw, cylinder head M6 10bNm (7.4blbfbft) ದ Screw, valve cover M6 10bNm (7.4blbfbft) ದ Jet screw, oil line M8 10bNm (7.4blbfbft) ದ Banjo bolt, oil line M8 10b

Nm (7.4blbfbft) ದ Screw, generator cover M8 10bNm (7.4blbfbft) ದ Plug, crankshaft location M8 10bNm (7.4blbfbft) ದ Screw, camshaft gear M8 28bNm (20.7blbfbft) Screw, engine sprocket M10 60bNm (44.3blbfbft) Screw, cylinder head M10 Step 1

40bNm (29.5blbfbft) Step 2

50bNm (36.9blbfbft) Ignition rotor nut M12x1 60bNm (44.3blbfbft) ದ Spark plug M12x1,25 17bNm (12.5blbfbft) ದ Bleeder flange, engine case M12x1,5

Loctite

ದ

Loctite

243™

222

243™

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 84

Oil drain plug with magnet M12x1,5 20bNm (14.8blbfbft) ದ Plug, oil pressure regulator valve M12x1.5 20bNm (14.8blbfbft) ದ Locking screw, oil sieve, short M16x1,5 10bNm (7.4blbfbft) Engine oil (any) Nut, inner clutch hub M18x1,5 120bNm (88.5blbfbft) Nut, primary gear M20LHx1,5 150bNm (110.6blbfbft) Screw-in fitting, cooling system in

cylinder head top Locking screw, oil sieve, long M20x1,5 15bNm (11.1blbfbft) ದ

M20x1,5

Loctite

243™

577

TECHNICAL DATA - CARBURETOR 85

7(&+1,&$/'$7$ &$5%85(725

450/525bXCbATV



Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3925H Needle position (450 XC ATV) 2nd position from top Needle position (525 XC ATV) 3rd position from top Idle mixture adjusting screw

Open 1.0bturn Pump membrane stop 2.15bmm (0.0846bin) Main jet 170 Jet needle OBEKR Idling jet (450 XC ATV) 40 Idling jet (525 XC ATV) 42 Main air jet 200 Idle air jet 100 Cold start jet 85 Throttle slide 15

TECHNICAL DATA - CHASSIS 86

7(&+1,&$/'$7$ &+$66,6

Frame Double cradle of chromium molybdenum steel tubes, powder-

coated

Wheel suspension

Front Single wheel suspension with double transverse control arm

Rear Rigid axle Suspension travel

Front 257bmm (10.12bin)

Rear 265bmm (10.43bin) Fork offset

Front 46bmm (1.81bin) Toe

Front 0bmm (0bin) Camber

Front 0° Toe width

Front 1,115bmm (43.9bin)

Rear 1,148bmm (45.2bin) Wheelbase 1,280±10bmm (50.39±0.39bin) Turning radius 5,625bmm (221.46bin) Fording depth 330bmm (12.99bin) Seat height unloaded 820bmm (32.28bin) Ground clearance unloaded 290bmm (11.42bin) Weight

fuel tank empty 163bkg (359blb.)

fuel tank full 173bkg (381blb.) Maximum allowable axle load

Front 144bkg (317blb.)

Rear 149bkg (328blb.) Maximum permissible overall weight 293bkg (646blb.) Vehicle length 1,810bmm (71.26bin) Vehicle width 1,148bmm (45.2 Vehicle height 1,125bmm (44.29bin) Brake system

Front Disc brakes, brake calipers fixed, 4 brake pistons per brake

caliper

Rear Disc brake, brake caliper floating, 1 brake piston Diameter of brake discs

Front 180bmm (7.09bin)

Rear 200bmm (7.87bin) Wear limit of brake discs

Front 3.5bmm (0.138bin)

Rear 3.5bmm (0.138bin) Tire air pressure off road 0.3bbar (4bpsi) Rim

Front 5x10"bDWTbAl 6061

Rear 8x9"bDWTbAlb6601 Rear wheel gearing 14:38 Chain 5/8 x 1/4" Rear sprockets available 36, 37, 38, 39

bin)

4Ah battery YTX5L-BS Battery voltage: 12bV

Nominal capacity: 4bAh maintenance-free

TECHNICAL DATA - CHASSIS 87

Lighting equipment

Headlight BA20d 12bV

35/35bW

Parking light W2,1x9,5d 12bV

5bW

Indicator lights W2x4,6d 12bV

1.2bW

Brake / tail light LED

Tires

Front tire Rear tire

21bxb7.00b-b10

MAXXIS RazrbMತ931 For further information, see the Service section under:

http://www.ktm.com

Capacity - fuel

Tank capacity 13.4bl (3.54bUSbgal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 95)

20bxb11.00b-b9

MAXXIS RazrbMತ932

Fuel reserve 3bl(3bqt.)

