KTM 65 SX, 65 XC Manual

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OWNER'S MANUAL 2009

65 SX

65 XC

ART. NO. 3211345en

DEAR KTM CUSTOMER

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

We wish you great pleasure riding the vehicle!

Enter the serial numbers of your vehicle below.

Chassis number ( p. 9)

Dealer's stamp

Engine number ( p. 9)

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

All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)

According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

Issued by: TÜV Management Service

KTM-Sportmotorcycle AG

5230 Mattighofen, Austria

CONTENTS

MEANS OF REPRESENTATION ............................................	4
IMPORTANT NOTES............................................................	5
VIEW OF VEHICLE...............................................................	7
View of the vehicle from the left front (example).................	7
View of the vehicle from the right rear (example) ................	8
LOCATION OF SERIAL NUMBERS ........................................	9
Chassis number...............................................................	9
Engine number................................................................	9
Shock absorber part number.............................................	9
CONTROLS .......................................................................	10
Throttle grip..................................................................	10
Clutch lever ..................................................................	10
Hand brake lever ...........................................................	10
Short circuit button .......................................................	10
Fuel tap........................................................................	10
Opening filler cap..........................................................	11
Closing filler cap ...........................................................	11
Choke...........................................................................	11
Shift lever.....................................................................	11
Kickstarter....................................................................	12
Foot brake pedal ...........................................................	12
Side stand (XC) .............................................................	12
Plug-in stand (SX) .........................................................	12
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION......................................................................	13
Advice on first use.........................................................	13
Running in the engine....................................................	14
RIDING INSTRUCTIONS ....................................................	15
Checks before putting into operation ...............................	15
Starting ........................................................................	15
Starting up ...................................................................	16
Shifting, riding..............................................................	16
Braking ........................................................................	16
Stopping, parking ..........................................................	17
Refueling......................................................................	17
SERVICE SCHEDULE.........................................................	18
Important maintenance work to be carried out by an
authorized KTM workshop. .............................................	18
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................	19
Performance of urgent inspection and maintenace work
by the supervisory individual...........................................	19
MAINTENANCE WORK ON CHASSIS AND ENGINE..............	20
Jacking up the motorcycle ..............................................	20
Removing the motorcycle from the work stand..................	20
Adjusting the compression damping of the shock
absorber .......................................................................	20
Adjusting the rebound damping of the shock absorber.......	20
Measuring rear wheel sag unloaded .................................	21
Checking the static sag of the shock absorber ..................	21
Checking the riding sag of the shock absorber ..................	21
Adjusting the spring preload of the shock absorber x......	22
Removing the shock absorber x.....................................	22
Installing shock absorber x...........................................	22
Adjusting the compression damping of the fork ................	23
Adjusting the rebound damping of the fork.......................	23
Vehicle level .................................................................	23
Adjusting the fork overhang x.......................................	24
Bleeding fork legs..........................................................	24
Cleaning the dust boots of the fork legs ...........................	25
Checking play of steering head bearing............................	25
Adjusting play of steering head bearing x.......................	25

