KTM 520 EXC, 520 SX User Manual

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Page 1

OWNERS HANDBOOK

MANUALE D’USO

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

2000

400/520 SX, EXC RACING

BEDIENUNGSANLEITUNG

Art.Nr. 3.205.72 11/99

Page 2

Page 3

ENGLISH

IMPORTANT

WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL

CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST

RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND

ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE

PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR

ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS:



WARNING



IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE.

CAUTION

IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE.

Please insert the series numbers of your motorcycle in the boxes below

Frame number

Engine number

Stamp of dealer

Tampering with noise control system prohibited

Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of mainten-

ance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and

(b) the use of the vehicle after such device or element of design has been removed or rendered

inoperative by any person.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

KTM S

PORTMOTORCYCLE

RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS

MATERIALS

SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS

OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI

TUTING THEM WITH OTHERS

. I

T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT

. I

N THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS

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Introduction

We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this opportunity to thank you for putting your trust in us; we will not let you down.

You are now owner of a sporty and modern motorcycle which you are bound to have a great time with provided you care for it properly. Before going for a first ride on your motorbike, you should

read this Owner’s Handbook carefully, even if this takes some of your precious time, so as to familiarize yourself with how your motorbike is to be operated and which features it offers you. Only by doing so will you learn how you can best tune your motorcycle to your needs and how you can avoid bodily injuries. In addition, this Owner’s Handbook contains invaluable information about motorcycle maintenance. At the time of printing, this User's Guide corresponded to the

latest state of this model family. It is, however, possible that we may have made slight modifications in the meantime due to development in our motorcycle design. The Owner’s Handbook is an essential part of the motorbike and should - when the bike is sold be handed over to the new owner.

Many motorcyclists have a good working knowledge of motorcycle mechanics; if this is true in your case, you will be able to use this Owner’s Handbook to carry out most of the maintenance steps yourself. If, on the other hand, you are not very familiar with motorcycles, it might be better to have a professional KTM dealer perform those steps marked by *found in the chapter entitled “Maintenance Work on Chassis and Engine” of this manual.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Be sure to have any maintenance jobs performed by an authorized KTM dealer. Address your special requests to an authorized KTM dealer who, should the need arise, will be supported by the KTM importer.

Please do not forget to don your helmet, eye protection, and protective clothing when going for a ride. KTM riders are responsible riders! We wish you a lot of fun when driving !

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments:

1 spare parts manual chassis 1 spare parts manual engine

KTM Austria’s certificate of achievement for its Quality System ISO 9001 is the beginning of an on-going total re-engineering quality plan for a brighter tomorrow.

Page 5

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Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4

OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4

Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . .4

Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Digital speedometer, indicator lamps (EXC) . . . . . . . . . . .5

Digital speedometer (EXC) . . . . . . . . . . . . . . . . . . . . . . .5

Odometer (EXC USA) . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Speedometer, indicator lamps (EXC - Australia) . . . . . . . .5

Short circuit button (SX) . . . . . . . . . . . . . . . . . . . . . . . . .5

Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6

Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . . . . . .6

Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Emergency OFF button (EXC) . . . . . . . . . . . . . . . . . . . . .6

Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . .6

Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Compression damping of fork . . . . . . . . . . . . . . . . . . . . .8

Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .9

Compression damping of shock absorber . . . . . . . . . . . .9

Rebound damping of shock absorber . . . . . . . . . . . . . . .9

Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .10

PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE

. .13

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .14

Changing the original position of the clutch lever . . . . .14

Checking and adjusting the steering head bearing . . . . .14

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .15

Cleaning the dust sleeves of the telescopic fork . . . . . . .15

How to change the handlebar position . . . . . . . . . . . . .15

Changing the spring preload of shock absorber . . . . . . .16

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .17

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

General informations about KTM disc brakes . . . . . . . .18

Adjusting of free travel at the hand brake lever . . . . . . .18

Checking of brake fluid level - front brake . . . . . . . . . . .19

Refilling the front brake fluid reservoir . . . . . . . . . . . . . .19

Page

Checking the front brake pads . . . . . . . . . . . . . . . . . . .19

Replacing the front brake pads . . . . . . . . . . . . . . . . . . .19

Changing the basic position of the brake pedal . . . . . .20

Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .20

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .20

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .21

Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .21

Dismounting and mounting the front wheel . . . . . . . . .21

Dismounting and mounting the rear wheel . . . . . . . . .22

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .23

Replacing the battery of the digital speedometer . . . . .23

Adjusting digital speedometer . . . . . . . . . . . . . . . . . . .24

Check/set distance of magnetic sensor . . . . . . . . . . . . .25

Battery (EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Fuse (EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Replacing head light lamp (H4) . . . . . . . . . . . . . . . . . .27

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .28

Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . .28

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .29

Replacing the glass fiber yarn packing of the silencer

. .29

Cleaning the spark arrestor (EXC USA) . . . . . . . . . . . . .29

Draining of float chamber of the carburetor . . . . . . . . .27

Checking adjustment of the hand decompression release cable

.30

Adjust the throttle cables . . . . . . . . . . . . . . . . . . . . . . .30

Checking the oil level of the hydraulic clutch . . . . . . . .30

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .30

Carburetor adjust idling . . . . . . . . . . . . . . . . . . . . . . . .31

Adjusting the mixture control screw . . . . . . . . . . . . . . .31

Checking the float level . . . . . . . . . . . . . . . . . . . . . . . .31

Draining of float chamber of the carburetor . . . . . . . . .32

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Checking engin oil level . . . . . . . . . . . . . . . . . . . . . . . .32

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .33

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .35

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

CONSERVATION FOR WINTER OPERARION . . . . . . . . .37

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Re-initiation after time of storage . . . . . . . . . . . . . . . . .37

TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . .38

TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .40

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . . . . .Appendix

INDEX

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Chassis number

The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1.

Engine number, engine type

The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Please note this number down on page 1.

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

Clutch lever

The clutch lever 1 is located on the left side of the handlebar. The adjusting screw

A is used to change the original position of the clutch lever (see

maintenance work on chassis and engine).

Hand decompression lever

The hand decompression lever 2 is needed only if a fall on your motorcycle causes overflowing in the carburetor. To "pump the engine free", pull the hand decompression lever during the starting procedure.

The outer end of the lever must at all times provide for a backlash of approx. 10mm (0,4 in). Only thereafter may it cause valve motion (to be recognized by the stronger resistance which the hand decompression level encounters).

CAUTION

–N

EVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE. RATHER,

USE THE SHORT

-CIRCUIT BUTTON OR THE EMERGENCY-OFF BUTTON.

–T

HE SETTING OF THE DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED. A

LACK OF PLAY IN THE DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE.

Hand brake lever

The hand brake lever 3 is mounted on the handle bars on the right and actuates the front wheel brake. The adjusting screw

B can be used to

change the basic position of the hand brake lever (see "Maintenance").



WARNING



IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY” (

TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE

BRAKE SYSTEM

. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE

BRAKE SYSTEM LOOKED OVER BY A

KTM DEALER.

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Digital speedometer, indicator lamps (EXC)

The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator.

The blue control lamp

2 lights up when the high beam is on.

Speedometer – digital (EXC)

Some models are equipped with a digital speedometer 3.

KMH = Speed, max. 200 km/h (is always indicated)

Aside from speed indication the following indications can be selected:

TRP = Trip distance STP = Stopwatch max. 10 h, automatic start/stop function DST = Total distance up to 99.999 km CLK = Clock

See maintenance work for change of battery and basic setting.

Odometer (EXC USA)

The odometer is a mileage indicator and can be set to 0 by means of the adjustment wheel

Speedometer, indicator lamps (EXC AUS)

The mileage indicator A in the speedometer 5 indicates overall mileage. When the turn indicator is on, the green indicator lamp

6 will be flashing in

the same rhythm. The blue indicator lamp

7 will be lit when the high beam is on

Short circuit button (SX)

The short circuit button 8 turns off the engine. When pressing this button, the ignition circuit is short-cicuited.

TRP

STP

DST

CLK

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Combination switch (EXC)

The light switch has 2, respetively 3 switch positions.

A = Light off (this function is not available in all models) B = Low beam on C = High beam on

You may use button

1 to actuate the horn.

The red short circuit button

2 serves to switch off the engine. Leave the

switch pressed until the engine stops.

Headlamp switch (EXC USA)

In this model the headlamp is switched on with the pull switch 3.

Flasher switch

Flasher left

Flasher right

Emergency OFF button (EXC)

The red emergency-OFF button 4 is arranged adjacent to the throttle grip. To turn off the engine, push the button until the engine comes to a standstill.

Pushing of the black starter button 5 actuates the E-starter.



WARNING



ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE (NEUTRAL) BEFORE

ACTUATING THE STARTER BUTTON

. IF YOU START THE MOTORCYCLE WITH A GEAR

ENGAGED

, THE MOTORCYCLE WILL MOVE FORWARD.

Emergency OFF switch (EXC Australia)

The red emergency-OFF switch 6 is arranged adjacent to the throttle grip.

In this position, the E-starter is operational and the engine can be started.

In this position, the E-starter and ignition circuits are interrupted. The E-starter cannot be actuated, and the engine will not start, not even if you attempt to start it with the kickstarter.

Pushing of the black starter button

5 actuates the E-starter.



WARNING



ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE (NEUTRAL) BEFORE

ACTUATING THE STARTER BUTTON

. IF YOU START THE MOTORCYCLE WITH A GEAR

ENGAGED

, THE MOTORCYCLE WILL MOVE FORWARD.

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Filler cap

To open filler cap: Turn the filler cap counter-clockwise. To close filler cap: ut filler cap on and tighten it by turning it clockwise.

Install tank breather hose

1 without kinks.

Fuel

The LC4 engine needs premium gasoline with an octane number of 95 or higher.

CAUTION

SE LEADED OR UNLEADED PREMIUM GRADE GASOLINE

(95 OCTANES). NEVER USE ANY

GASOLINE HAVING LESS THAN

95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE.



WARNING



ASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED

WHEN HANDLING GASOLINE

. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR

BURNING CIGARETTES

. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE

CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT

. WIPE UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES,

SEEK A DOCTOR

’S ADVICE IMMEDIATELY.

Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).

Fuel tap

OFF

In this position the fuel tap is closed. No fuel may flow to the carburetor.

ON During operation the twist grip must be turned to ON. This means

that the fuel can flow to the carburetor. With the twist grip in this position the tank will be emptied until only the reserve is left.

RES The reserve tank cannot be tapped until the rotating handle is turned

to the RES position. Fill the tank as soon as possible and remember to turn the rotating handle back to the ON position so that you will have backup fuel next time, too.

Reserve (EXC). . . . . . . . . . . . . 1.0 l (0,3 US gallons)

CAUTION

HE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP

IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE

35 mm

ON RESOFF

EXC

Page 10

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Choke

If you pull the choke button 1 out as far as possible, a bore in the carburetor will be unblocked through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts.

To deactivate the choke, push the choke button back into its basic position.

Shift lever

The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear.

Kickstarter

The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled.



WARNING



–IF YOU WANT TO START THE ENGINE

, MAKE SURE THAT YOU ALWAYS PUT ON STURDY

MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

. YOU MIGHT SLIP OFF THE KICK-

STARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE

–A

LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.

ICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM, AND AN OPENED

THROTTLE GRIP INCREASE THE KICK

-BACK HAZARD.

Foot brake pedal

The foot brake pedal is disposed in front of the right foot rest. Its basic position can be adjusted to your seat position (see maintenance work).



WARNING



F THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY”

(

TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE

BRAKE SYSTEM

. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE

BRAKE SYSTEM LOOKED OVER BY A

KTM DEALER.