TECHNICAL DATA - FRONT SHOCK ABSORBER 88

7(&+1,&$/'$7$ )52176+2&. $%625%(5

Shock absorber type 36PRC Setting number KT 7702 Compression damping

Standard 14bclicks

Maximum deviation from standard value ෥5… 5bclicks Rebound damping

Standard 20bclicks

Maximum deviation from standard value ෥5… 5bclicks Cross over 17±1.5bmm (0.67±0.059bin) Clip position, spring preload

Standard 7 th position from top

Corresponds to a spring preload of 5bmm (0.2bin) Spring preload 5bmm (0.2bin) Spring rate, main spring 21… 30bN/mm (120… 171blb/in) Spring rate, auxiliary spring 30bN/mm (171blb/in) Spring length, main spring 275bmm (10.83bin) Spring length, auxiliary spring 60bmm (2.36bin) Fitted length 463bmm (18.23bin)

TECHNICAL DATA - REAR SHOCK ABSORBER 89

7(&+1,&$/'$7$ 5($56+2&. $%625%(5

Shock absorber type 46PRCQ Setting number KT 7710 Compression damping

Standard 15bclicks

Maximum deviation from standard value ෥5… 5bclicks Rebound damping

Standard 15bclicks

Maximum deviation from standard value ෥5… 5bclicks Spring preload

Standard 3bmm (0.12bin) Spring rate 62bN/mm (354blb/in) Spring length 250bmm (9.84bin) Fitted length 457bmm (17.99bin)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 90

7(&+1,&$/'$7$ &+$66,67,*+7(1,1* 72548(6

Remaining nuts, chassis M6 15bNm (11.1blbfbft) ದ Remaining screws, chassis M6 10bNm (7.4blbfbft) ದ Screw on fuel tank M6 6bNm (4.4blbfbft) ದ Screw, rear brake caliper M6 10bNm (7.4blbfbft) Screw, foot brake cylinder M6 7bNm (5.2blbfbft) Screw, clamping nut, rear axle M6 10bNm (7.4blbfbft) ದ Remaining nuts, chassis M8 30bNm (22.1blbfbft) ದ Remaining screws, chassis M8 25bNm (18.4blbfbft) ದ Screw, front brake disc M8 25bNm (18.4blbfbft) Screw, rear brake disc M8 25bNm (18.4blbfbft) Screw, front brake caliper M8 20bNm (14.8blbfbft) Screw, rear brake caliper M8 20bNm (14.8blbfbft) Screw, bearing support, steering M8 25bNm (18.4blbfbft) ದ Screw, steering bridge M8 20bNm (14.8blbfbft) ದ Screw, handlebar clamp M8 20bNm (14.8blbfbft) ದ Screw, subframe M8 35bNm (25.8blbfbft) Screw, rear wheel eccentric element M8 20bNm (14.8blbfbft) ದ Nut, ball head, A-arm top M10x1,25 35bNm (25.8blbfbft) ದ Nut, rear sprocket screw M10x1,25 45bNm (33.2blbfbft) Nut, tie rod end M10x1,25 45bNm (33.2blbfbft) ದ Wheel nut M10x1,25 45bNm (33.2blbfbft) ದ Nut, handlebar support M10 45bNm (33.2blbfbft) ದ Remaining nuts, chassis M10 50bNm (36.9blbfbft) ದ Remaining screws, chassis M10 45bNm (33.2blbfbft) ದ Engine carrying screw M10 60bNm (44.3blbfbft) ದ Screw, A-arm top M10x52 45bNm (33.2blbfbft) ದ Screw, A-arm bottom M10x70 45bNm (33.2blbfbft) ದ Screw, front shock absorber M10 45bNm (33.2blbfbft) ದ Screw, footrest M10 45bNm (33.2blbfbft) ದ Screw, steering column at bottom of