Removing the fork legs x..............................................	26
Installing the fork legs x...............................................	26
Removing the fork protector x.......................................	27
Installing the fork protector x.......................................	27
Removing the lower triple clamp x................................	28
Installing the lower triple clamp x.................................	28
Greasing the steering head bearing x.............................	29
Dismounting the front fender ..........................................	29
Installing the front fender...............................................	29
Dismounting the start number plate ................................	30
Installing the start number plate .....................................	30
Handlebar position ........................................................	30
Adjusting handlebar position x......................................	31
Checking the play in the throttle cable.............................	31
Adjusting the play in the throttle cable x.......................	31
Checking chain dirt .......................................................	32
Cleaning the chain.........................................................	32
Checking the chain tension ............................................	32
Checking the chain tension - installing rear wheel.............	33
Checking rear sprocket / engine sprocket for wear .............	33
Adjusting the chain tension ............................................	33
Adjusting chain tension - after checking ..........................	34
Adjusting chain tension - installing rear wheel..................	34
Adjusting the chain guide x..........................................	34
Adjusting basic position of clutch lever............................	35
Checking the fluid level of hydraulic clutch......................	35
Changing the hydraulic clutch fluid x............................	35
Checking brake discs .....................................................	36
Checking free play of hand brake lever.............................	36
Adjusting basic position of handbrake lever......................	37
Checking the front brake fluid level .................................	37
Adding front brake fluid x............................................	38
Checking the front brake linings......................................	38
Removing front brake linings x.....................................	39
Installing the front brake linings x.................................	39
Changing the front brake linings x.................................	40
Checking the free travel of the foot brake lever .................	40
Adjusting the free travel of the foot brake pedal x...........	41
Adjusting the basic position of the foot brake pedal x.....	41
Checking rear brake fluid level........................................	42
Adding rear brake fluid x..............................................	42
Checking the rear brake linings .......................................	43
Removing rear brake linings x.......................................	43
Installing the rear brake linings x..................................	43
Changing the rear brake linings x..................................	44
Removing the front wheel x..........................................	45
Installing the front wheel x...........................................	45
Removing the rear wheel x...........................................	46
Installing the rear wheel x............................................	46
Checking the tire condition.............................................	47
Checking tire air pressure...............................................	47
Checking spoke tension..................................................	48
Removing the seat .........................................................	48
Mounting the seat .........................................................	48
Cooling system ..............................................................	49
Checking the antifreeze and coolant level ........................	49
Checking the coolant level..............................................	50
Draining the coolant x..................................................	50
Refilling coolant x.......................................................	51
Glass fiber yarn filling of main silencer ............................	51
Removing main silencer .................................................	51

CONTENTS	3
Installing the main silencer ............................................	51
Removing the glass fiber yarn filling of the main
silencer x...................................................................	52
Installing the glass fiber yarn filling of the main
silencer x...................................................................	52
Removing the air filter x...............................................	52
Installing the air filter x...............................................	53
Cleaning air filter x......................................................	53
Carburetor - idle ............................................................	53
Carburetor - adjusting the idle speed x..........................	53
Emptying the carburetor float chamber x.......................	54
Checking gear oil level ...................................................	55
Changing the gear oil x................................................	55
Draining the gear oil x.................................................	55
Filling up with gear oil x..............................................	56
Adding gear oil x.........................................................	56
TROUBLESHOOTING.........................................................	57
CLEANING........................................................................	59
Cleaning motorcycle ......................................................	59
STORAGE .........................................................................	60
Storage.........................................................................	60
Putting into operation after storage .................................	60
TECHNICAL DATA - ENGINE..............................................	61
Capacity - gear oil..........................................................	61
Capacity - coolant..........................................................	61
TECHNICAL DATA - ENGINE TIGHTENING TORQUES..........	62
TECHNICAL DATA - CARBURETOR.....................................	63
TECHNICAL DATA - CHASSIS ............................................	64
Tires ............................................................................	64
Capacity - fuel...............................................................	64
TECHNICAL DATA - FORK..................................................	65
SX................................................................................	65
XC................................................................................	65
TECHNICAL DATA - SHOCK ABSORBER .............................	66
SX................................................................................	66
XC................................................................................	66
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........	67
SUBSTANCES...................................................................	68
AUXILIARY SUBSTANCES..................................................	70
STANDARDS.....................................................................	72
INDEX ..............................................................................	73

MEANS OF REPRESENTATION

Symbols used

The symbols used are explained in the following.

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

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

All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

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

Formats used

The typographical and other formats used are explained in the following.

Proper name	Identifies a proper name.
Name®	Identifies a protected name.
Brand™	Identifies a brand in merchandise traffic.

IMPORTANT NOTES

Use definition

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

Info

The motorcycle must be used only in closed off areas remote from public road traffic.

Maintenance

A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.

Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

Warranty

The work prescribed in the service schedule must be carried out in an authorized KTM workshop only and confirmed in the customer's service record, since otherwise no warranty claims will be honored. No warranty claims can be honored for damage resulting from manipulations and/or alterations to the vehicle.