Compression damping of fork

Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs. Turn the adjusting screws

2 clockwise to increase damping, turn it counter-

clockwise to reduce damping during compression. STANDARD ADJUSTMENT

– turn adjusting screw clockwise as far as it will go – turn it back by as many clicks as are specified for the relevant type of

fork

WP 0518U782 . . . . . . . . . 14 clicks

WP 0518U791 . . . . . . . . . 14 clicks

2,3,4 (5,6)

Page 11

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Rebound damping of fork

Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw

1 (REB), the degree of damping of

the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.

STANDARD ADJUSTMENT – turn adjusting screw clockwise as far as it will go – turn it back by as many clicks as are specified for the relevant type of

fork

WP 0518U782 . . . . . . . . . 14 clicks

WP 0518U791 . . . . . . . . . 14 clicks

Compression damping of shock absorber

The damping force of the compression damping can be adjusted with knob

2 The higher the number the higher the damping force.

STANDARD ADJUSTMENT:

WP 1218U716 . . . . . . . . . . . . . . . . . . . 5 clicks

WP 1218U721 . . . . . . . . . . . . . . . . . . . 4 clicks



WARNING



THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH-COMPRESSION

NITROGEN

. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN-

ANCE WORK YOURSELF

. SEVERE INJURIES COULD BE THE RESULT.

Rebound damping of shock absorber

By using the adjusting screw 3, the degree of damping of the rebound can be adjusted. Turn the knob to the right side to increase damping, turn it to the left side to reduce damping during rebounding. STANDARD ADJUSTMENT: – Turn the adjusting screw clockwise to the stop. – Then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

WP 1218U716 . . . . . . . . . . . . . . . . . . 18 clicks

WP 1218U721 . . . . . . . . . . . . . . . . . . 20 clicks

Steering lock

The handlebar can be locked by means of the lock located on the steering head. To lock it, turn handlebar all the way to the right, insert key, turn it to left, press it in, turn it to right, and remove it.

CAUTION

EVER LEAVE THE KEY INSERTED IN THE STEERING LOCK. IF YOU TURN THE HANDLEBAR

TO THE LEFT THE KEY COULD GET DAMAGED

Side stand

Push the side stand to the ground with your foot and load it with the motorcycle. Make sure that you put your bike on solid ground and in a secure position. For off-road riding, you can use the rubber band

4 to

additionally secure the center stand in its folded-up position.

CAUTION

–T

HE SIDE STAND IS ONLY DESIGNED FOR THE WEIGHT OF THE MOTORCYCLE. IF YOU

GET ON THE MOTORCYCLE AND THUS PUT ADDITIONAL WEIGHT ON THE SIDE STAND

THE SIDE STAND OR THE FRAME CAN BE DAMAGED AND THE MOTORCYCLE MAY FALL

ON THE SIDE

–A

LWAYS CHECK BEFORE GOING FOR A RIDE THAT YOU HAVE FOLDED UP THE SIDE

STAND AS FAR AS POSSIBLE

. IF THE STAND TOUCHES THE GROUND WHILE YOU ARE

DRIVING

, YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE.

Page 12

ENGLISH

DRIVING INSTRUCTIONS



WARNING



–T

HE SX MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS AND

FREEWAYS

–W

HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT

OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Read these operating instructions carefully before your first

ride. – Familiarize yourself with the operating elements. – Set the clutch lever, the handbrake lever, and the footbrake

pedal to the positions that are most convenient for you. – Get used to handling the motorcycle on an empty parking

lot or open space, before starting on a longer drive. Also try

to drive as slowly as possible and in standing position, to

improve your feeling for the vehicle. – Do not drive along off-road tracks which go beyond your

abitily and experience. – Hold the handle bars with both hands and leave your feet

on the foot rests while driving. – Remove your foot from the foot brake lever when you are

not braking. If the foot brake lever is not released the brake

pads rub continuously and the braking system is over-

heated. – Do not make any alterations to the motorcycle and always

use ORIGINAL KTM SPARE PARTS. Spare parts from other

manufacturers can impair the safety of the motorcycle. – Motorcycles are sensitive to alterations in the distribution of

weight. If you are taking luggage with you, this should be

secured as close as possible to the middle of the vehicle; dis-

tribute the weight evenly between the front and rear wheel.

Never exceed the maximum permissible laden weight and

the axle weights. The maximum permissible laden weight is

made up of the following components:

– Motorcycle ready for operation and tank full

– Luggage

– Driver with protective clothing and helmet. – Pay attention to running-in procedure.

Running in the Racing models

Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding across one another for quite some time. Therefore, every engine needs to be broken in. For this reason, do not load the engine more than 50% of its capacity during the first 3 operating hours. Besides, the engine speed must not exceed 7000 rpm. Avoid going full-throttle! In the following 12 operating hours, you may load the engine up to 75% of its capacity. Use the motorcycle on various types of terrain (road, easy off-road trails).

CAUTION

HE 400/520 SC/EXC RACING MODELS WERE UNCOMPROMISINGLY

DESIGNED FOR OFF

-ROAD COMPETITION PURPOSES ONLY. EVEN THOUGH

THE

EXC MODELS ARE APPROVED FOR USE ON PUBLIC ROADS, THEIR USE

ON ROADS IS RECOMMENDABLE ONLY TO A VERY LIMITED EXTENT

. AVOID

EXTENDED ON

-ROAD RIDES AT FULL THROTTLE.

Check the following before each start

When you start off, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start.

The following checks should be performed: 1 CHECK THE OIL LEVEL

Insufficient oil results in premature wear and consequently to engine damage.

2 FUEL

Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.

3 CHAIN

A loose chain can fall from the chain wheels; an extremely worn chain can tear, and insufficient lubrication can result in unnecessary wear to the chain and chain wheels. Excessive tensioning of the chain will put additional load on the components of the secondary drivetrain (chain, bearings of transmission and rear wheel). Aside from resulting premature wear, if worst comes to worst the chain may rupture or the countershaft of the transmission may break.

4 TIRES

Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance.

5 BRAKES

Check correct functioning of the braking system. Check for sufficient brake fluid in the reservoir. The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn. If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided. Also check the state of the brake hose and the thickness of the brake linings. Check free travel at hand brake lever and foot brake lever.

6 CABLES

Check correct setting and easy running of all control cables.

7 COOLING FLUID

Check the level of cooling fluid when the engine is cold.

8 ELECTRICAL SYSTEM

Check correct functioning of headlamps, tail-lights, brake lights, indicators, control lamps and horn while the engine is running.

9 LUGGAGE

If you are taking luggage with you, check that this is securely fastened.



WARNING



–WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER

KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A

JACKET

, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A

SHORT TRIP

. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLO-

RED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE.

–A

LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE

–D

O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

–O

NLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR

EXAMPLE

, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF

THE MOTORCYCLE

. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT

DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES

–T

HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH

TIRES THAT HAVE THE SAME PROFILE TYPE

–T

HE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR 1 PER-

SON ONLY. NEVER TAKE ANOTHER RIDER ALONG.

Page 13

ENGLISH

Starting when the engine is cold

1 Open the fuel tap 1. 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke

5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or

actuate the E-starter.



WARNING



–I

F YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY

MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

. YOU MIGHT SLIP OFF THE KICK-

STARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE

–A

LWAYS KICK KICKSTARTER BRISKLY ALL THE WAY WITHOUT OPENING THE THROTTLE.

ICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM

, AND AN OPENED

THROTTLE GRIP INCREASE THE KICK

-BACK HAZARD

–DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA

. EXHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH

ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING

CAUTION

–M

AXIMAL PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5

SECONDS BEFORE TRYING AGAIN

–D

ON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN

COLD

. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED

CYLINDER

, IT CAN CAUSE ENGINE DAMAGE.

Starting when the engine is warm

1 Open the fuel tap 1. 2 Swing up the side stand. 3 Put the gear in neutral. 4 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or

actuate the E-starter.

What to do when the engine is „flooded”

In the event of a fall, more fuel than necessary may get into the engine. In order to "pump the engine free", pull the hand decompression lever, fully rev up the engine, actuate the kickstarter 5 to 10 times or actuate the Estarter 2 times for 5 seconds each. Then, start the engine as described above. If the engine fails to start, unscrew the spark plug and dry it. NOTE: The carburetor has an accelerator pump. Every time you open the throttle, fuel will be injected into the intake passage. When starting, be sure that you open the throttle completely only once.

Starting off

Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open throttle at the same time.



WARNING



–B

EFORE YOU START OFF, CHECK THAT THE SIDE STAND HAS BEEN SWUNG UP FULLY.

F THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF

CONTROL

–A

LWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE

OF YOU AS EARLY AS POSSIBLE

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever in and shift to the next higher gear. Let clutch lever go again and give gas. If you turned on the choke, make sure you turn it off again as soon as engine is warm. When you reach full speed through opening the throttle all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas.

Page 14

ENGLISH

Only give as much gas as the engine can handle. Through quick and high reving of throttle, the fuel usage increases. By shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear. Let clutch lever go slowely and open throttle or shift down again.

NOTE: D

EDICATED TO NOTHING BUT OFFROAD RACING, 400/520 SX/EXC

MODELS MAKE NO COMPROMISES IN THEIR DESIGN

. AS SUCH, THEY DO

NOT INCLUDE ANY RADIATOR FAN

, AND THE SIZE OF THE RADIATOR IS

DIMENSIONED FOR OPTIMUM ERGONOMICS

IN NORMAL RACING

, THE COOLING SYSTEM IS SUFFICIENT.

F YOU USE YOUR MOTORBIKE IN OTHER CONDITIONS, PLEASE NOTE THAT

–

THE E-STARTER ALLOWS YOU TO START EXC MODELS AGAIN AT ANY TIME

. THEREFORE, TURN OFF THE ENGINE IF YOU INTEND TO RUN

YOUR MOTORCYCLE IN IDLE OR AT STANDSTILL FOR LONGER PERIODS OF TIME

(MORE THAN 2 MINUTES).

–A

VOID LETTING THE CLUTCH SLIP FREQUENTLY AND FOR EXTENDED

PERIODS

. THIS WOULD CAUSE THE ENGINE OIL TO HEAT UP, THEREBY

HEATING UP THE ENGINE AND THE COOLING SYSTEM

. RATHER, YOU

SHOULD DRIVE AT LOW SPEEDS

(4-STROKE STYLE - LETTING THE

ENGINE PULL YOU

) AND NOT AT HIGH SPEEDS NOT BY LETTING THE

CLUTCH SLIP

(2-STROKE STYLE).



WARNING



–OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING

TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE

–ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

–D

RIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.

–WHEN DRIVING OFF

-ROAD, ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY

, SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE

–REPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR

DAMAGED

. IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR

LENS

, THE OPERATOR WILL BE BLINDED.

–AFTER FALLING WITH THE MOTORCYCLE

, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

–A

TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DO NOT ADJUST

THE HANDLEBAR

, IT WILL LOSE STA

-BILITY.

CAUTION

–H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. WE RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP

. AFTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

. THE ENGINE HAS REACHED ITS OPERA-

TING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM

–N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

A LOWER GEAR

. THE ENGINE WILL OVER-REV, DAMAGING THE VALVES.

IN ADDITION, THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

–L

ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN

LEAD TO MOTOR DAMAGE

–I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT

–IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION

-RELATED NOISE, STOP IMMEDIA-

TELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER

–N

EVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN-

TED; OTHERWISE, DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR

Braking

Close throttle and apply the hand and foot brakes at the same time. When driving on sandy, wet or slippery ground use mainly the rear wheel brake. Always brake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. When driving down hill, use the braking effect of the engine. Change down one or two gears but do not overspeed the engine. In this way, you will not need to brake so much and the brakes will not overheat.



