KTM 450 XC ATV, 525 XC ATV User Manual

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.

© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

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.

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.

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