M10 25bNm (18.4blbfbft) ದ

steering lever Engine bracket screw M10 60bNm (44.3blbfbft) ದ Nut, A-arm top M12x1,25 30b

Nm (22.1blbfbft) ದ Lock nut, tie rod, outside M12x1,25 20bNm (14.8blbfbft) ದ Lock nut, tie rod, inside M12LHx1,25 20bNm (14.8blbfbft) ದ Nut, ball head, A-arm bottom M12x1,5 40bNm (29.5blbfbft) ದ Nut, front wheel hub M12 70bNm (51.6blbfbft) ದ Screw, rear top shock absorber M12 60bNm (44.3blbfbft) ದ Screw, rear bottom shock absorber M12 70bNm (51.6blbfbft) ದ Nut, swingarm pivot M16x1,5 100bNm (73.8blbfbft) ದ Nut, rear wheel hub M18x1,5 130bNm (95.9blbfbft) ದ Screw, steering column, top M20x1,5 25bNm (18.4blbfbft) ದ Screw, steering column, bottom M20x1,5 40bNm (29.5blbfbft) ದ Clamping nut, rear axle 2"-10UNS-2B-LH 25bNm (18.4blbfbft) Only applies when using:

Loctite

243™

Open-end wrench accessory 46mm (83019010461)

WIRING DIAGRAM 92

:,5,1*',$*5$0

450/525bXCbATV



450/525 XC ATV 2008

-S7

-S1

-L1

-A1

-B1

-L2

-H4

C_EK/2

C_CA/4

C_EJ/2

1st

GND

C_CE/4

C_BU/18

12 13 14 15 16 17 18

C_AM/3

C_AR/3

C_AL/2

C_AT/2

pos.

-H6

45,46

43,44

C_AH/2

C_AK/2

-S10

C_BC/4

C_DG/4

1234

-X301

low

high

-X302

51,52

47,49

C_EH/1

C_EI/1

66 27

56,57

C_AJ/3

C_BG/3

-X201

2.1

C_AN/4

2.2

2.1

-X200

-S8

C_AK/2

C_AH/2

-X101

C_BV/2

C_BO/2

-X300

-X102

C_CU/4

2.1

2.2 2.3 2.4

36,39

41,42

-H3

-X6

-H2

-H1

50,48

54,55

C_AC/6

C_BC/6

C_BR/4

C_BK/4

-S9

-S5

-S2

34,38,37

10A

34,19,35

-X3

20,21,28,29,30

-X1

-X2

16,17,25,31,32

-F1

15A

-F2

10A

-F3

10A

-F4

10A

-F5

C_BY/4

C_CV/4

-X4

1,2,3,4

-M2

C_AU/2

C_BI/2

-S4

C_AV/2

-S3

C_AH/2

C_AK/2

-X24

C_AY/1

ACC1

-X23

C_AY/1

-X22

C_AY/1

ACC2

-X21

C_AY/1

C_AL/2

C_AT/2

-S6

-M1

-K1

C_AE/4

C_AU/2

C_BI/2

5,6,7,10,8,9

-X5

-H5

-G2

-N1

-G1

600146-10

WIRING DIAGRAM 93

Components

A1 CDI controller ACC1 Socket connector for auxiliary devices (switching on with ignition) ACC2 Socket connector for auxiliary devices (permanent positive) B1 Throttle valve sensor TPS G1 Battery G2 Generator H1 Idling speed indicator lamp H2 Reverse gear indicator lamp H3 Ignition indicator lamp H4 High beam indicator light H5 Brake / tail light H6 Headlight K1 Starter relay with fuse L1 Ignition coil L2 Pulse generator M1 Starter motor M2 Radiator fan N1 Voltage regulator/rectifier S1 Switch for throttle lever S2 Ignition switch S3 Emergency OFF switch with rip cord S4 Temperature switch for radiator fan S5 Light switch S6 Clutch switch S7 Gear sensor switch S8 Front brake light switch S9 Electric starter button, ENG.bSTOPbswitch S10 Rear brake light switch X201 Ignition curve plug connection