WARNING



–I

N CASE OF RAIN, AFTER WASHING THE MOTORCYCLE, AFTER RIDES

THROUGH WATER AND IN CASE OF RIDES ON WET OFF

-ROAD TRACKS,

HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE

BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN

–RIDES ON SALT-STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRA-

KING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN.

–D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS

–W

HEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER

AND BRAKE FLUID HEAT UP

. THE HOTTER THESE PARTS GET, THE WEA-

KER THE BREAKING EFFECT

. IN EXTREME CASES, THE ENTIRE BRAKING

SYSTEM CAN FAIL

Stopping and parking

Apply the brakes fully and put the engine into neutral. To turn off the engine, push the short-circuit button or the emergencyOFF button with the engine at idling speed until the engine stops. Turn the fuel tap to the OFF position, park on an area where the ground is firm, and lock the motorcycle.



WARNING



–NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING

–M

OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE

RUNNING

. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND

SHOCK ABSORBERS CAN BECOME VERY HOT

. DO NOT TOUCH ANY OF

THESE PARTS AFTER OPERATING THE MOTORCYCLE

, AND TAKE CARE TO

PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET

BURNED

CAUTION

–N

EVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE

ENGINE

. RATHER, USE THE SHORT-CIRCUIT BUTTON OR THE EMER-

GENCY-OFF BUTTON.

–CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE

.OTHERWISE THE

CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE

–N

EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS

NOTE REGARDING THE SIDE STAND: Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways. Make sure that the ground is solid and that your motorcycle is standing securely. Just in case, you can shift into first gear.

CAUTION

THE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE

MOTORCYCLE

. THE SIDE STAND AND/OR THE FRAME CAN BE DAMAGED

AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR

CYCLE, THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND.

Page 15

ENGLISH

Check engine oil level



Change engine oil

 

Clean short and long oil screens and magnet of the drain plug whenever you exchange the engine oil



Change short and long oil filter unit

 

Check oil line for leakage and proper instalment



Check valve clearance and adjust if necessary



Change spark plug



Drain and clean carburator float bowl



Adjust idling



Check breather hoses of engine gase, gas tank and carburator for correct position without buckles



Clean air filter and air filter box



Check sprockets, chain guides and chain for wear



Clean and lube chain

 

Check chain tension



Check cooling liquid level



Check quality of antifreeze



Check cooling system for leaks



Check exhaust system for leakage



Change exhaust muffler packing



Clean spark arrestor (EXC USA)



Check exhaust brackets



Check brake fluid level front and rear



Change brake fluid



Check brake pad thickness



Check brake discs for wear and damage



Check condition and correct instalment of brake hoses



Check freeplay and easy operation of hand brake lever and foot brake lever



Check oil level of the master cylinder of the hydraulic clutch



Change the oil of the hydraulic clutch



Check adjustment and function of telescopic fork



Check telescopic fork for leaks



Loosen breather screws at fork legs (overpressure)



Change fork oil



Perform a full maintenance job for the telescopic fork



Clean dust scrabber on telescopic fork



Check steering head bearing clearance and adjust if necessary



Clean and grease steering head bearings and its seals



Check adjustment and funktion of shock absorber



Perform a full maintenance job for the shock absorber



Servicing swingarm pivots



Check tightness of spokes and rim join



Check wheel bearings for clearance



Check tire condition and air pressure



Check cables for damage and easy working



Lube and adjust cables

 

Check the electrical system



Check adjustment of head light



Spray emergency OFF switch, short circuit button and light switch with contact spray



Check all screws, nuts and hose clamps for proper tightness



Grease or lube all pivot points and sliding components



PERIODIC MAINTENANCE SCHEDULE

before each start

after washing

1st service, after

3 hours or

20 l fuel consumption

after 15 hours or

00 l fuel consumption

after 30 hours or

00 l fuel consumption

at least once a year

KTM

rider

KTM

dealer

IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE

RACING, THE 15 HOUR SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RACE

11.99

400/520 SX RACING

400/520 EXC RACING

Page 16

ENGLISH



WARNING



MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF.

CAUTION

–W

HEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE

, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CAR-

BURETOR, ELECTRIC CONNECTORS ETC.

–W

HEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT

THE FUEL TAP IS IN THE

OFF POSITION

- IF THE MOTORCYCLE SHOULD FALL OVER, NO FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK

–ONLY USE SPECIAL SCREWS WITH AN APPROPRIATE THREAD LENGTH SUPPLIED BY KTM TO FIX THE SPOILERS ON THE TANK. USING OTHER SCREWS OR

LONGER SCREWS CAN CAUSE LEAKS IN THE TANK THROUGH WHICH FUEL CAN FLOW OUT

–D

O NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING

LOOSE

. INSTEAD, USE SELF-LOCKING NUTS.

–L

ET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.

–R

EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.

–U

NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL CONTAMINATES

1.000.000

LITERS WATER.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Changing the original position of the clutch lever

The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar.

CAUTION

DJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CERTAIN LIMITS

NLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE.

Checking and adjusting the steering head bearing *

Check steering head bearing for play periodically. For check put motorcycle on stand so that the front wheel is off the ground. Now try to move the fork forward and backward. For readjusting, loosen the five pinch bolts

of the top triple clamp and turn steering stem bolt clockwise 3 until there is no more play. Don’t tighten the steering stem bolt all the way, otherwise the bearings will be damaged. With a plastic hammer, lightly rap on the triple clamp to release tension. Retighten the five pinch bolts to 20 Nm (15 ft.lb).



WARNING



F THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTORCY-

CLE WILL EXHIBIT UNSTEADY DRIVING CHARACTERISTICS AND CAN GET OUT OF CONTROL.

CAUTION

IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS, THE

BEARINGS AND SUBSEQUENTLY THE BEARING SEATS IN THE FRAME WILL BE DESTROYED

The steering head bearings should be regreased at least once a year (i.e. Shell Advance Grease).

Page 17

ENGLISH

Breather plug front fork

After every 5 hours of use for competitive racing, slacken the breather plugs

1 a few turns in order to relieve excess pressure from the inside of

the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to have this job performed in the course of the periodical maintenance service.

CAUTION

XCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF

YOUR FORK IS LEAKING

, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE

HAVING THE SEALS REPLACED

Cleaning the dust sleeves of the telescopic fork

The dust-protection bellows 2 are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lever the dust-protection bellows out of the outer tubes and slide them downward.

Clean dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil them thoroughly with silicone spray or engine oil. Then, push dust-protection bellows into the outer tubes by hand.

How to change the handlebar position

The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar to the position that is the most convenient for you. The upper triple clamp

3 includes 2 bores arranged at a distance of 15 mm (0,6 in) from

one another. The bores at the handlebar support

4 are offset from the cen-

ter by 3.5 mm (0,13 in). Accordingly, you can mount the handlebar in 4 different positions.

For this purpose, remove screws

5 of the handlebar clamps and screws 6

of the handlebar support. Position handlebar support, and tighten screws 6 to 40 Nm (30 ft.lb). Mount handlebar and handlebar clamps, and tighten screws 5 to 20 Nm (15 ft.lb). The gap between handlebar support and handlebar clamps is to be of equal size in the front and in the rear.

15 mm

3,5 mm

Page 18

ENGLISH

Changing the spring preloading of the shock absorber

The spring preload can be changed by turning the adjusting ring 1. For this purpose, you should dismount the shock absorber and clean it thoroughly.

NOTE: – Before changing the spring preload note down the basic setting, e.g.

how many threads are visible above the adjusting ring.

– One rotation of the adjusting ring 1 changes the spring pretension by

approximately 1,75 mm (0,07 in).

Loosen the clamping screw

2 and use the hook wrench contained in the

vehicle tool set to turn the adjusting ring as desired. Turning it counterclockwise will reduce the preload, turning it clockwise will increase the preload. After readjusting the clamping screw

2, tighten it to 8 Nm (6 ft.lb)

ADJUSTMENT VALUES - SPRING PRELOAD

minimum preload . . . . . . . . . . . . . . . . . 4 mm (0,15 in)

STANDARD PRELOAD . . . . . . . . . . . . . 6 mm (0,24 in)

maximum preload . . . . . . . . . . . . . . . . . 10 mm (0,4 in)

Pivot bearing

The pivot bearing 3 for PDS suspension struts at the swinging fork is Teflon-coated and must not be lubricated with either grease or other lubricants. Grease and other lubricants cause the Teflon coat to dissolve, whereby the bearing’s lifecycle will be reduced dramatically.

When cleaning your bike with a high-pressure cleaner, do not aim the highpressure spray directly at the pivot bearing.

Check chain tension

To check the chain tension, park the motorcycle. Press chain upward at the end of the chain sliding component. The distance between chain and swing arm should be approx. 15 mm (0.6 in). In the course of this procedure, the upper chain portion A must be taut (see illustration). If necessary, correct chain tension.



WARNING



–E

XCESSIVE TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE COMPO-

NENTS OF THE SECONDARY DRIVETRAIN (CHAIN, BEARINGS OF TRANSMISSION AND REAR WHEEL

). ASIDE FROM RESULTING PREMATURE WEAR, IF WORST COMES TO

WORST THE CHAIN MAY RUPTURE OR THE COUNTERSHAFT OF THE TRANSMISSION MAY BREAK

–T

OO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN

JUMPING OFF THE CHAIN WHEELS

. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK

THE REAR WHEEL OR DAMAGE THE ENGINE

–I

N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.

15 mm

Page 19

ENGLISH

Correct chain tension

Loosen collar nut 2, loosen lock nuts 3, and turn right and left adjusting screws

4 equally far. Tighten lock nuts.

To ensure the correct alignment of the rear wheel, the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks

A. Tighten the counter nut of the adjusting screws.

Tighten collar nut

2 to 80 Nm (60 ft.lb).



WARNING



–I

F YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A

KTM DEALER AS SOON AS

POSSIBLE

. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE

–T

IGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE

NOTE: The large adjusting range of the chain adjusters (32mm) allows you to use different secondary ratios in combination with the same chain length. The chain adjusters 5 can be rotated around 180°.

Chain maintenance

For long chain life, good maintenance is very important. Chains without Orings should be cleaned in fireproof solvent regularly and afterwards treated with hot grease or chain spray (i.e. Shell Advance Bio Chain). O-ring chains on the other hand are very simple to clean. The best way is to use lots of water, but never use brushes or cleaning liquids. After letting the chain dry, you can use a special O-ring chain spray (i.e. Shell Advance Bio Chain).



WARNING



NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISKS

, EITHER-

WISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRON- GLY REDUCED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL.

CAUTION

HEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK

CLIP MUST POINT IN RUNNING DIRECTION

Also check sprockets and chain guides for wear, and replace if necessary.

Chain wear

In order to check the chain wear, regard the following indications: Shift the gear into idling and pull the upper chain strand with approx. 10-15 Kilogramm (33 lb) upwards (see figure). Now one can measure a space of 18 chain reels at the lower chain strand. The chain should be replaced at the latest when a space of 272 mm (10.70 in) is measured. Chains do not always wear off evenly, therefore repeat the measurement at different places on the chain.

NOTE: If you mount a new chain, the sprockets should also be replaced. New chains wear faster if used on old used sprockets.

CAUTION

ECURE THE SCREWS OF THE CHAIN WHEEL BY APPLYING LOCTITE AND FASTEN THEM IN A

CROSSWISE ORDER

IGHTENING TORQUE FOR NUTS: 35 NM (25 FT.LB)

IGHTENING TORQUE FOR SCREWS: 50 NM (37 FT.LB)

15 KG 33 lbs

max. 272 mm

1 2 3

16 17 18

✓

max. 10,7 in

Page 20

ENGLISH

General information about KTM disc brakes

BRAKE CALIPERS: The brake calipers of this series use a „floating” mount. This means that the brake calipers are not solidly attached to the caliper support, which enables them to „float” for maximum braking contact.

BRAKE PADS: Brake pads are equipped with a sintered lining (TOSHIBA TT2701) in the front and an organic lining in the back (FERODO ID450). These linings make up the best mix of controllability, braking power and life. The type of lining is specified on the backside of the brake pads and also entered in the approval documents.

For competition purposes, also other types of linings are available: FRONT TOSHIBA H38 (sintered) - less braking power, longer life; for wet,

slippery terrain. FERODO ID450 (organic) - good braking power, shorter life; for dry terrain, cheaper.

REAR GOLDFREE KBA60878 (sinter) - higher braking power, longer life.

FERRIT 222 (organic) - better controllability, shorter life.

BRAKE DISCS: Due to wear, the thickness of the brake disc in the area of the contact face

1 of the brake pads decreases. At their thinnest point A, the brake

discs must not be more than 0.40 mm (0,016 in) thinner than the pad's nominal thickness. Measure the nominal thickness in a location

B outside

the contact face. Check wear in several locations.



WARNING



–B

RAKE DISCS SUFFERING FROM WEAR GREATER THAN 0,4 MM (0,016 IN) CONSTI-

TUTE A SAFETY RISK. HAVE THE BRAKE DISCS REPLACED IMMEDIATELY AS SOON AS THEY REACH THE WEAR LIMIT

–H

AVE ANY REPAIRS ON THE BRAKE SYSTEM BE PERFORMED BY A KTM DEALER

BRAKE FLUID RESERVOIRS: The brake fluid reservoirs on front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid. If the brake fluid level drops below the minimum level either the brake system has a leak or the brake pads are completely worn. In this case, consult an authorized KTM dealer immediately.

BRAKE FLUID: KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. If you do not have any DOT 5.1 for refilling, you may use DOT 4 brake fluid. However, you should replace it as soon as possible by DOT 5.1. Never use brake fluid DOT 5. The color of this silicon oil-based product is purple red. The gaskets and brake hoses of KTM motorcycles are not designed for DOT 5 brake fluid!



WARNING



HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR

MOTORCYCLE OFTEN

, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FREQUENTLY.

RAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCKETS MAY FORM IN

OLD"

BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING THE BRAKE SYSTEM TO

FAIL

Adjusting of free travel at the hand brake lever

Free travel at the hand brake lever may be readjusted by using adjustment screw

2. In this way, the position of the point of pressure (i.e., the resi-

stance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size.

CAUTION

T THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN). ONLY

THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED

(TO BE RECOGNIZED BY

THE GREATER RESISTANCE OF THE HAND BRAKE LEVER

). IF THIS FREE TRAVEL IS NOT PRO-

VIDED, PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM, AND THE FRONT-WHEEL BRAKE MAY FAIL DUE TO OVERHEATING

DOT

5.1

DOT

✓

min. 3 mm

A B

Page 21

ENGLISH

Checking of brake fluid level - front brake

The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass. With the reservoir in a horizontal position, the brake fluid level should not drop below the middle of the glass.



WARNING



F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN

. IN THIS CASE, CONSULT AN

AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the front brake fluid reservoir *

Loosen screws 1 and remove lid 2 and membrane 3. Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0.2 in) below the rim with clean brake fluid DOT 5.1 (i.e. Shell Advance Brake DOT 5.1). Replace membrane and lid, tighten screws. Rinse off spilled or overflowing brake fluid with water.



WARNING



–N

EVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR

. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–B

RAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.

F YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT

A DOCTOR

CAUTION

–D

ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT

REMOVER

–U

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

Checking the front brake pads

The brake pads can be inspected from below. The linings nust be at least 1 mm (0.04 in) thick.



WARNING



AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY

DON

’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

F THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN

, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,

THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing front brake pads *

Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips

4 and pull out bolt 5. Remove brake pads

from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and grease guide bolts if necessary.

min.

1 mm

5 mm

Page 22

ENGLISH

Mount the right brake pad and fix it with the bolt. Mount the left brake pad and insert the bolt until it stops. Mount the clips. When mounting the brake pads, be sure to check for correct fit of the sliding metal-sheet

6 in the caliper support and of the leaf spring 7.



WARNING



–I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS.

THERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

–A

FTER ASSEMBLY, CHECK IF CIRCLIPS HAVE BEEN FITTED CORRECTLY.

–HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALWAYS

ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER

, RESPECTIVELY SO AS TO

ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED

Changing the basic position of the foot brake pedal *

The basic position of the foot brake pedal can be altered by turning the stop screw

1. The free play at the foot brake pedal must then be adjusted by

means of the piston rod

Measured on the outside, the foot brake pedal must have 3-5 mm (0.12–0.20 in) of free play, before the piston rod can move the piston in the brake cylinder (to be recognised from the resistance on the foot brake pedal).

CAUTION

F THIS FREE PLAY IS NOT PRESENT

, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM

WHEN DRIVING

, CAUSING THE REAR WHEEL TO BRAKE.THE BRAKING SYSTEM OVERHEATS

AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES

Checking rear brake fluid level

The reservoir for the rear disc brake is disposed on the engine in the vicinity of the oil filters. The brake fluid level must not drop below the „MlN” marking when the vehicle is in an upright position.



WARNING



F THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A

LEAK OR THE BRAKE PADS ARE COMPLETELY WORN

. IN THIS CASE, CONSULT AN

AUTHORIZED

KTM DEALER IMMEDIATELY.

Refilling the rear brake fluid reservoir *

When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir. This is done by first unscrewing the cap

3 and rubber bellows 4. Add

brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1) until it reaches the MAX mark, then screw rubber bellows and cap back on. Rinse off spilled or overflowing brake fluid with water.



WARNING



–N

EVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE

COLOR

. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT.

–S

TORE BRAKE FLUID OUT OF REACH OF CHILDREN.

–B

RAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES.

F YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT

A DOCTOR

CAUTION

–D

ON’T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT

REMOVER

–U

SE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

3-5mm

Page 23

ENGLISH

Checking the rear brake pads

The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in).



WARNING



T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN

1 MM

, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE

. FOR YOUR OWN SAFETY

DON

’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.

CAUTION

IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY

WORN

, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC,

THEREBY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC.

Replacing the rear brake pads *

Push the brake caliper 1 toward the chain wheel in order to move the brake piston into its basic position. Remove clips

2, pull out the bolt 3,

and remove the brake pads. Thoroughly clean the brake caliper with compressed air and check the sleeves of the guide bolts for damage.

Insert the left brake pad into the brake caliper and secure it with the bolt. Insert the right brake pad and push the bolt

3 into the brake caliper up to

the stop. Reattach clips



WARNING



–I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS

THERWISE, THE BRAKING EFFECT WOULD BE STRONGLY REDUCED.

–A

FTER ASSEMBLY, CHECK IF CLIPS HAVE BEEN FITTED CORRECTLY.

–HAVING PERFORMED ANY WORK ON THE BRAKING SYSTEM, ONE MUST ALWAYS

ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER

, RESPECTIVELY SO AS TO

ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED

Dismounting and mounting the front wheel

To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen the collar nut

Loosen the 4 clamping screws

5 on the fork fists.

Hold the front wheel, pull out the wheel spindle

NOTE: The wheel spindle can be easily removed if you slightly revolve it with a ring span-ner (SW 21 mm) or a hexagon socket screw key (6 mm). Remove front wheel carefully from the fork and take the speedometer drive

7 off the hub.

NOTE: Models with a digital speedometer have a distance bushing instead of the speed-ometer drive.

CAUTION

–D

O NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN

DISMOUNTED

–M

AKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,

OTHERWISE THE BRAKE DISC CAN BE DAMAGED

Prior to mounting the front wheel, clean and grease sealing ring

8 and

running surface

9 at the speedometer drive.

Lift front wheel into fork, and insert speedometer drive or distance sleeve into hub. Make sure that the driving tabs

bk engage with the slot of the

drive. Position front wheel and speedometer drive or distance sleeve and mount wheel spindle.

min.

1 mm

Page 24

ENGLISH

The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer. Mount the collar nut

4, turn the speedometer drive such that the speedo-

meter shaft is directed upward parallel to the fork leg (see photo), and tighten the collar nut to 40 Nm (30 ft.lb). Take the motorcycle off the stand and bounce the fork hard a few times to align the fork legs. Then tighten clamping screws

5 to a max. torque of 10 Nm (7 ft.lb).



WARNING



–IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A

KTM DEALER AS SOON AS

POSSIBLE

. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE

–A

FTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE

PRESSURE POINT RETURNS

–I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED

Dismounting and mounting the rear wheel

Jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Loosen the collar nut

1, remove chain tensioner 2, hold the rear wheel

and pull out the wheel spindle

3 until the rear wheel is free but the brake

caliper support is still held. Push the rear wheel as far forward as possible, take the chain from the chain wheel and carefully take the rear wheel out of the swingarm.

CAUTION

–D

O NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED.

–MAKE SURE THE BRAKE DISC IS ALWAYS ON TOP WHEN YOU LAY DOWN THE WHEEL,

OTHERWISE THE BRAKE DISC CAN BE DAMAGED.

–I

F THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND

COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE TO PREVENT THE THREAD FROM JAMMING

The rear wheel is remounted in reverse order. Before tightening the collar nut to 80 Nm (60 ft.lb), push the rear wheel forwards so that the chain tensioners lie on the tension screws.



WARNING



–IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU

HAVE THE TIGHTENING TORQUE CORRECTED BY A

KTM DEALER AS SOON AS

POSSIBLE

. A

LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR

MOTORCYCLE

–A

FTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE REAR BRAKE UNTIL THE

PRESSURE POINT RETURNS

–I

T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS,

EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED.

–TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE. A LOOSE WHEEL SPINDLE

MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE

Page 25

ENGLISH

Tires, air pressure

Tire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in their homolo-

gation certificate

– Tire condition has to be checked every time you want to ride your

motorcycle. Before leaving, check tires for punctures and nails or other sharp objects that might have become embedded in them. Refer to the specific regulations in your country for minimum tire tread requirements. We recommend you replace the tires at the latest when the tread is down to 2 mm (0.08 in).

– Tire pressure should be checked regularly on a “cold” tire. Proper pres-

sure ensures optimum driving comfort and extends the life of your tires.



WARNING



–D

O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY

KTM. OTHER TIRES

COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES

–

FRONT AND REAR WHEELS MAY ONLY BE FITTED WITH TIRES HAVING THE SAME TREAD LAYOUT

. USE HOMOLOGATED TIRES

–F

OR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY.

–W

ORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE

PERFORMS

, ESPECIALLY ON WET SURFACES

–I

F AIR PRESSURE IS TOO LOW, ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN

RESULT

Checking spoke tension

The correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. For checking, tap on each spoke with the blade of a screwdriver (see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer.



WARNING



POKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO AN

UNSTABLE HANDLING OF YOUR MOTORCYCLE

Replacing the battery of the digital speedometer

After approx. 2 years, the battery of the digital speedometer will be empty and must be replaced. For this purpose, the speedometer must be dismounted. Remove headlight mask, and pull speedometer illumination system

1 out

of the speedometer housing.

Use a screwdriver to lever the blue speedometer glass

2 downward and

out of the speedometer housing

3. The two noses A must be disengaged

from the speedometer housing. Remove screws 4, and take speedometer out of housing. Before you remove the battery, do not forget to write down the following data: – total kilometer reading (DST) – wheel circumference (WS) (KTM standard tires = 2205 mm)

Remove the battery cover on the back of the speedometer and detach the batteries. The new batteries must be inserted with the plus pole on top. Make sure that the seal ring has the right position on the cover when mounting the battery cover. Now total mileage, wheel circumference and time have to be entered.

To mount the speedometer, proceed by following the reverse order of the above procedure.

front rear

Off road 1,0 bar 1,0 bar

Road driver only 1,5 bar 2,0 bar

TIRES-AIR PRESSURE

Page 26

ENGLISH

TOTAL MILEAGE „DST“

TIME „CLK“

AFTER CHANGING BATTERY

1 sec

5 sec

1 sec

1. use the right button to

select the position to be changed

1. make sure the time is indicated and push the button on the back approx. 5 seconds (time starts blinking)

2. push the left button until the right figure is showed in the display

3. by pushing the right button you jump to the next figure

4. repeat nos. 2 + 3 until correct time is indicated

5. push the button on

the back approx. 1 second to terminate the setting procedure

2. push the left button until the right figure is showed in the display

3. by pushing the right button you jump to the next figure

4. repeat nos. 2 + 3 until the previously noted total mileage is indicated

5. push the button on the back with a sharp object approx. 1 second to terminate the setting procedure (the value is thus stored)

Page 27

ENGLISH

Check/set distance of the magnetic sensor

The distance between magnet 2 and sensor 1 must be 2-4 mm (0,08-0,16 in), otherwise malfunctions on the speedometer might occur.

This distance can be corrected by screwing in or off the sensor

WHEEL CIRCUMFERENCE „WS“

1. make sure that the indication

"TRP" is active and push the button on the back approx. 5 seconds ("WS" appears)

2. use the right button to select the position to be changed

3. push the left button until the right figure is showed in the display

4. repeat nos. 2 + 3 until correct wheel circumference is indicated

5. push the button on the back for approx. 1 second to terminate the setting procedure

5 sec

1 sec

mm x 3,14

km/h:

WS = mm x 3,14

mp/h:

WS = (mm x 3,14) : 1,61

Wheel circumference with standard tires = 2205 mm

Page 28

ENGLISH

Battery (EXC)

The battery is mounted under the seat. The battery has a closed system and therefore requires no maintenance. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary.

Removing the battery: First disconnect the negative and then the positive pole of the battery. Remove filter box cover and unhitch both rubber bands

Remove battery. When replacing, connect first the positive and then the negative pole.



WARNING



–I

F ELECTROLYTE

(SULPHURIC ACID)

LEAKS FROM THE BATTERY, PROCEED WITH GREAT

CARE

. THE ELECTROLYTE CAN CAUSE SEVERE BURNS

–I

N THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER

–I

N THE CASE OF CONTACT WITH THE EYES

, THOROUGHLY RINSE EYES WITH WATER

FOR AT LEAST

15 MINUTES. IMMEDIATELY CONSULT A DOCTOR!

–T

HE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES

VOID SPARKS AND OPEN FIRE NEAR THE BATTERY

–D

EFECT BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN. ENSURE

PROPER DISPOSAL OF DISCARDED BATTERIES

CAUTION

–T

O AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR

–NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL

DESTROY THE RECTIFIER

-REGULATOR.

BATTERY STORAGE: When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not expose to direct sun radiation.

Charging the battery

Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring.

If the battery is empty, it can be recharged for a maximum period of 10 hours at 0.5 A and a maximum of 14.4 V.

CAUTION

–T

O AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.

–A

LWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE

CHARGING UNIT ON

–W

HEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTI-

LATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS.

–C

HARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES.

THERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES.

–A

VOID QUICK CHARGING IF POSSIBLE.

off load voltage charging level charging time

charging voltage

Volt % 0,5 A

>12,7 100 –– ~12,5 75 4 h

max.

~12,2 50 7 h

14,4 V

~12,0 25 11 h ~11,8 0 14 h

VOLT

Page 29

ENGLISH

Fuse (EXC)

The fuse 1 is disposed in the starter relay of the E-starter 2 underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover

A, you will be able to see the fuse.

The following loads are connected to it: – E-starter system – horn – flasher lights

The starter relay also contains a (10 amp) spare fuse

Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere.

CAUTION

NDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE

ALLOWED TO BE

“REPAIRED”. AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE

ELECTRICAL INSTALLATION

Replacing headlight lamp (H4)

Loosen both rubber bands 4 and tilt headlight mask to the front. Remove bulb plug

5 and remove rubber cap 6. Turn the supporting ring counter-

clockwise and remove it from the reflector together with the bulb.

Insert a new bulb such that the noses

7 fit into the recess 8. Do not touch

the glass body of the bulb, to keep if free from grease. Mount supporting ring, rubber cap and plug. Position headlight mask with the bottom holders, and fasten it with the rubber bands.

Page 30

ENGLISH

Cooling system

Coolant is circulated by a water pump 1 located in the engine. When the engine is cold the coolant circulates only through the cylinder and the cylinder head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat

2 opens and the coolant is also pumped

through both aluminum radiators. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down. Dirty radiators also reduce the cooling efficiency. Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap

3; a water temperature rising up to 120° C

(248° F) is admissible, without fear of problems.



WARNING



–I

F POSSIBLE

, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD.

F YOU HAVE TO OPEN THE RADIATOR CAP 3 WHEN THE ENGINE IS HOT

, USE A RAG

TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE

. C

AUTION -

SCALDING

HAZARD

–D

O NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT

. THE ESCAPING

HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS

–I

N CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING

COLD WATER RIGHT AWAY

–COOLANT IS TOXIC

. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN!

–I

N CASE COOLANT IS INGESTED, GO SEE A DOCTOR IMMEDIATELY!

–I

F COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDIATELY

AND GO SEE A DOCTOR

A mixture of 40% anti freeze liquid and 60% water is used as coolant. However, the anti-freeze protection must be at least -25° C (-13° F). This mixture offers anti-freeze protection but also good corrosion protection and should therefore not be replaced by pure water.

CAUTION

–I

F THE COOLANT HAS BEEN DRAINED, IT WILL BE ABSOLUTELY NECESSARY TO BLEED

THE COOLING SYSTEM DURING FILLING

(SEE BELOW

–F

OR THE COOLING SYSTEM, USE ONLY WITH HIGH-GRADE ANTIFREEZE (I.E. SHELL

ADVANCE COOLANT). USING LOWER-GRADE ANTIFREEZE AGENTS, CAN CAUSE

CORROSION AND COOLANT FOAMING

Checking the coolant level

The coolant should be 10 mm (0.4 in) above the radiator fins when the engine is cold (cf. diagram). In the event of the coolant being drained, always fill and bleed the system.



WARNING



–IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD.

F YOU HAVE TO OPEN THE RADIATOR CAP 3 WHEN THE ENGINE IS HOT, USE A RAG

TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE

. CAUTION - SCALDING

HAZARD

–D

O NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE ESCAPING

HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS

–I

N CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING

COLD WATER RIGHT AWAY

–C

OOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN!

–I

N CASE COOLANT IS INGESTED, GO SEE A DOCTOR IMMEDIATELY!

–I

F COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDIATELY

AND GO SEE A DOCTOR

CAUTION

F THE COOLANT HAS BEEN DRAINED, IT WILL BE ABSOLUTELY NECESSARY TO BLEED THE

COOLING SYSTEM DURING FILLING

(SEE BELOW).

Bleeding the cooling system

By removing the screw 4 at the front end of the cylinder you can drain the coolant. To bleed the cooling system, fill in approx. 0.8 liters (0,2 US Gallons) of coolant and remove the bleeder screw

5. Do not reinstall the bleeder screw

until coolant escapes at the bore without any bubbles. Then, fill in the coolant until it reaches a level about 10mm above the radiator fins. After a short ride, check the coolant level once more.

when engine is cold

10 mm

Page 31

ENGLISH

Cleaning the air filter *

A dirty air filter impairs the air-flow rate, reduces the engine performance, and increases the fuel consumption. In extreme cases, dirt may even get into the engine and cause damage. Therefore, change the air filter in regular intervals. For this purpose, rotate the two quick-release fasteners

1 counter-clock-

wise and pull them outward up to the stop, pull the filter box cover forward and remove it. Unhook the filter holding brackets

2 at the bottom, swing

them sideways and take the air filter

3 together with the filter support 4

out of the filter box.

CAUTION

–D

O NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE

THE FOAM

. KTM RECOMMENDS THE PRODUCTS MADE BY PUTOLINE FOR AIR FIL-

TER MAINTENANCE.„A

CTION CLEANER” FOR CLEANING PURPOSES AND „ACTION

FLUID”

TO OIL THE AIR FILTER

–N

EVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS

. OTHERWISE, DUST

AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR

Thoroughly wash the air filter in special cleaning fluid and allow it to dry well. Only press out the filter, do not wring it out under any circumstances. Oil the dry air filter with a high-grade filter oil. Also clean the air filter box. Check carburetor collar for damage and that it is filled correctly. Mount the air filter on the filter support. Apply grease to the face

A of the

filter to improve its sealing properties. Mount the filter together with the filter support in the filter box, making sure to properly center them, and fix them with the filter holding bracket.

Replacing the glass fiber yarn packing of the silencer *

Aluminum silencers are filled with glass fiber yarn to muffle noise. The effect of heat causes the glass fiber yarn to become loose. This may lead to a loss of performance and reduce the silencer's muffling power. By experience, the front glass fiber yarn packing

5 needs to be replaced more often

than the rear silencing mat

For this purpose, remove the silencer from the vehicle and dismount the front cap

7. Pull the front glass fiber yarn packing together with the inner

exhaust pipe

8 out of the silencer. Clean the front inner exhaust pipe.

To facilitate the mounting procedure, you can make a mounting tool

9 out

of wood, plastic, or metal. Insert the mounting tool into the inner pipe and mount the glass fiber packing. Push the inner pipe containing the packing into the silencer such that the slot engages the web

C. Use a blunt ended

object to stuff the glass fiber yarn packing all the way into the silencer, and mount the front cap.

To change the rear silencing mat, start by removing the front packing and the inner exhaust pipe. Then, drill open the rivets and remove the end cap.

NOTE! In every exhaust repair procedure, the O-rings must be replaced by new ones. Glass fiber yarn packings are available at your licensed KTM mechanic.



WARNING



THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING. TO

AVOID BURNS

DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY

COOLED DOWN

Cleaning the spark arrester (EXC USA) *

The spark arrester should be cleaned every time the glass fiber yarn filling is changed or at least once annually. For this purpose, dismount the silencer cap and remove any deposits that might exist in region

D. Renew the O-ring and mount the silencer cap.

EXC

Page 32

ENGLISH

Checking the adjustment of the hand decompression release cable *

Start the engine and, at idling speed, slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever. The backlash until said thumping should be approx. 10mm, measured at the lever's outer end. If necessary, correct this backlash. To adjust move back the protective cover

1, loosen the counter nut 2 and

correct the adjustment screw

3 accordingly. Tighten counter nut and push

back protective cover.

CAUTION

IF THERE IS NO PLAY IN THE DEKO-LEVER, THIS CAN RESULT IN ENGINE DAMAGE.

NOTE: No adjustment need be made to the automatic decompressor.

Adjusting the throttle cables *

The throttle grip should always provide for a backlash of 3-5mm. Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right. To adjust the throttle cables, dismount the seat and the tank together with spoilers. Slide back the protection cover

4. Loosen the counter nut 5 and

turn the adjusting screw

6 accordingly. Turning the adjusting screw coun-

terclockwise will reduce the backlash, turning the adjusting screw clockwise will increase the backlash. Tighten the counter nut and check whether the throttle grip can be actuated smoothly. Mount tank and seat.

Checking the oil level of the hydraulic clutch

To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws

7 and cover together with the rubber

boot

8. The oil level in the horizontal-standing master cylinder should be

4 mm below the upper edge. If necessary add SAE 10 hydraulic oil (e.g. Shell Naturelle HF-E15).

CAUTION

NLY USE SAE 10 MINERAL HYDRAULIC OIL TO REFILL THE MASTER CYLINDER. NEVER

USE BRAKE FLUID

Bleeding of the hydraulic clutch *

For bleeding, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove screws

7 and take off cover together

with rubber bellows

8. At the slave cylinder of the clutch, remove the

bleeder nipple

4. At its place, mount the bleeder syringe 9 which is filled

with SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore

of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased at your KTM dealer.

CAUTION

AVING COMPLETED THE BLEEDING PROCEDURE, YOU HAVE TO VERIFY THAT THE OIL

LEVEL IN THE MASTER CYLINDER IS CORRECT

. FOR FILLING OF THE MASTER CYLINDER, USE

SAE 10 MINERAL HYDRAULIC OIL (e.g. Shell Naturelle HF-E15) ONLY; NEVER USE

BRAKE FLUID

10 mm

Page 33

ENGLISH

CARBURETOR – Adjust idling (MX-FCR39) *

Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly.

The idle speed is controlled by means of the adjusting wheel

1 and the

mixture control screw

2. The adjusting wheel is used to adjust the basic

setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system. Clockwise turning reduces the fuel quantity (lean mixture), counterclockwise turning increases the fuel quantity (rich mixture).

TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS: 1 Turn in mixture control screw

2 up to the stop, and turn it back out to

the basic position (see tecnical date engine) 2 Warm up the engine 3 Use the adjusting wheel

3 to set the normal idle speed (1400 - 1500

rpm). 4 Turn mixture control screw

2 slowly clockwise until idling speed starts to

decrease. Memorize this position, and turn mixture control screw slowly

counterclockwise until the idling speed will decrease again. Adjust the

point of the highest idling speed between these two positions. If, in the

course of this procedure, the speed undergoes a relatively high increase,

reduce the idle speed to a normal level and repeat the procedure speci-

fied in 4. Serious competitive racers will choose a setting approx. 1/4

turn (clockwise) leaner than this ideal value because their engine will

heat up more when used in competitions.

NOTE: If you fail to obtain a satisfying result by following the procedure

described above, an incorrectly dimensioned idling nozzle may be the

cause. In case:

a) the mixture control screw has been screwed in up to the stop without

causing any change in rotational speed, a smaller idling jet has to be

installed;

b) the engine dies when the mixture control screw is still open by

2 turns, a larger idling jet needs to be selected;

Naturally, in cases of jet changes, you have to start your adjusting work

from the beginning. 5 Then, use the adjusting wheel to set the desired idle speed. 6 In cases of greater changes in outside temperature and extremely

different altitudes, the idling speed should be readjusted.

Basic information on carburetor wear

As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 200 hours.

Adjusting the mixture control screw *

Especially on the EXC models, accessing the mixture control screw is difficult. For this reasons, we have created an appropriate special tool. Introduce the special tool into the bore

A at the carburetor bottom. Press

the tool slightly upward and turn the adjusting wheel

3until the tool enga-

ges the slot of the mixture control screw

Now, you can go about adjusting the screw. Marks were provided on the adjusting wheel, making it easier to keep track of the turns.

Checking the float level (float height) *

For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it (see photo). Now, use a sliding caliper to measure the distance

H between the casing

edge and the float's upper edge. The float height

H is to be 9mm.

If the float height does not correspond to the desired value, check the float needle valve and, if necessary, replace it.

If the float needle valve is o.k., you can adjust the float height by bending of the float lever

Mount the float chamber, install the carburetor, and adjust the idle speed.

Page 34

ENGLISH

Draining of float chamber of the carburetor

Following every wet cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes malfunction.

Perform this task on a cold engine. Close the fuel tap and place a cloth underneath the carburetor, which is able to absorb any escaping fuel. Unscrew the plug 1 and clean it with compressed air. Check the O-ring and reinstall the plug. Open the fuel tap and check the float chamber for leaks.



WARNING



–F

UEL IS EASILY FLAMMABLE AND TOXIC. WHEN HANDLING FUEL, BE SURE TO EXERCISE

THE UTMOST CAUTION

. NEVER PERFORM ANY WORK ON THE FUEL SYSTEM IN THE

PROXIMITY OF OPEN FLAMES OR BURNING CIGARETTES

–A

LWAYS ALLOW THE ENGINE TO COOL OFF FIRST

. IMMEDIATELY CLEAN UP ANY FUEL

WHICH MAY HAVE BEEN SPILLED

. MATERIALS SATURATED WITH FUEL ARE ALSO EASILY

FLAMMABLE

. IN CASE YOU INGESTED FUEL OR FUEL SPLASHED INTO YOUR EYES

CONSULT A DOCTOR IMMEDIATELY

–D

ISPOSE THE FUEL PROPERLY

Oil circuit

Via the long oil screen 2, the oil pump 1 draws engine oil from the oil sump of the transmission. This engine oil flows through an oil line 3 into the cylinder head for camshaft lubrication 4; the oil quantity is controlled by the jet screw 5. An oil duct branches off to the long oil filter 6 where the coarser particles contained in the engine oil are filtered away. Then, the engine oil arrives at the short oil filter 7 which also filters the fine particles. Now, the purified engine oil is pumped past the bypass valve 8 to the conrod bearing 9 and sprayed from below onto the piston through a nozzle bk. The second oil pump bl draws the engine oil via the short oil screen bm out of the crankcase, thereby lubricating the transmission gears bn.

Checking the engine oil level

The engine oil level can be checked with the engine being either warm or cold. Place the motorcycle in an upright position and on a horizontal surface (not on the side stand).

If the engine is cold, the engine oil must be visible at the lower edge of the inspection glass

If the engine is warm, the engine oil must be visible up to the upper edge of the inspection glass

Replenish the engine oil, if necessary.

CAUTION

NSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMATURE WEAR IN

THE ENGINE

If the inspection glass is heavily soiled (e.g. after a race in muddy terrain), the engine oil level can also be measured with the oil dipstick. For this purpose, unscrew the dipstick and wipe it clean with a cloth. Screw the dipstick back in and screw it out again. If the engine is warm, the oil level should be near the MAX mark

C (+0mm –5mm) (+0in –0,2in).

CAUTION

HEN REMOVING THE OIL DIPSTICK, BE CAREFUL TO AVOID THAT NO DIRT MAY GET

INTO THE ENGINE

Check engine for leaks.

Page 35

ENGLISH

Engine oil

Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or surpassing the quality requirements of API classes SG or SH (see specifications on the container).

CAUTION

NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE

Changing the engine oil *

NOTE: WHEN CHANGING THE ENGINE OIL

, IT IS NECESSARY TO CLEAN THE SHORT AND

LONG OIL SCREENS AND TO REPLACE BOTH OIL FILTERS

Engine oil has be changed with the engine being at operating temperature.

CAUTION

N ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE VERY

HOT

- DO NOT BURN OR SCALD YOURSELF!

Place the motorcycle on a horizontal surface, remove the plug

1 and allow

the oil to drain into a receptacle. Clean plug (with magnet) thoroughly. Once the entire oil has been drained, clean the sealing surface, mount the plug together with the sealing ring and tighten it to 20 Nm (15 ft.lb).

CLEANING THE SHORT OIL SCREEN The short oil screen

2 is accommodated in the hex-socket plug 3 at the

engine bottom. Insert a pin-type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug. Dismount the oil screen, clean the components thoroughly and blow compressed air through them. Check the O-rings for damage and, if necessary, replace them. Mount the oil screen together with the plug again and tighten the plug to 10 Nm (7 ft.lb).

CLEANING THE LONG OIL SCREEN The long oil screen is accommodated in the hexagon plug

4 adjacent the

engine number. Dismount the plug together with the oil screen, clean the components thoroughly and blow compressed air through them. Check the O-rings for damage and, if necessary, replace them.

To mount the long oil screen

5, place it on an approx. 300 mm (12 in) long

pin-type key or a similar tool. Insert the pin-type key through the opening into the bore of the opposite engine casing wall. Then, push the oil screen into the engine casing as far as possible. Remove the pin-type key, mount the plug and tighten it to 15 Nm (11 ft.lb).

 

–

0°C

32°F

15W 40 15W 50

10W 40 10W 50

API: SG, SH

TEMPERATURE

Page 36

ENGLISH

CHANGING THE OIL FILTERS Remove the screw

1 and swing the brake fluid container sideward. Place a

receptacle underneath the engine to collect the drained oil. Remove the 4 screws

2 and dismount the two oil filter covers.

Using circlip pliers, you may now pull the oil-filter inserts 3 out of the housing. Clean the oil filter cover, the sealing surfaces of the O-rings and the engine casing. Check the O-rings of the oil filter covers for damage and, if necessary, replace them.

Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil. Insert the long oil filter at the front and the short oil filter at the back of the housing. Grease the O-rings

4 of the oil filter covers and mount the covers. Mount

the screws and tighten them to 8 Nm (6 ft.lb). Position the brake fluid container and tighten the screw to 8 Nm (6 ft.lb).

Return the motorcycle to its upright position.

Remove the oil dipstick

6 at the clutch cover and fill in 1.2 liters of fully

synthetic engine oil (Shell Advance Ultra 4).

Start the engine and check all screwed connection and oil filter cover for leaks.

Finally, check the engine oil level and, if necessary, correct it.

Page 37

ENGLISH

TROUBLE SHOOTING

If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.

TROUBLE

Engine doesn’t crank (E-starter).

Engine cranks but doesn’t start (E-starter). Engine will not start (Kickstarter).

Engine fails to idle

CAUSE

Operating errror

Blown fuse

Discharged battery.

Operating error

The motorcycle has been out of operation for a longer period of time. Therefore old fuel has accumulated in the float chamber

Fuel supply interrupted

Flooded engine

Sooty or wet spark plug

Electrode gap too large

Spark plug connector or spark plug faulty

Short circuit cable scored in wiring harness, emergency OFF switch or short circuit button faulty

The plug connection of the CDIunit, the pulse generator or the ignition coil has oxydized

Water in carburetor or jets blocked

Glogged idling jet

Oncorrect adjustment of adjusting screws on carburetor

Defective spark plug

Defective ignition system

REMEDY

Turn on the emergency-OFF switch (Australia only)

Dismount the left paneling and the filter box cover and replace the fuse in the starter relay.

Recharge the battery and investigate the causes for discharging; contact a KTM dealer.

Open fuel tap, tank fuel, actuate choke. Pay attention to starting information (see driving instructions).

The easily inflammable components of the new fuels evaporate during longer periods of standstill. When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel.

Close fuel tap, loosen fuel hose at carburettor, lead into a basin and open fuel tap – if fuel leaks out, the carburetor might need cleaning – if no fuel leaks out, check tank ventilation, i.e. clean fuel tap

In order to "pump the engine free", pull the hand decompression lever, fully rev up the engine, actuate the kickstarter 5 to 10 times or actuate the E-starter 2 times for 5 seconds each. Then, start the engine as described above. If the engine fails to start, unscrew the spark plug and dry it.

Clean and dry the spark plug or exchange it, respectively

Adjust spark plug elektrode gap to 0,6 mm

Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate starter, a strong spark must be produced at the spark plug – If no spark is created exchange the spark plug. – If the new spark plug doesn't produce a spark either, dis-

connect the spark plug connector from the ignition cable,

hold it a distance of approx. 5 mm from ground and start. – If a spark now occurs, replace spark plug cap – If no spark is produced, control ignition system

Dismount the fuel tank, disconnect the black/yellow cable from the cable of the emergency-OFF switch and the short-circuit button, respectively, and check the ignition spark. If a spark is generated, look for the problem in the short-circuit circuit.

Remove the seat and the fuel tank. Clean the plug connection and treat it with contact spray

Dismount and clean carburetor

Disassemble carburetor and clean jets

Have carburetor adjusted

Replace spark plug

Have ignition system checked

Page 38

ENGLISH

TROUBLE

Engine does not rev high

Engine will not reach full power

Engine stops or splutters in carburettor

Engine gets to hot

High oil consumption

All switched on lamps blown out

Horn, flasher lights, and E-starter do not work

The battery is discharged

CAUSE

Carburettor fuel level too high because float needle valve is dirty or worn out

Loose carburettor jets

Electronical ignition timing faulty

Fuel supply partically interrupted or carburettor dirty

Float leaks

Air filter very dirty

Exhaust system is not tight, deformed, or the silencer contains not enough glass fiber yarn

Valve gap to small

Loss of compression because hand decompressor has no play

Electronical ignition timing faulty

Insuffient fuel

Engine takes air out of control

Insufficient cooling liquid

Not enough air stream

Cooling system has not been bled

Radiators very dirty

Foam formation in cooling system

Bent cooling hose

Thermostat defective

Hose of engine ventilation is bent

Engine oil level too high

Motor oil too thin (viscosity)

Capacitor or voltage regulator faulty

Blown fuse in the starter relay

The battery isn’t charged by the generator because

REMEDY

Dismount carburettor and check if worn out

Tighten jets

Have ignition system checked

Clean and check fuel system as well as carburettor

Replace the float

Clean or replace air filter

Check if exhaust is damaged, replace glas fibre yarn in exhaust silencer

Adjust valve gap

Check setting of the hand decompression cable

Have ignition system checked

Clean and check fuel system and carburettor

Check rubber sleeve and carburetor for tight fit

Refill cooling liquid (see maintenace work), check cooling system for leaks

Drive on briskly

Bleed cooling system

Clean radiators with water jet

Replace cooling liquid, use anti freeze liquid with brand name

Shorten or replace cooling hose

Dismount and check thermostat (opening temperature 70°C, (158°F) or replace it

Dislocate i.e. replace non-buckling vetilation hose

Check engine oil level and, if necessary, correct it

Use thicker engine oil; see chapter „Engine oil“

Dismount seat and fuel tank and check connections, have capacitor and voltage regulator checked

Dismount left side paneling and filter box cover, replace fuse

Remove seat and fuel tank and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer.

Page 39

ENGLISH

Should you desire to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil, short and long oil filters (old engine oil contains aggressive contaminations). – Check antifreezer and amount of cooling liquid. – Warm up the engine once again, close the fuel cock and wait until the engine dies. Then open the drain plug of the float chamber

to remove the remaining fuel.

– Remove spark plug and fill in approx. 5 ccm of engine oil into the cylinder through the opening. Actuate kick-starter 10 times in

order to distribute the oil onto the cylinder walls and mount the spark plug.

– Set piston to compression so that the valves will be closed (slowly operate the kickstarter, until you can hear the automatic

decompressor click (release)) – Let fuel flow out of tank into an appropriate container. – Correct tire pressure. – Lubricate pivot points of the control levers, foot rests, etc. as well as the chain. – Service the shock absorber linkage – Disassemble and charge battery (see chapter: BATTERY). – The storage place should be dry and not subject to excessive temperature fluctuations. – Cover the motorcycle with an air permeated tarpaulin or blanket. Do not use non air permeable materials as a possible humidity

might not be able to escape and could cause corrosion.

CAUTION

T WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD. THE ENGINE WOULD NOT GET WARMED UP ENOUGH

AND THE THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COMBUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST

RE-INITIATION AFTER TIME OF STORAGE

– Mount the charged battery (regard polarity). – Fill up tank with fresh fuel. – Check motorcycle as before each start (see driving instructions). – Take a short, careful test ride first.

NOTE: Before you put your motorcycle away for the winter, you have to check all parts for their function and wear. Should any service jobs, repairs, or any refitting be necessary, you should have them carried out during the off-season (lower workload at mechanics’ shops). This way, you can avoid the long waiting times at your mechanic at the beginning of the next biking season.

STORAGE

Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge.

The hard dirt can be removed before washing with the help of a soft water jet.

CAUTION

NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE

ELECTRICAL COMPONENTS

, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC. AND CAUSE DISTURBANCES OR LEAD TO A PREMATURE

DESTRUCTION OF THESE PARTS

– You should use normal brand-name detergents to clean the motorcycle. Especially dirty parts should be cleaned additionally with

the help of a paint brush.

– After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber of

the carburetor. Then take a short drive until the engine has reached the working temperature and also use the brakes. By warming these components, the residual water can evaporate from inaccessable parts of the engine and the brakes.

– Slide back the protective covers on the handlebar-mounted instruments so that any water that may have seeped into this part of

the motorcycle is allowed to evaporate.

– Once the motorcycle has cooled down, oil or grease all sliding and bearing points. Treat the chain with a chain spray. Also oil the

fuel tap.

– To avoid any malfunction of the electric system, you should treat emergency-OFF switch, short-circuit button, light switch and

socket connectors with a contact spray.

CLEANING

In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying, you will have to take precautions against the aggressive road salt. – clean motorcycle thoroughly and let it dry after each riding – treat engine, carburetor, swing arm, and all other bare or galvanized parts (except for brake discs) with a wax-based anti-corrosion

agent.



WARNING



EEP ANTI-CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS, FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER

CAUTION

FTER RIDES ON SALTED ROADS, CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL!

CONSERVATION FOR WINTER OPERATION

Page 40

ENGLISH

Type 400 SX RACING 400 EXC RACING 520 SX RACING 520 EXC RACING Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 ccm 510 ccm Bore/Stroke 89 / 64 mm 95 / 72 mm Ratio 11 : 1 Fuel unleaded premium gasoline with at least RON 95 Valve Timing 4 valves over rocker arm and 1 overhead camshaf, camshaft drive through single chain Camshaft 01 55 Valve diameter Intake: 35 mm Exhaust: 30 mm Valve clearence cold 0,12 mm (feeler gage 0,10 light, feeler gage 0,15 should not inserted) Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy cast alluminium alloy forged Piston rings 1 compression ring, 1 oil scraper ring Engine lubrication pressure circulation lubrication mit two rotorpumps Engine oil fullsynthetic oil (Shell Advance Ultra 4) Quantity of engine oil 1,25 liters Primary ratio straight geared spur wheels 33:76 Z Clutch multi disc clutch in oil bath Transmission 4-speed claw shafted 6-speed claw shafted 4-speed claw shafted 6-speed claw shafted Gear ratio 1

Gear 14:34 14:34 14:34 14:34

Gear 18:30 17:31 18:30 17:31

Gear 20:28 19:28 20:28 19:28

Gear 22:26 22:26 22:26 22:26

Gear – 24:23 – 24:23 6thGear – 26:21 – 26:21 Iginition system contactless DC-CDI ignition with digital advanced system by KOKUSAN Generator 12V 40W 12V 110W Spark plug NGK CR8 EK Spark plug gap 0,6 mm Cooling system liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter, 40% antifreeze, 60% water, at least -25° (-13° F) Starting equipment kickstarter kick - electric starter kickstarter kick - electric starter

TECHNICAL DATA – ENGINE

400/520 SX, EXC RACING 2000

BASIC CARBURETOR SETTING

Type MX-FCR39 MX-FCR39 MX-FCR39 Carb.-setting number 250899 130799 100699 Main jet 175 175 175 Jet needle OBDTM OBDVR (OBDTM) OBDTM Idling jet 52 48 48 Main air jet 200 200 200 Idling air jet 100 100 100 Needle clip position 2nd from top 3rd from top 2nd from top Starting jet 85 85 85 Mixture control screw open

2 1,25 2,5 Throttle valve 15 15 15 Performance restrictor – slide stop 24,5 mm – Stop pump membrane 055 055 055

400/520 SX RACING

400 EXC RACING

400 EXC RACING (12kW)

520 EXC RACING (12,5kW)

520 EXC RACING

Page 41

ENGLISH

TIGHTENING TORQUES

Hexagon collar screw engine case, clutch cover, ignition cover M6 8 Nm (6 ft.lb) Oil drain plug M12x1,5 20 Nm (15 ft.lb) Allan head plug oil screen short M16x1,5 10 Nm (7 ft.lb) Hexagon plug oil screen long M20x1,5 15 Nm (11 ft.lb) Plug pressure valve M12x1,5 20 Nm (15 ft.lb) Jet screw and hollow screw oil line M8 10 Nm (7 ft.lb) Screws oil pump cover M5 Loctite 243 + 6 Nm (5 ft.lb) Hex.collar screw cylinderhead top section, water pump cover M6 8 Nm (6 ft.lb) Hexagon collar screw exhaust flange M6 Loctite 243 + 8 Nm (6 ft.lb) Cylinder head screw M10 40/50 Nm (30/35 ft.lb) Allan head screw camshaft gear M8 Loctite 243 + 28 Nm (21 ft.lb) Stop screw autodecopression M5 Loctite 243 + 6 Nm (5 ft.lb) Allan head screw cap rocker arm M5 5 Nm (4 ft.lb) Counter nuts valve adjustment screw M6x0,75 13 Nm (10 ft.lb) Allan head screw primary gear, free wheel M6 Loctite 243 + 18 Nm (13 ft.lb) Hexagon nut primary gear M20x1,5 Loctite 243 + 150 Nm (132 ft.lb) Allan head screw balancer shaft gear M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw clutch spring M6 8 Nm (6 ft.lb) Allan head screw shift roller locking piece M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw locking lever M5 Loctite 243 + 6 Nm (6 ft.lb) Hexagon collar screw securing guide, chain guide, chain tensioner M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw chain adjuster M6 8 Nm (6 ft.lb) Hexagon collar screw stator EXC M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw stator SX M5 Loctite 243 + 6 Nm (5 ft.lb) Hexagon collar screw pulser coil M5 Loctite 243 + 6 Nm (5 ft.lb) Hexagon collar nut flywheel M12x1 60 Nm (44 ft.lb) Hexagon collar screw bump part kickstarter M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw spring hanger kickstarter M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw cover E-starter, only SX M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon collar screw hanger vent hose M6 Loctite 243 + 8 Nm (6 ft.lb) Allan head screw kickstarter M8 Loctite 243 + 25 Nm (19 ft.lb) Hexagon collar screw shift lever M6 Loctite 243 + 8 Nm (6 ft.lb) Hexagon screw engine sprocket M10 Loctite 243 + 60 Nm (44 ft.lb)

 

–

0°C

32°F

15W 40 15W 50

10W 40 10W 50

API: SG, SH

TEMPERATURE

Engine oil

Use only oil brands, which meet quality requirements (Shell Advance Ultra 4) of API-classes SG or SH (informations on bottles) or higher.

CAUTION

OOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR.

Page 42

ENGLISH

TECHNICAL DATA – CHASSIS 400/520 SX, EXC RACING 2000

WP 1218U721 WP 1218U716

Compression adjuster 5 5

Rebound adjuster 20 18

Spring PDS2–250 PDS3-250

Spring preload 6 mm (0.24 in) 6 mm (0.24 in)

STANDARD ADJUSTMENT - SHOCK ABSORBER

WP 0518U782 WP 0518U791

Compression adjuster 14 14

Rebound adjuster 14 14

Spring 4,2 N/mm 4,2 N/mm

Spring preload 7 mm (0.27in) 6,5 mm (0.26in)

Air chamber length 120 mm (5.2in) 140 mm (5.5in)

Capacity per fork leg approx. 450 ccm approx. 450 ccm

Fork oil SAE 5 SAE 5

STANDARD ADJUSTMENT-FORK

Collar nut front wheel spindle M 16x1,5 40 Nm (30ft.lb)

Brake caliper front M 8

Loctite 243 + 25 Nm (19ft.lb)

Brake disk front M 6

Loctite 243 + 15 Nm (11ft.lb)

Brake disk rear M 6

Loctite 243 + 15 Nm (11ft.lb)

Clamping screws upper fork bridge M 8 20 Nm (15ft.lb)

Clamping screws lower fork bridge M 8 15 Nm (11ft.lb)

Clamping screws fork stubs M 8 10 Nm (7ft.lb)

Collar nut rear wheel spindle M 20x1,5 80 Nm (59ft.lb)

Hexagon nut swing arm bolt M 14x1,5 100 Nm (74ft.lb)

Hexagon collar screw handlebar clamp M 8 20 Nm (15ft.lb)

Allan head screw handlebar support M 10

Loctite 243 + 40 Nm (30ft.lb)

Shock absorber top M 12 60 Nm (44ft.lb)

Shock absorber bottom M 12 60 Nm (44ft.lb)

Sprocket screws M 8

Loctite 243 + 35 Nm (25ft.lb)

Ball joint for push rod M 6

Loctite 243 + 10 Nm (7ft.lb)

Engine mounting bolt M 10 45 Nm (33ft.lb)

Engine brace M 8 33 Nm (24ft.lb)

Screw adjusting ring spring preload shock abs.

M6 8 Nm (6ft.lb)

Other screws on chassis M 6 10 Nm (7ft.lb)

M 8 25 Nm (19ft.lb)

M 10 45 Nm (33ft.lb)

Other collar nuts on chassis M 6 15 Nm (11ft.lb)

M 8 30 Nm (22ft.lb)

M 10 50 Nm (37ft.lb)

TIGHTENING TORQUES - CHASSIS

400 SX RACING 520 SX RACING 400/520 EXC RACING

400/520 EXC RACING USA

Frame Central chrom-moly-steel frame Fork White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated Brake disc Wear limit max. 0,4 mm (0,016 in) Front tires 80/100 - 21“ 90/90 - 21“ 80/100 - 21“ Air pressure offroad 1,0 bar (14 psi) 1,0 bar (14 psi) 1,0 bar (14 psi) Air pressure road driver only

– 1,5 bar (21 psi) 1,5 bar (21 psi) Rear tires 110/90 - 19“ 140/80 - 18“ 110/100 - 18“ Air pressure offroad 1,0 bar (14 psi) 1,0 bar (14 psi) 1,0 bar (14 psi) Air pressure road driver only

– 2,0 bar (28 psi) 2,0 bar (28 psi) Fuel tank capacity 7,5 Liter (2 US Gallons) 9 Liter (2,3 US Gallons) Final drive ratio 14:50t 14:48t

400-15:45t / 520-15:40t 400-14:50t / 520-14:48t Chain O-ring 5/8 x 1/4 " Available final sprockets 38t, 40t, 42t, 45t, 48t, 50t, 52t Steering head angle 63,5° Wheel base 1481 ± 10 mm (58,3 ± 0,4 in) Seat hight, unloaded 925 mm (36,5 in) Ground clearance, unloaded

380 mm (15,1 in)

Dead-weight * 107 kg (236 lbs) 112 kg (247 lbs)

* Dead-weight without fuel

Page 43

ENGLISH

Page

Adjust the throttle cables ....................................................30

Adjusting digital speedometer.............................................24

Adjusting of free travel at the hand brake lever...................18

Adjusting the mixture control screw....................................31

Battery (EXC)......................................................................26

Bleeding of the hydraulic clutch ..........................................30

Bleeding the cooling system................................................28

Breather plug front fork ......................................................15

Carburetor adjust idling ......................................................31

Chain maintenance.............................................................17

Chain wear .........................................................................17

Changing the basic position of the brake pedal...................20

Changing the engine oil......................................................33

Changing the original position of the clutch lever ..............14

Changing the spring preload of shock absorber ..................16

Charging battery.................................................................26

Chassis number.....................................................................4

Check chain tension............................................................16

Check/set distance of magnetic sensor ...............................25

Checking adjustment of the hand decompression release cable

...30

Checking and adjusting the steering head bearing ..............14

Checking engin oil level ......................................................32

Checking of brake fluid level - front brake ..........................19

Checking rear brake fluid level............................................20

Checking spoke tension ......................................................23

Checking the coolant level..................................................28

Checking the float level ......................................................31

Checking the front brake pads............................................19

Checking the oil level of the hydraulic clutch ......................30

Checking the rear brake pads..............................................21

Choke...................................................................................8

Cleaning .............................................................................37

Cleaning the air filter ..........................................................29

Cleaning the dust sleeves of the telescopic fork ..................15

Cleaning the spark arrestor (EXC USA)................................29

Clutch lever .........................................................................4

Combination switch (EXC) ....................................................6

Compression damping of fork...............................................8

Compression damping of shock absorber..............................9

Conservation for winter operarion ......................................37

Cooling system ...................................................................28

Correct chain tension..........................................................17

Digital speedometer (EXC)....................................................5

Digital speedometer, indicator lamps (EXC)...........................5

Dismounting and mounting the front wheel .......................21

Dismounting and mounting the rear wheel.........................22

Page

Draining of float chamber of the carburetor........................27

Draining of float chamber of the carburetor........................32

Driving instructions.............................................................10

Emergency OFF button (EXC)...............................................6

Emergency OFF switch (EXC Australia) .................................6

Engine number, engine type ................................................4

Engine oil............................................................................33

Filler cap ...............................................................................7

Flasher switch .......................................................................6

Foot brake pedal...................................................................8

Fuel ......................................................................................7

Fuel tap ................................................................................7

Fuse (EXC)..........................................................................27

General informations about KTM disc brakes......................18

Hand brake lever ..................................................................4

Hand decompression lever....................................................4

Head word index ................................................................41

Headlamp switch (EXC USA).................................................6

How to change the handlebar position ...............................15

Kickstarter.............................................................................8

Odometer (EXC USA) ...........................................................5

Oil circuit............................................................................32

Periodic maintenance schedule ...........................................13

Pivot bearing ......................................................................16

Re-initiation after time of storage .......................................37

Rebound damping of fork.....................................................9

Rebound damping of shock absorber....................................9

Refilling the front brake fluid reservoir ................................19

Refilling the rear brake fluid reservoir..................................20

Replacing head light lamp (H4)...........................................27

Replacing the battery of the digital speedometer ................23

Replacing the front brake pads ...........................................19

Replacing the glass fiber yarn packing of the silencer .........29

Replacing the rear brake pads.............................................21

Shift lever .............................................................................8

Short circuit button (SX)........................................................5

Side stand.............................................................................9

Speedometer, indicator lamps (EXC - Australia) ....................5

Steering lock.........................................................................9

Storage...............................................................................37

Technical specifications - chassis .........................................40

Technical specifications - engine .........................................38

Tires, air pressure................................................................23

Trouble shooting.................................................................35

Wiring diagramme ...................................................Appendix

HEAD WORD INDEX

Page 44

4T-Racing 2000

ANHANG – APPENDICE

APPENDIX – APÉNDICE

Kabelstrangbez.:

hi.:125-380 EXC '98

vo.:

Franzˆsisch

ƒnderungsstand:

RAC00USA

Zeichnungsnr.:

Datum, Name:

Italienisch

13.10.99 TH

Englisch

USA

Land:

Deutsch

503.11.076.000

590.11.075.100

hinten:

vorne:

Kabelstrangnummer:

1 phare

2 fusible 10A

4 regulateur

5 generateur

6 bobine d'allumage

3 interr. d' eclairage

1 faro

2 fusibile 10A

4 regol. di tens.

5 dinamo

6 bobina d'accens.

3 interr. della luce

1 headlight

2 fuse 10 A

4 voltage limiter

5 generator

6 ignition coil

3 light switch

1 Scheinwerfer

2 Stecksicherung 10A

4 Spannungsbegrenzer

5 Generator

6 Z¸ndspule

3 Lichtschalter

11 relais de demarreur

10 CDI-unite

8 feu arriere

7 bougie

9 connect.multiple (3)

11 rele d'avviamento

10 CDI-seatola

8 fanale posteriore

7 candela

9 connettore a 3 poli

11 starter relay

10 CDI-unit

8 rearlight

7 spark plug

9 multip.cont.plug (3)

11 Startrelais

10 CDI-Einheit

9 3-pol. Stecker

8 Schluﬂlicht

7 Z¸ndkerze

bl bleu

16 condensateur

15 batterie 12V 4Ah

14 demarreur electrique

13 ba.de.dem/arr.d'urg

12 connect.multiple (4)

bl blu

16 condensatore

15 batteria 12V 4Ah

14 mot.d'avviamento

13 disinteritor/partire

12 connettore a 4 poli

bl blue

16 capacitor

15 battery 12V 4Ah

14 starter engine

13 startsw./run off

12 multip.cont.plug (4)

bl blau

16 Kondensator

15 Batterie 12V 4Ah

14 Startermotor

13 Start/Not Aus

12 4-pol. Stecker

gr gris

br brun

ge jaune

gr grigio

br marrone

ge giallo

gr grey

br brown

ge yellow

gr grau

br braun

ge gelb

r rouge

o orange

g vert

r rosso

o arancione

g verde

r red

o orange

g green

r rot

o orange

g gr¸n

v violet

w blanc

s noir

v violetto

w bianco

s nero

v violet

w white

s black

v violett

w weiﬂ

s schwarz

Spanisch

1 faro

2 fusible prin. 10A

3 interruptor d'luz

Start- Notaus- Schalter

Domino

10 unidad cdi

4 regulador de tension

8 luz de trasera

5 generador

6 bobina de encendido

7 bujia

9 conect.multiple (3)

11 rele de arranque

15 batteria 12V 4Ah

12 conect.multiple (4)

16 condensador

14 motor de arranque

13 bott.de arr.par.de u

br marron

bl azul

gr gris

ge amarillo

g verde

s negro

r rojo

o naranja

v violeta

w blanco

s-w

r-w

ge-r

s-ge

400/520 EXC RACING 2000

Modell:

SERVICE

4 K 3

KOKUSAN

br ge-r

s-r

r-w

w br

g w

bl-w

s-w

s-ge

ge-r

r-w

ge-r

SPORTMOTORCYCLES

Page 45

ANHANG – APPENDICE

APPENDIX – APÉNDICE

Page 46

ANHANG – APPENDICE

APPENDIX – APÉNDICE

Page 47

KTM SPORTMOTORCYCLE AG

5230 Mattighofen

Austria

nternet: www.ktm.at