Fuel, oils, etc.

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

Spare parts, accessories

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

The current KTM PowerParts for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

Work rules

Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses. Ex.: valve spring mounter (59029019000)

During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers) must be replaced by new parts.

If a thread locker is used for the screw connections (e.g. Loctite®), follow the specific manufacturer instructions regarding its use. Parts that are to be reused after disassembly must be cleaned and checked for damage and wear. Change damaged or worn parts. After repair and maintenance, ensure that the vehicle is roadworthy.

Transport

Note

Danger of damage The parked vehicle can roll away or fall over.

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

Note

Fire hazard Some vehicle components get very hot when the machine is driven.

–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first.

–Switch off the engine.

–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT NOTES

Environment

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

Notes/warnings

Pay close attention to the notes/warnings.

Info

Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize sources of danger and may therefore be injured.

Grades of risks

Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Warning

Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.

Owner's manual

–Carefully read this owner's manual in its entirety together with your child before letting your child ride the motorcycle for the first time. It contains a lot of information and tips to help you and your child operate and handle the motorcycle. Only then will you find out how to customize the motorcycle ideally for your child's use and how to protect your child from injury. The owner's manual also contains important information on servicing the motorcycle.

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

VIEW OF VEHICLE

View3.1 of the vehicle from the left front (example)

300673-10

1Clutch lever

2Filler cap

3Shift lever

4Chain guide

5Choke lever

6Fuel tap

7Quick release for seat lock

VIEW OF VEHICLE

View3.2 of the vehicle from the right rear (example)

300672-10

1Kickstarter

2Shock absorber compression adjustment

3Shock absorber rebound adjustment

4Level viewer for brake fluid, rear

5Foot brake pedal

6Fork protector

7Chassis number

8Hand brake lever

9Throttle grip

10Short circuit button

LOCATION OF SERIAL NUMBERS

Chassis4.1 number

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

700390-01

Engine4.2 number

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

700391-01

Shock4.3 absorber part number

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

700392-01

CONTROLS

Throttle5.1 grip

Trottle grip is fitted on the right side of the handlebar.

700408-01

Clutch5.2 lever

The clutch lever is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

700393-10

Hand5.3 brake lever

Hand brake lever is fitted on the right side of the handlebar.

The hand brake lever is used to activate the front brake.

700394-01

Short5.4 circuit button

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

Possible states

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

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

700395-01

Fuel5.5 tap

Fuel tap is on the left of the fuel tank.

Possible states

•Fuel tap is closed – The knurled screw is turned all the way clockwise. Fuel cannot flow out of the fuel tank.

•Fuel tap is open – The knurled screw is turned all the way counterclockwise. Fuel can flow out of the fuel tank.

700407-01

CONTROLS

Opening5.6 filler cap

–Press release button , turn filler cap counterclockwise and lift it free.

700396-01

Closing5.7 filler cap

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

Info

Run the fuel tank breather hose without kinks.

700397-01

Choke5.8

700402-01

Choke lever is fitted on the left side of the carburetor.

Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.

Info

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

Possible states

•Choke function activated – The choke lever is pushed down all the way.

•Choke function deactivated – The choke lever is pushed up all the way.

Shift5.9 lever

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

700398-01

The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

700399-01

CONTROLS

Kickstarter5.10

The kickstarter is fitted on the right of the engine.

The kickstarter can be swiveled.

Info

Before riding, swing the kickstarter inwards towards the engine.

700403-01

Foot5.11 brake pedal

Foot brake pedal is located in front of the right footrest.

The foot brake pedal is used to activate the rear brake.

700400-01

Side5.12 stand (XC)

700401-01

700404-01

Note

Danger of damage The parked vehicle can roll away or fall over.

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

Note

Material damage Damage and destruction of components due to excessive load.

–The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.

To park the motorcycle, press side stand to the ground with your foot and lean the motorcycle on it.

When you are riding, side stand must be folded up and secured with rubber band .

Plug5.13 -in stand (SX)

700406-01

Note

Danger of damage The parked vehicle can roll away or fall over.

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

To park the motorcycle, insert plug-in stand into the plug-in stand bracket on the left side of the vehicle.

Info

Remove the plug-in stand before riding.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

Advice6.1 on first use

Warning

Danger of accidents Physical and mental readiness of a child.

–Your child must be able to ride a bicycle and must be able to erect the vehicle independently after a fall. In addition, your child must understand the regulations and instructions from you or from other guardians. Do not ask too much of your child; participation in a race should not be considered until your child's stamina, riding techniques and motivation are at the necessary levels. Children often underestimate or fail to recognize dangerous situations; make it clear to your child that it should not, under any circumstances, operate the vehicle without supervision and that your child may only drive at speeds that are commensurate with the child's riding abilities and the road conditions.

–Only let your child ride on the vehicle if it is physically and mentally ready to operate the vehicle.

Warning

Risk of injury Missing or poor protective clothing present an increased safety risk.

–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the motorcycle. You and your child should always used protective clothing that is in good condition and meets the legal requirements. When you ride a motorcycle, set an example for your child and wear suitable protective clothing.

Warning

Danger of crashing Impairment of ride behavior due to different tire tread patterns on front and rear wheels.

–The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.

Warning

Danger of accidents Critical riding behavior due to inappropriate riding.

–Ensure that your child adjusts the riding speed to the road conditions and to his or her riding abilities.

Warning

Danger of accidents Accident risk caused by presence of a passenger.

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

Warning

Danger of accidents Brake system failure.

–If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Ensure that your child raises his or her foot from the foot brake pedal when the child does not want to brake.

Warning

Danger of accidents Destruction of chassis components.

–Do not exceed the maximum allowable rider weight.

Warning

Risk of misappropriation Usage by unauthorized persons.

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

Info

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

–Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.

–Carefully read the entire owner's manual together with your child before going for the first ride.

Info

Pay special attention to the safety warnings and injury risks.

Explain to your child the techniques of riding and falling, e.g. how shifting weight can influence handling characteristics.

–Familiarize your child with the controls.

–Adjust the basic position of clutch lever. ( p. 35)

–Adjust the basic position of the handbrake lever. ( p. 37)

–Adjust the basic position of the foot brake pedal. x( p. 41)

–Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of your child.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION

–Accustom your child to the handling of the motorcycle on suitable terrain, preferably on a large open meadow.

Info

To give your child a feel for the brake, you should push your child at first. Do not start the engine until your child can is able to apply the necessary brake pressure.

Initially, let your child ride to another person who can help your child stop and turn.

–Erect obstacles for your child to navigate around to accustom your child to handling the vehicle.

–Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.

–Do not let your child ride on terrain that exceeds your child's capabilities and experience.

–Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.

–Do not exceed the maximum allowable rider weight. Guideline

Maximum rider weight	< 50 kg (< 110 lb.)

–Check the spoke tension. ( p. 48)

Info

The spoke tension must be checked after riding the motorcycle for one half hour.

–Run the engine in. ( p. 14)

Running6.2 in the engine

–During the running-in phase, do not exceed the specified engine performance. Guideline

Maximum engine performance

During the first 3 service hours	< 70 %

During the first 5 service hours	< 100 %

– Avoid fully opening the throttle!

RIDING INSTRUCTIONS

Checks7.1 before putting into operation

Info

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

Info

In the interests of riding safety, make it your own and your child's habit to perform a general check before going for a ride. Insist that your child perform the general checks himself or herself.

–Check the gear oil level. ( p. 55)

–Check the chain tension. ( p. 32)

–Check the chain dirt accumulation. ( p. 32)

–Check the tire condition. ( p. 47)

–Check the tire air pressure. ( p. 47)

–Check the front brake fluid level. ( p. 37)

–Check the rear brake fluid level. ( p. 42)

–Check the front brake linings. ( p. 38)

–Check the rear brake linings. ( p. 43)

–Check the brake system function.

–Check the coolant level. ( p. 50)

–Check the settings of all controls and ensure that they can be operated smoothly.

–Check that the electrical equipment is functioning properly.

Starting7.2

Danger

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

–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space without an effective exhaust extraction system.

Note

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

–Always warm up the engine at low engine speeds.

Info

If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.

If the float chamber is filled with fresh fuel, the engine starts immediately.

Engine has been out of use for more than 1 week

– Empty the carburetor float chamber. x( p. 54)

–Turn the knurled screw on the fuel tap all the way counterclockwise. Fuel can flow from the fuel tank to the carburetor.

–Remove the motorcycle from the stand.

–Shift gear to neutral.

The engine is cold

– Push the choke lever down all the way.

–Forcefully step on the kickstarter, pushing it all the way down.

Info

Do not open the throttle.

RIDING INSTRUCTIONS

Starting7.3 up

Info

While riding, the side stand must be folded up and secured with the rubber band, or the plug-in stand must be removed.

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

Shifting,7.4 riding

Warning

Danger of accidents If you shift down at high engine speed, the rear wheel can lock up.

–Do not shift into a low gear at high engine speed. The engine races and the rear wheel can lock up.

Info

If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

–When conditions allow (incline, road situation, etc.), your child can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.

–If the choke function was activated, deactivate it after the engine has warmed up.

–When you reach maximum speed after fully opening the throttle, turn back the throttle to about ¾ of its range. The speed hardly drops, but the fuel consumption falls considerably.

–Your child should always open the throttle only as much as the engine can handle – abruptly opening the throttle increases fuel consumption.

–To shift down, brake and close the throttle at the same time.

–Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.

–Your child should switch off the engine if he or she expects to be standing for a long time. Guideline

≥2 min

–Your child should avoid frequent and extended slipping of the clutch. This heats the engine oil, the engine and the cooling system.

–Insist that your child ride with a low rpm instead of with a high rpm and a slipping clutch.

Braking7.5

Warning

Danger of accidents If you brake too hard, the wheels can lock.

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

Warning

Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.

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

Warning

Danger of accidents Reduced braking efficiency due to wet or dirty brakes.

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

–On sandy, wet or slippery surfaces, use the rear brake.

–Braking should always be completed before you go into a bend. Your child should change down to a lower gear appropriate to the road speed.

–Insist that your child take advantage of the braking action of the engine when riding on long downhills. To do so, shift back one or two gears, but do not overrev the engine. Your child will need to apply the brakes far less often and the brakes are not overheated.

RIDING INSTRUCTIONS

Stopping,7.6 parking

Warning

Risk of misappropriation Usage by unauthorized persons.

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

Warning

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

–Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them.

Note

Danger of damage The parked vehicle can roll away or fall over.

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

Note

Fire hazard Some vehicle components get very hot when the machine is driven.

–Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first.

Note

Material damage Damage and destruction of components due to excessive load.

–Brake the motorcycle.

–Shift gear to neutral.

–Press and hold the short circuit button while the engine is idling until the engine stops.

–Turn the knurled screw on the fuel tap all the way clockwise.

–Park the motorcycle on firm ground.

Refueling7.7

Danger

Fire hazard Fuel is highly flammable.

–Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.

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

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

Environmental hazard Improper handling of fuel is a danger to the environment.

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

–Switch off the engine.

–Open the filler cap. ( p. 11)

–Fill the fuel tank with fuel up to measurement .

0		Guideline

		Measurement of		35 mm (1.38 in)
A

		Fuel tank capac-	3.5 l (3.7 qt.)	Super unleaded gasoline, mixed with
		ity, approx.		2-stroke engine oil ( p. 69)

	– Close the filler cap. (		p. 11)

400214-10

SERVICE SCHEDULE

Important8.1 maintenance work to be carried out by an authorized KTM workshop.

								S20A	S40A

Engine	Change the gear oil. x(		p. 55)						•
	Check spark plug and replace if required. x							•	•

	Clean spark plug connectors and check for tightness. x							•	•
	Check engine mounting screws for tightness.							•	•

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

	Check idle.							•	•

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

Attachments	Check the cooling system for leakage.								•

	Check the antifreeze and coolant level. (					p. 49)			•

	Check exhaust system for leakage and looseness.							•	•

	Check throttle cables for damage, smooth operation and routing without sharp bends.								•

	Check the fluid level of the hydraulic clutch. (						p. 35)	•	•

	Clean the air filter. x(		p. 53)					•	•

Brakes	Check the front brake linings. (			p. 38)					•

	Check the rear brake linings. (			p. 43)					•

	Check the brake discs. (		p. 36)						•

	Check the front brake fluid level. (				p. 37)			•	•

	Check the rear brake fluid level. (				p. 42)			•	•

	Check brake lines for damage and leakage.								•

	Check the free play of the hand brake lever. (						p. 36)	•	•

	Check the free travel of the foot brake lever. (						p. 40)	•	•

	Check the function of the brake system.							•	•

	Check screws and guide bolts of brake system for tightness.							•	•

Chassis	Check shock absorber and fork for leakage and functioning. x							•	•
	Clean the dust boots of the fork legs. (					p. 25)		•	•

	Bleed fork legs. (	p. 24)						•	•

	Check swingarm bearing.								•

	Check play of steering head bearing. (					p. 25)			•

	Check all screws to see if they are tight.							•	•

Wheels	Check the spoke tension. (		p. 48)					•	•

	Check rim run-out.							•	•

	Check the tire condition. (		p. 47)					•	•

	Check the tire air pressure. (			p. 47)				•	•

	Check the chain wear.							•	•

	Check the chain tension. (		p. 32)					•	•

	Clean the chain. (	p. 32)						•	•

	Check wheel bearing for play.							•	•

	Clean and grease adjusting screws of chain adjuster.							•	•

S20A: every 20 service hours

S40A: every 40 service hours

SERVICE SCHEDULE

Important8.2 maintenance work to be carried out by an authorized KTM workshop. (as additional order)

		S20A	S40A	J1A

Check/set the carburetor components. x				•
Check intake membrane for wear. x		•	•

Check wear of the clutch lining disc. x		•	•
Check clutch spring length. x		•	•
Check cylinder and piston for wear. x		•	•

Check exhaust control for functioning and smooth operation, clean. x		•	•
Change the spring of the exhaust control. x			•
Check the seating of the piston pin. x		•	•

Check main bearing of the crankshaft. x		•	•
Check radial clearance of conrod bearing. x		•	•
Change crankshafts and conrod bearings. x			•

Fully check the transmission. x			•
Carry out a complete fork service. x				•
Carry out a complete shock absorber service. x				•

Clean and lubricate swingarm bearing. x				•
Grease the steering head bearing. x(	p. 29)			•
Change the glass fiber yarn filling of the main silencer. x		•	•

Change the hydraulic clutch fluid. x(	p. 35)			•
Change the front brake fluid. x				•
Change the rear brake fluid. x				•

S20A: every 20 service hours
S40A: every 40 service hours
J1A: annually

Performance8.3	of urgent inspection and maintenace work by the supervisory individual.

							NB1A

Check the gear oil level. (			p. 55)				•

Check the front brake fluid level. (					p. 37)		•

Check the rear brake fluid level. (					p. 42)		•

Check the front brake linings. (				p. 38)			•

Check the rear brake linings. (				p. 43)			•

Check and adjust throttle cables.							•

Bleed fork legs. (		p. 24)					•

Clean the dust boots of the fork legs. (						p. 25)	•

Clean the chain. (		p. 32)					•

Check the chain tension. (			p. 32)				•

Check the chain wear.							•

Check rear sprocket / engine sprocket for wear. ( p. 33)							•

Clean the air filter. x( p. 53)							•
Check the tire air pressure. (			p. 47)				•

Check the tire condition. (			p. 47)				•

Check the coolant level. (			p. 50)				•

Empty the carburetor float chamber. x(						p. 54)	•
Check all controls for smooth operation.							•

Check braking.							•

Check all screws, nuts and hose clamps regularly for tightness.							•

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE

Jacking9.1 up the motorcycle

Note

Danger of damage The parked vehicle can roll away or fall over.

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

–Jack up the motorcycle underneath the engine.

Work stand (54829055000)

–Secure the motorcycle against falling over.

700405-01

Removing9.2 the motorcycle from the work stand

Note

Danger of damage The parked vehicle can roll away or fall over.

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

–Remove the motorcycle from the work stand.

–Remove the work stand.

Adjusting9.3 the compression damping of the shock absorber

Danger

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.)

–Turn adjusting knob counterclockwise all the way.

–Turn clockwise by the number of clicks corresponding to the shock absorber type. Guideline

Compression damping

Comfort	10 clicks

Standard	9 clicks

Sport	3 clicks

700409-01	Info

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

Adjusting9.4 the rebound damping of the shock absorber

Danger

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.)

–Turn adjusting screw clockwise to the last perceptible click.

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

Guideline

Rebound damping

Comfort	10 clicks

Standard	9 clicks

Sport	6 clicks

700410-01

MAINTENANCE WORK ON CHASSIS AND ENGINE

Info

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

Measuring9.5 rear wheel sag unloaded

–Jack up the motorcycle. ( p. 20)

400220-10

–Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover.

–Make a note of the value as measurement .

–Remove the motorcycle from the work stand. ( p. 20)

Checking9.6 the static sag of the shock absorber

	–
	–
	–
0A	–
	–
0B
400221-10

Measure distance of rear wheel unloaded. ( p. 21) Ask someone to help you by holding the motorcycle upright.

Measure the distance between the rear axle and the fixed point again. Make a note of the value as measurement .

Info

The static sag is the difference between measurements and .

Check the static sag.

Static sag	12 mm (0.47 in)

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

– Adjust the spring preload of the shock absorber. x( p. 22)

Checking9.7 the riding sag of the shock absorber

400222-10

–Measure distance of rear wheel unloaded. ( p. 21)

–Hold the motorcycle in a vertical position and seat the rider, wearing a full set of protective clothing, on the motorcycle in the normal sitting position (feet on the footrests). The rider should bounce up and down several times so that the rear wheel suspension can level out.

–Now measure the distance between the rear axle and the fixed point again.

–Make a note of the value as measurement .

Info

The riding sag is the difference between measurements and .

–Check the riding sag.

Riding sag	90 mm (3.54 in)

»If the riding sag differs from the specified measurement:

– Adjust the riding sag. x

MAINTENANCE WORK ON CHASSIS AND ENGINE

Adjusting9.8 the spring preload of the shock absorber x

Danger

Danger of accidents Disassembly of pressurized parts can lead to injury.

–The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be pleased to help.)

–Remove shock absorber. x( p. 22)

–After removing the shock absorber, clean it thoroughly.

–Measure the full spring length while it is under tension and note down the value.

–Loosen lock ring .

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

Combination wrench (50329080000)

Hook wrench (T106S)

–Measure the overall spring length when not under tension.

–Tighten the spring by turning adjusting ring to measurement.

	Guideline
700449-01	Guideline

	Spring preload

	Comfort	7 mm (0.28 in)

	Standard	7 mm (0.28 in)

	Sport	7 mm (0.28 in)

Info

The spring preload is the difference between the relaxed spring length and the tensioned spring length.

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

–Tighten lock ring .

–Install the shock absorber. x( p. 22)

Removing9.9 the shock absorber x

–Jack up the motorcycle. ( p. 20)

–Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position.

–Remove screw , push splash protector to the side, and remove the shock absorber.

700416-10


Installing9.10	shock absorber x
			– Push splash protector to the side and position the shock absorber. Mount and

				tighten screw .
				Guideline

				Screw, top shock absorber	M10	45 Nm
						(33.2 lbf ft)

			– Mount and tighten screw .
				Guideline

				Screw, bottom shock absorber	M10	45 Nm
		700416-11				(33.2 lbf ft)

–Remove the motorcycle from the work stand. ( p. 20)

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