Cable colors

1 green 2 green 3 green 4 green 5 white-red 6 white-red 7 white-red 8 white-red 9 white-red 10 white-red 11 red 12 yellow 13 white-black 14 yellow-red 15 black-red 16 brown 17 brown 18 yellow-red 19 brown 20 orange 21 orange

WIRING DIAGRAM 94

22 yellow 23 blue-red 24 orange 25 brown 26 yellow-green 27 black-yellow 28 orange 29 orange 30 orange 31 brown 32 brown 33 black 34 brown 35 brown 36 brown 37 brown 38 brown 39 brown 40 black-green 41 yellow-green 42 yellow-green 43 brown 44 brown 45 brown 46 brown 47 yellow 48 white 49 yellow 50 white 51 yellow 52 yellow 53 green 54 blue 55 blue 56 white-green 57 white-green 58 white-blue 59 brown 60 white 61 blue-red 62 green 63 white-red 64 white-black 65 yellow-green 66 black-yellow 67 red 68 green 69 blue 70 yellow 71 black

SUBSTANCES 95

68%67$1&(6

Super unleaded (ROZ 95 / RON 95 / PON 91)

according to

ದ DINbENb228 (ROZ 95 / RON 95 / PON 91)

Long-life grease

according to

ದ NLGI

Specification

ದ Use only grease that complies with the specified standards (see specifications on the container) and that possesses the corre-

sponding properties. KTM recommends Motorex

Supplier

Motorex ದ LongbThermb2000

Brake fluid DOTb4b/bDOTb5.1

according to

ದ DOT

Specification

ದ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-

sponding properties. KTM recommendsbCastrol andbMotorex

Supplier Castrol ದ RESPONSEbBRAKEbFLUIDbSUPERbDOTb4

Motorex ದ BrakebFluidbDOTb5.1

products.

Hydraulic fluid (15)

according to

ದ ISO VG (15)

Specification

ದ Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the

corresponding properties. KTM recommends Motorex

Supplier

Motorex

products.

ದ HydraulicbFluidb75

Coolant

Specification

ದ Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.

KTM recommends Motorex

products.

Mixture ratio

Antifreeze: ෥25… ෥45b°C (෥13… ෥49b°F) 50b% Anti-corrosion/antifreeze

50b% distilled water

Coolant (mixed ready to use)

Antifreeze ෥40b°C (෥40b°F)

Supplier

Motorex ದ AntibFreeze

Engine oil (SAE 10W/50)

according to

ದ JASObT903bMA ( P. 98) ದ SAE ( P. 98) (SAE 10W/50)

Specification

ದ 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

Synthetic engine oil

products.

SUBSTANCES 96

Supplier

Motorex ದ CrossbPowerb4T

Engine oil (SAE 5W/40)

according to

ದ JASObT903bMA ( P. 98) ದ SAE ( P. 98) (SAE 5W/40)

Specification

ದ 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

Synthetic engine oil

Supplier

Motorex ದ PowerbSyntb4T

products.

AUXILIARY SUBSTANCES 97

$8;,/,$5<68%67$1&(6

Chain cleaner

Specification

ದ

KTM recommendsbMotorex

Supplier

Motorex ದ ChainbCleanb611

Offroad chain spray

Specification

ದ

KTM recommends Motorex

Supplier

Motorex ದ ChainbLubeb622

Air filter cleaner

Specification

ದ

KTM recommends Motorex

Supplier

Motorex ದ TwinbAirbDirtbBiobRemover

products.

Oil for foam air filter

Specification

ದ

KTM recommends Motorex

Supplier

Motorex ದ TwinbAirbLiquidbPower

products.

Motorcycle cleaner

Specification

ದ

KTM recommendsbMotorex

Supplier

Motorex ದ MotobCleanb900

products.

Cleaning and polishing materials for metal, rubber and plastic

Specification

ದ

KTM recommendsbMotorex

Supplier

Motorex ದ Protectb&bShineb645

products.

High-luster polish for paint

Specification

ದ

KTM recommendsbMotorex

Supplier

Motorex ದ MotobPolish

products.

Contact spray

Specification

ದ

KTM recommendsbMotorex

Supplier

Motorex ದ AccubContact

products.

STANDARDS 98

67$1'$5'6

JASObT903bMA

Different technical development directions required a new specification for 4-stroke motorcycles ದ 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 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.

KTM 450 XC ATV, 525 XC ATV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual