KTM 65 SX, 65 XC User Manual

OWNER'S MANUAL 2009

65 SX
65 XC

ART. NO. 3211345en

DEAR KTM CUSTOMER 1

DEARKTM CUSTOMER

Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you 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.

© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.

ISO 9001(12 100 6061)
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 2

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 4

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

Brand™ Identifies a brand in merchandise traffic.

Identifies a protected name.

IMPORTANT NOTES 5

Use definition

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

Info

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

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 6

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 7

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

1 Clutch lever
2 Filler cap
3 Shift lever
4 Chain guide
5 Choke lever
6 Fuel tap
7 Quick release for seat lock

300673-10

VIEW OF VEHICLE 8

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

1 Kickstarter
2 Shock absorber compression adjustment
3 Shock absorber rebound adjustment
4 Level viewer for brake fluid, rear
5 Foot brake pedal
6 Fork protector
7 Chassis number
8 Hand brake lever
9 Throttle grip
10 Short circuit button

300672-10

LOCATION OF SERIAL NUMBERS 9

4.1Chassis number

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

700390-01

4.2Engine number

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

4.3Shock absorber part number

700391-01

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 10

5.1Throttle grip

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

700408-01

5.2Clutch lever

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

5.3Hand brake lever

5.4Short circuit button

700393-10

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

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.

5.5Fuel tap

700395-01

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 11

5.6Opening filler cap

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

700396-01

5.7Closing 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.

5.8Choke

5.9Shift lever

700397-01

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.

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

700398-01

700399-01

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

CONTROLS 12

5.10Kickstarter

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

5.11Foot brake pedal

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

5.12Side stand (XC)

700400-01

700401-01

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 .

5.13Plug-in stand (SX)

700404-01

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 13

6.1Advice 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 14

– 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)

6.2Running 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 15

7.1Checks 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.

7.2Starting

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 16

7.3Starting 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.

7.4Shifting, 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.

7.5Braking

Warning

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

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

Warning

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

– Check the brake system and do not continue riding. (Your authorized KTM workshop will be 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 17

00

0

A

7.6Stopping, parking

Warning

Risk of misappropriation Usage by unauthorized persons.

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

Warning

Danger of burns Some vehicle components 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 compo-

nents 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.

– 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.

– 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.

7.7Refueling

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 imme-

diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

Warning

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

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

400214-10

–

Switch off the engine.

– Open the filler cap. ( p. 11)
– Fill the fuel tank with fuel up to measurement .

Guideline

Measurement of  35 mm (1.38 in)

Fuel tank capac­ity, approx.

– Close the filler cap. ( p. 11)

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

SERVICE SCHEDULE 18

8.1Important maintenance work to be carried out by an authorized KTM workshop.

S20A S40A

Engine

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

Attachments Check the cooling system for leakage. •

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

Chassis

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

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. • •

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

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)

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. • •

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. • •

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 19

8.2Important 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

8.3Performance of urgent inspection and maintenace work by the supervisory individual.

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

•

•

NB1A: Depending on conditions of use according to requirements.

MAINTENANCE WORK ON CHASSIS AND ENGINE 20

9.1Jacking 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

9.2Removing 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.

9.3Adjusting 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.

9.4Adjusting 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.)

700410-01

– 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

MAINTENANCE WORK ON CHASSIS AND ENGINE 21

00AA

000BB

0

0

AA

CC

0

0

AA

Info

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

9.5Measuring rear wheel sag unloaded

– Jack up the motorcycle. ( p. 20)
– 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)

400220-10

9.6Checking the static sag of the shock absorber

– 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 .

– Check the static sag.

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

400221-10

9.7Checking the riding sag of the shock absorber

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

Static sag 12 mm (0.47 in)

–

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

Info

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

400222-10

– 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 22

9.8Adjusting 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.

700449-01

Guideline

Spring preload

Comfort 7 mm (0.28 in)
Standard 7 mm (0.28 in)
Sport 7 mm (0.28 in)

9.9Removing the shock absorber x

700416-10

9.10Installing shock absorber x

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)

– 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.

– 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)

700416-11

– Mount and tighten screw .

Guideline

Screw, bottom shock absorber M10 45 Nm

(33.2 lbf ft)

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 23

9.11Adjusting the compression damping of the fork

Info

The hydraulic compression damping determines the fork suspension behavior.

– Turn adjusting screw  clockwise all the way.

Info

Adjusting screw  is located at the top end of the left fork leg and is
labeled with a C.

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

Guideline

Compression damping

700450-01

9.12Adjusting the rebound damping of the fork

Standard 10 clicks

Info

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

Info

The hydraulic rebound damping determines the fork suspension behavior.

– Turn adjusting screw  clockwise all the way.

Info

Adjusting screw  is located at the top end of the right fork leg and is
labeled with an R.

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

Guideline

Rebound damping

700451-01

Standard 10 clicks

Info

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

9.13Vehicle level

Warning

Danger of accidents Modifications to the suspension settings can seriously alter

the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride

behavior.

700533-01

The vehicle level at the front can be adjusted via the fork legs clamp.
The fork overhang can be individually adjusted to the size of the child. The fork should
be pushed through no further than position . Position  corresponds to the standard
setting.

Upper triple clamp flush



with top position
Upper triple clamp flush

 Standard

with 1st ring
Upper triple clamp flush



with 2nd ring
Upper triple clamp flush



with 3rd ring

MAINTENANCE WORK ON CHASSIS AND ENGINE 24

9.14Adjusting the fork overhang x

Warning

Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

– Loosen screws  on the lower triple clamp.
– Loosen screw  on the upper triple clamp.

Info

Loosen the screws to the point where the fork leg can be moved without
damaging it.
Make the adjustments first on one fork leg and then on the other.

700534-01

– Adjust the fork overhang.

Guideline

Upper triple clamp flush with end of
outer tube

Upper triple clamp flush with 1st ring  Standard
Upper triple clamp flush with 2nd ring 
Upper triple clamp flush with 3rd ring 



9.15Bleeding fork legs

700533-01

– Tighten screw .

Guideline

Screw, top triple clamp M8 25 Nm

(18.4 lbf ft)

– Tighten screws .

Guideline

Screw, bottom triple clamp M8 25 Nm

(18.4 lbf ft)

– Repeat the adjustment on the other fork leg.

Info

The setting of the vehicle level via the fork legs must be identical on both
fork legs.

– Jack up the motorcycle. ( p. 20)
– Remove bleeder screws  briefly.

Any excess pressure escapes from the interior of the fork.

– Mount and tighten bleeder screws.
– Remove the motorcycle from the work stand. ( p. 20)

700417-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 25

9.16Cleaning the dust boots of the fork legs

– Jack up the motorcycle. ( p. 20)
– Push dust boots  of both fork legs downwards.

Info

The dust boots remove dust and coarse dirt particles from the fork tubes.
Over time, dirt can penetrate behind the dust boots. If this dirt is not
removed, the oil seals behind the boots can start to leak.

Warning

700448-01

– Clean and oil the dust boots and inner fork tube of both fork legs.

– Press the dust boots back into their normal position.
– Remove excess oil.
– Remove the motorcycle from the work stand. ( p. 20)

Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.

– Always keep the brake discs free of oil and grease, and clean them with

brake cleaner when necessary.

Universal oil spray ( p. 71)

9.17Checking play of steering head bearing

Warning

Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.

– Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be pleased to help.)

Info

If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can
be damaged after time.

– Jack up the motorcycle. ( p. 20)
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in

the direction of travel.

No play should be noticeable in the steering head bearing.

» If there is noticeable play present:

–

Adjust play of the steering head bearing. x ( p. 25)

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

The handlebar must move smoothly over the entire steering range. There should

400387-10

be no perceptible detent positions.

» If detent positions are noticeable:

–

Adjust play of the steering head bearing. x ( p. 25)

– Check the steering head bearing and replace if required.

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

9.18Adjusting play of steering head bearing x

– Jack up the motorcycle. ( p. 20)
– Loosen screw .
– Loosen and retighten screw .

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

700418-01

Guideline

Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 26

Guideline

Screw, top triple clamp M8 25 Nm

(18.4 lbf ft)

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

9.19Removing the fork legs x

–

Remove the front wheel. x ( p. 45)

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

300663-10

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

300664-10

9.20Installing the fork legs x

Warning

Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.

– Following modifications, ride slowly at first to get the feel of the new ride behavior.

– Position the fork legs.

Info

Position the bleeder screw  to the front.

300665-10

– Adjust the fork overhang.

Guideline

Upper triple clamp flush with end of
outer tube

Upper triple clamp flush with 1st ring  Standard
Upper triple clamp flush with 2nd ring 
Upper triple clamp flush with 3rd ring 



700533-01

Info

The setting of the vehicle level via the fork legs must be identical on both
fork legs.

MAINTENANCE WORK ON CHASSIS AND ENGINE 27

– Tighten screws .

Guideline

Screw, top triple clamp M8 25 Nm

(18.4 lbf ft)

– Tighten screws .

Guideline

Screw, bottom triple clamp M8 25 Nm

300664-11

300663-11

9.21Removing the fork protector x

– Position brake caliper, mount and tighten screws .

Guideline

Screw, brake caliper M8 20 Nm

(14.8 lbf ft)

– Position the brake line. Mount the clamp and screws .

–

Install the front wheel. x ( p. 45)

– Remove screws . Take off clamp .
– Remove screw  on the left fork leg. Take off the fork protector.

(18.4 lbf ft)

Loctite®243™

700431-01

700432-01

9.22Installing the fork protector x

700432-10

– Remove screw  on the right fork leg. Take off the fork protector.

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

Guideline

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 28

0011

0022

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

Guideline

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

– Position the brake line. Mount clamp .
– Mount the screws .

700433-01

9.23Removing the lower triple clamp x

–

Remove the fork legs. x ( p. 26)

– Dismount the start number plate. ( p. 30)
– Dismount the front fender. ( p. 29)
– Remove fuel tank breather .
– Remove screw . Remove screw , take off top triple clamp with the handlebar

and place it on one side.

Info

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

300666-10

300667-10

9.24Installing the lower triple clamp x

– Remove protector ring .
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.

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

Long-life grease ( p. 70)

– Insert the lower triple clamp with the steering stem. Mount the upper steering head

bearing.

Info

Check whether the top steering head seal  is correctly positioned.

– Push on protective ring .

300668-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 29

– Position the upper triple clamp with the steering.
– Mount and tighten screw .

Guideline

Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft)

– Position fuel tank breather .
– Install the front fender. ( p. 29)
– Install the start number plate. ( p. 30)

–

300666-11

300668-10

9.25Greasing the steering head bearing x

Install the fork legs. x ( p. 26)

– Mount and tighten screw .

Guideline

Screw, top triple clamp M8 25 Nm

(18.4 lbf ft)

– Check that the cable harness, throttle cables, brake and clutch line can move freely

and are routed correctly.

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

–

Remove the lower triple clamp. x ( p. 28)

–

Install the lower triple clamp. x ( p. 28)

9.26Dismounting the front fender

9.27Installing the front fender

300669-01

– Remove screws . Remove the front fender.

700414-10

– Position the fender with holding lugs  into the drill holes on the start number

plate.

700415-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 30

00BB

0

0

AA

– Position the front fender. Mount and tighten screws .

Guideline

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

700414-11

9.28Dismounting the start number plate

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

700412-10

9.29Installing the start number plate

700413-01

700411-10

9.30Handlebar position

– Position the start number plate with the drill holes onto the holding lugs  of the

fender.

– Mount and tighten screw .

Guideline

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

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

On the upper triple clamp, there are 2 holes at a distance of  to each other.

Distance  between holes 15 mm (0.59 in)

The holes on the handlebar support are placed at a distance of  from the center.

Distance  between holes 3.5 mm (0.138 in)

The handlebar supports can be mounted in 4 different positions.

400271-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 31

002

0

11

9.31Adjusting handlebar position x

Warning

Danger of accidents Handlebar breakage.

– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle-

bar.

– Remove the four screws . Remove the handlebar clamp. Remove the handlebar

and lay it to one side.

Info

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

– Remove the two screws . Remove the handlebar support.
– Place the handlebar support in the required position. Mount and tighten the two

400271-10

screws .
Guideline

Screw, handlebar support M10 40 Nm

– Position the handlebar.

Loctite®243™

(29.5 lbf ft)

9.32Checking the play in the throttle cable

700453-10

9.33Adjusting the play in the throttle cable x

Info

Make sure cables and wiring are positioned correctly.

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

Guideline

Screw, handlebar clamp M8 20 Nm

(14.8 lbf ft)

Info

Make sure the gap width is even.

– Move the handlebar to the straight-ahead position.
– Push back bellows .
– It must be possible to raise the outer casing of the throttle cable away from the

adjusting screw by distance  without encountering a resistance.

Play in gas throttle cable 3… 5 mm (0.12… 0.2 in)

» If the throttle cable play does not meet specifications:

–

Adjust the play in the throttle cable. x ( p. 31)

– Push on bellows . Check the throttle grip for smooth operation.

– Move the handlebar to the straight-ahead position.
– Push back bellows .
– Loosen nut . Turn adjusting screw  in as far as possible.
– Turn the adjusting screw so that there is play at the outer casing of the throttle

cable.
Guideline

Play in gas throttle cable 3… 5 mm (0.12… 0.2 in)

700453-01

– Tighten the nut.
– Push on bellows . Check the throttle grip for smooth operation.

MAINTENANCE WORK ON CHASSIS AND ENGINE 32

9.34Checking chain dirt

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty:

– Clean the chain. ( p. 32)

400678-01

9.35Cleaning the chain

Warning

Danger of accidents Oil or grease on the tires reduces their grip.

– Remove oil and grease with a suitable cleaning material.

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

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

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

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

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

Chain cleaner ( p. 70)
Offroad chain spray ( p. 70)

9.36Checking the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may
snap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the engine
sprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension and
adjust if necessary.

– Jack up the motorcycle. ( p. 20)
– Push the chain at the end of the chain sliding component upward to measure the

chain tension .

700537-01

Info

The upper chain section  must be taut.
Because chain wear is not always even, repeat this measurement at differ­ent chain positions.

Chain tension 5… 8 mm (0.2… 0.31 in)

» If the chain tension does not meet specifications:

– Adjusting chain tension - after checking. ( p. 34)

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 33

9.37Checking the chain tension - installing rear wheel

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may
snap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the engine
sprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension and
adjust if necessary.

– Make sure that the chain adjusters are fitted correctly on the adjusting screws.
– Push the chain at the end of the chain sliding component upward to measure the

chain tension .

Info

The upper chain section  must be taut.
Because chain wear is not always even, repeat this measurement at differ­ent chain positions.

700537-01

Chain tension 5… 8 mm (0.2… 0.31 in)

» If the chain tension does not meet specifications:

– Adjust the chain tension when installing the rear wheel. ( p. 34)

9.38Checking rear sprocket / engine sprocket for wear

– Check rear sprocket / engine sprocket for wear.

» If the rear sprocket / engine sprocket are worn:

– Replace rear sprocket / engine sprocket.

Info

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

400227-01

– Check the chain guide for tightness and wear.

9.39Adjusting the chain tension

Warning

Danger of accidents Danger caused by incorrect chain tension.

– If the chain is over tensioned, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear-

ings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain may
snap or the countershaft of the transmission can break. On the other hand, if the chain is loose, it may jump off the engine
sprocket or the rear sprocket, causing the rear wheel to lock or damage the engine. Check for correct chain tension and
adjust if necessary.

700537-01

– Jack up the motorcycle. ( p. 20)
– Push the chain at the end of the chain sliding component upward to measure the

chain tension .

Info

The upper chain section  must be taut.
Because chain wear is not always even, repeat this measurement at differ­ent chain positions.

MAINTENANCE WORK ON CHASSIS AND ENGINE 34

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

Guideline

Chain tension 5… 8 mm (0.2… 0.31 in)
Turn adjusting screws  equally on the left and right. Check that the rear wheel

is aligned with the front wheel.

700452-01

9.40Adjusting chain tension - after checking

700452-10

– Tighten nuts .
– Make sure that chain adjusters  are fitted correctly on adjusting screws .
– Tighten nut .

Guideline

Nut, rear wheel spindle M12x1 40 Nm

(29.5 lbf ft)

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

–

Loosen nut .

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

Guideline

Chain tension 5… 8 mm (0.2… 0.31 in)
Turn adjusting screws  equally on the left and right. Check that the rear wheel

is aligned with the front wheel.

– Tighten nuts .
– Make sure that the chain adjusters  are fitted correctly on the adjusting

screws .

– Tighten nut .

Guideline

Nut, rear wheel spindle M12x1 40 Nm

(29.5 lbf ft)

9.41Adjusting chain tension - installing rear wheel

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

Guideline

Chain tension 5… 8 mm (0.2… 0.31 in)
Turn adjusting screws  equally on the left and right. Check that the rear wheel

is aligned with the front wheel.

– Tighten nuts .

700452-11

9.42Adjusting the chain guide x

Info

The size of the chain wheel varies with the number of teeth. The chain guide can be adjusted on small sprockets.

– Loosen screw .
– Position the chain guide.
– Tighten screw.

Guideline

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

700459-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 35

9.43Adjusting basic position of clutch lever

– Adjust the basic setting of the clutch lever to the size of your child's hand by turn-

ing the adjusting screw .

Info

Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.

700393-11

9.44Checking the fluid level of hydraulic clutch

Info

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

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

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

Fluid level under top level of container 4 mm (0.16 in)

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

– Correct the fluid level of the hydraulic clutch.

700419-01

Hydraulic fluid (15) ( p. 68)

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

9.45Changing the hydraulic clutch fluid x

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

The fluid level rises with increasing wear of the clutch lining disc.

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

300669-10

300670-10

– Fill bleeding syringe  with the appropriate hydraulic fluid.

Bleed syringe (50329050000)
Hydraulic fluid (15) ( p. 68)

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 36

A

A

– Inject the liquid into the system until it escapes from drill hole  of the master

cylinder without bubbles.

– To prevent overflow, drain fluid occasionally from the master cylinder reservoir.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.

Guideline

Fluid level under top level of container 4 mm (0.16 in)

300671-10

9.46Checking brake discs

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

Warning

Danger of accidents Reduced braking efficiency due to worn brake disc(s).

– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be pleased to help.)

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

to see if it conforms to measurement .

Info

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

Brake discs - wear limits

Front 2.5 mm (0.098 in)

400257-10

– Check the front and rear brake discs for damage, cracking and deformation.

Rear 2.5 mm (0.098 in)

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

– Change the brake disc.

» If the brake disk exhibits damage, cracking or deformation:

– Change the brake disc.

9.47Checking free play of hand brake lever

Warning

Danger of accidents Brake system failure.

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

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

– Push the hand brake lever forwards and check free play .

Free play of hand brake lever ≥ 3 mm (≥ 0.12 in)

» If the free travel does not meet specifications:

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

700394-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 37

9.48Adjusting basic position of handbrake lever

– Check the free play of the hand brake lever. ( p. 36)
– Adjust the basic setting of the hand brake lever to the size of your child's hand by

turning adjusting screw .

Info

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

700394-11

9.49Checking the front brake fluid level

Warning

Danger of accidents Brake system failure.

– If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system

is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your
authorized KTM workshop will be pleased to help.)

The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will

be pleased to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

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

700420-10

Brake fluid level under top level of con-

5 mm (0.2 in)

tainer

» If the brake fluid level does not meet specifications:

–

Add front brake fluid. x ( p. 38)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

MAINTENANCE WORK ON CHASSIS AND ENGINE 38

9.50Adding front brake fluid x

Warning

Danger of accidents Brake system failure.

– If the brake fluid level drops below the specified marking or the specified value, this is an indication that the brake system

is leaking or that the brake linings are completely worn down. Check the brake system and do not continue riding. (Your
authorized KTM workshop will be pleased to help.)

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will

be pleased to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

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

Guideline

Brake fluid level under top level of con-

5 mm (0.2 in)

tainer

700420-10

Brake fluid DOT 4 / DOT 5.1 ( p. 68)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

9.51Checking the front brake linings

Warning

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

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

700423-01

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the front brake linings. x ( p. 40)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

–

Change the front brake linings. x ( p. 40)

MAINTENANCE WORK ON CHASSIS AND ENGINE 39

9.52Removing front brake linings x

Warning

Danger of accident Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be pleased to help.)

–

Remove the front wheel. x ( p. 45)

– Remove the lock washer .
– Remove screw .

700425-01

– Remove the brake linings.
– Clean brake caliper and brake caliper support.

700426-01

9.53Installing the front brake linings x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

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

Warning

Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.

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

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 36)
– Insert the brake linings.

Info

Ensure that the brake linings are correctly positioned in the holding spring.

700426-01

700427-01

– Mount and tighten screw .
– Mount lock washer .

–

Install the front wheel. x ( p. 45)

MAINTENANCE WORK ON CHASSIS AND ENGINE 40

9.54Changing the front brake linings x

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will

be pleased to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

–

Remove the front brake linings. x ( p. 39)

– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws .
– Remove cover  with diaphragm .
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Install the front brake linings. x ( p. 39)

– Correct the brake fluid level.

Guideline

700420-10

Brake fluid level under top level of con-

5 mm (0.2 in)

tainer

Brake fluid DOT 4 / DOT 5.1 ( p. 68)

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

Info

Clean up overflowed or spilt brake fluid immediately with water.

9.55Checking the free travel of the foot brake lever

Warning

Danger of accidents Brake system failure.

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

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

700455-01

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

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

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

» If the free travel does not meet specifications:

–

Adjust the free travel of the foot brake pedal. x ( p. 41)

MAINTENANCE WORK ON CHASSIS AND ENGINE 41

– Attach spring .

9.56Adjusting the free travel of the foot brake pedal x

Warning

Danger of accidents Brake system failure.

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

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

– Detach the spring.
– Loosen nut .
– Turn push rod  until clearance  is created.

Guideline

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

– Hold push rod  and tighten nut .
– Attach the spring.

700535-01

– Check whether the basic position of the foot brake pedal is suitable for the rider.

» If the basic position of the foot brake pedal needs to be adjusted:

–

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

9.57Adjusting the basic position of the foot brake pedal x

Warning

Danger of accidents Brake system failure.

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

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

– Detach the spring.
– Loosen nut .
– Turn back push rod .
– Loosen nut .
– To adjust the basic position of the foot brake lever, turn screw  accordingly.

Info

The range of adjustment is limited.

700535-10

– Hold screw  and tighten nut .

Guideline

Remaining nuts, chassis M8 30 Nm

(22.1 lbf ft)

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

Guideline

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

» If the free travel at the foot brake pedal does not meet specifications:

–

Adjust the free travel of the foot brake pedal. x ( p. 41)

– Attach spring .

MAINTENANCE WORK ON CHASSIS AND ENGINE 42

9.58Checking rear brake fluid level

Warning

Danger of accidents Failure of the brake system.

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

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

Warning

Danger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will

be pleased to help.)

– Stand the vehicle upright.
– Check the brake fluid level in the viewer .

» When an air bubble is visible in the viewer :

–

Add rear brake fluid. x ( p. 42)

700421-01

9.59Adding rear brake fluid x

Warning

Danger of accidents Failure of the brake system.

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

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

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will

be pleased to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

700422-01

– Jack up the motorcycle. ( p. 20)
– Remove screws .
– Remove the cover with O-ring  and diaphragm .
– Add brake fluid to the top edge of the level viewer.

Brake fluid DOT 4 / DOT 5.1 ( p. 68)

– Position the cover with the O-ring and diaphragm.

MAINTENANCE WORK ON CHASSIS AND ENGINE 43

Info

Clean up overflowed or spilt brake fluid immediately with water.

– Mount and tighten the screws.

9.60Checking the rear brake linings

Warning

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

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

– Check the brake linings for minimum thickness .

Minimum thickness  ≥ 1 mm (≥ 0.04 in)

» If the minimum thickness is less than specified:

–

Change the rear brake linings. x ( p. 44)

– Check the brake linings for damage and cracking.

» If damage or wear is encountered:

–

Change the rear brake linings. x ( p. 44)

700424-01

9.61Removing rear brake linings x

Warning

Danger of accident Brake system failure.

– Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be pleased to help.)

–

Remove the rear wheel. x ( p. 46)

– Remove lock washer .
– Remove screw .

700428-01

– Remove the brake linings.
– Clean brake caliper and brake caliper support.

700430-01

9.62Installing the rear brake linings x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

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

MAINTENANCE WORK ON CHASSIS AND ENGINE 44

Warning

Danger of accidents Reduced braking efficiency due to use of non-approved brake linings.

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

tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM
brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi­nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.

– Check the brake discs. ( p. 36)
– Insert the brake linings.

Info

Ensure that the brake linings are correctly positioned in the holding spring.

700430-01

– Mount screw .
– Mount lock washer .

–

Install the rear wheel. x ( p. 46)

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

and there is a pressure point.

700429-01

9.63Changing the rear brake linings x

Warning

Skin irritation Brake fluid can cause skin irritation on contact.

– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents Reduced braking efficiency due to old brake fluid.

– Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will

be pleased to help.)

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Never user DOT 5 brake fluid! This is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!

–

Remove the rear brake linings. x ( p. 43)

MAINTENANCE WORK ON CHASSIS AND ENGINE 45

– Stand the vehicle upright.
– Remove screws .
– Remove cover  with the O-ring and diaphragm .
– Press the brake piston back to its basic position and make sure that no brake fluid

overflows from the brake fluid reservoir.

–

Install the rear brake linings. x ( p. 43)

– Add brake fluid to the top edge of the level viewer.

9.64Removing the front wheel x

700422-01

700436-01

Brake fluid DOT 4 / DOT 5.1 ( p. 68)

– Position the cover with the O-ring and diaphragm.

Info

Clean up overflowed or spilt brake fluid immediately with water.

– Mount and tighten the screws.

– Jack up the motorcycle. ( p. 20)
– Remove screw .

– Loosen screw .
– Hold the front wheel and pull out wheel spindle . Take the front wheel out of the

fork.

Info

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

700437-01

9.65Installing the front wheel x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

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

– Clean and grease wheel spindle .

Long-life grease ( p. 70)

– Lift the front wheel into the fork, position it, and insert wheel spindle .
– Tighten screws .

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

700438-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 46

– Mount and tighten screw .

Guideline

Screw, front wheel spindle M10 40 Nm

(29.5 lbf ft)

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

700436-10

– Operate the hand brake lever several times until the brake pads are lying correctly

on the brake disc.

– Loosen screw .
– Pull the front wheel brake and push down hard on the fork several times to align

the fork legs.

– Tighten screws .

Guideline

Screw, fork stub M6 10 Nm (7.4 lbf ft)

700536-01

9.66Removing the rear wheel x

– Jack up the motorcycle. ( p. 20)
– Remove nut .
– Remove washer  and chain adjuster .

700439-01

– Withdraw the wheel spindle  only enough to allow the rear wheel to be pushed

forward.

– Push the rear wheel forward as far as possible. Remove the chain from the rear

sprocket.

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

swingarm.

Info

Do not operate the foot brake when the rear wheel is removed.

700440-10

Always lay the wheel down in such a way that the brake disc is not dam­aged.

9.67Installing the rear wheel x

Warning

Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.

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

– Clean and grease wheel spindle .

Long-life grease ( p. 70)

– Lift the rear wheel into the swingarm, positioning it as far forward as possible, and

place the chain on the rear sprocket.

– Insert the wheel spindle  with washer  and chain adjuster .

700440-11

MAINTENANCE WORK ON CHASSIS AND ENGINE 47

– Position chain adjuster  and washer . Mount nut , but do not tighten it yet.
– Check chain tension when installing the rear wheel. ( p. 33)
– Make sure that the chain adjusters are fitted correctly on the adjusting screws.
– Tighten nut .

Guideline

Nut, rear wheel spindle M12x1 40 Nm

(29.5 lbf ft)

700439-10

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

and there is a pressure point.

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

9.68Checking the tire condition

Info

Only mount tires that have been approved and/or recommended by KTM.
Other tires could have a negative effect on vehicle handling.
The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the motorcycle.
The tires mounted on the front and rear wheels must have the same profile.
Worn tires have a negative effect on vehicle handling, especially on wet surfaces.

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

» If the tires exhibit cuts, run-in objects or other damage:

– Change the tires.

– Check the depth of the tread.

Info

Note local national regulations concerning the minimum tread depth.

400602-10

Minimum tread depth ≥ 2 mm (≥ 0.08 in)

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

– Change the tires.

– Check the tire age.

Info

The tire's date of manufacture is usually part of the tire markings and is
indicated by the last four digits of the DOT marking. The first two digits refer
to the week of manufacture and last two digits refer to the year of manufac­ture.
KTM recommends that the tires be changed regardless of the actual wear, at
the latest after 5 years.

» If a tire is more than 5 years old:

– Change the tires.

9.69Checking tire air pressure

Info

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

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

Tire air pressure off road

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

» If the tire pressure does not meet specifications:

– Correct the tire pressure.

700434-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 48

– Mount the dust cap.

9.70Checking spoke tension

Warning

Danger of accidents Instable handling due to incorrect spoke tension.

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

Info

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

– Briefly strike each spoke with the blade of a screwdriver.

Info

The frequency of the tone depends on the spoke length and diameter.
If you hear different tone frequencies from spokes of the same length and
thickness, this is an indication that the spoke tension differs.

You should hear a high note.

9.71Removing the seat

9.72Mounting the seat

700435-01

300633-10

» If the spoke tension differs:

–

Correct the spoke tension. x

– Check the spoke torque.

Guideline

Spoke nipple M3.5 3 Nm (2.2 lbf ft)

Torque wrench with various accessories in set (58429094000)

– Open quick release  and raise the rear of the seat.
– Pull back the seat and remove it.

– Hook the seat onto screw  and lower the seat at the rear while pushing it forward.

Projection  hooks into the fuel tank.

300634-10

MAINTENANCE WORK ON CHASSIS AND ENGINE 49

– Close quick release .

300633-11

9.73Cooling system

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

120 °C (248 °F)

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

700445-01

9.74Checking the antifreeze and coolant level

Warning

Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the

engine and cooling system cool down first. If you get scalded, immediately flush the affected areas with lukewarm water.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

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

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

Info

Carry out this work with a cold engine.

– Stand the motorcycle upright on a horizontal surface.
– Remove radiator cap .
– Check the antifreeze of the coolant.

−25… −45 °C (−13… −49 °F)

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

– Correct the antifreeze of the coolant.

700446-01

400243-10

– Check the coolant level in the radiator.

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

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

Coolant ( p. 68)

Alternative 2

Coolant (mixed ready to use) ( p. 68)

MAINTENANCE WORK ON CHASSIS AND ENGINE 50

– Mount the radiator cap.

9.75Checking the coolant level

Warning

Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the

engine and cooling system cool down first. If you get scalded, immediately flush the affected areas with lukewarm water.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

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

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

Info

Carry out this work with a cold engine.

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

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

» If the coolant level does not meet specifications:

– Correct the coolant level.

Alternative 1

400243-10

Coolant ( p. 68)

Alternative 2

Coolant (mixed ready to use) ( p. 68)

– Mount the radiator cap.

9.76Draining the coolant x

Warning

Scalding hazard During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, radiator hoses and other components of the cooling system while the engine is warm. Let the

engine and cooling system cool down first. If you get scalded, immediately flush the affected areas with lukewarm water.

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

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

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

Info

Carry out this work with a cold engine.

300632-10

– Stand the vehicle upright.
– Place a suitable container beneath the water pump cover.
– Remove screw . Remove the radiator cap.
– Completely drain the coolant.
– Mount and tighten screw  with a new seal ring.

Guideline

Drain plug, water pump cover M6 6 Nm (4.4 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 51

9.77Refilling coolant x

Warning

Danger of poisoning Coolants are poisonous and a health hazard.

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

contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor
immediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.

– Make sure that the screw  is tightened.
– Stand the vehicle upright.
– Add coolant to level .

Guideline

Level  above the radiator fins 10 mm (0.39 in)

Coolant 0.55 l (0.58 qt.) Coolant ( p. 68)

Coolant (mixed ready to use) ( p. 68)

700447-01

– Mount the radiator cap.
– Make a short test ride.
– Check the coolant level. ( p. 50)

9.78Glass fiber yarn filling of main silencer

The main silencer is filled with glass fiber yarn.
Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".
Not only is the noise level higher, the performance characteristic changes.

9.79Removing main silencer

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Remove screw .
– Pull the main silencer off of the manifold at the rubber sleeve .

700442-01

9.80Installing the main silencer

– Mount the main silencer with the rubber sleeve .
– Position the wide collar bushing  and the narrow collar bushing .

700444-01

MAINTENANCE WORK ON CHASSIS AND ENGINE 52

– Mount and tighten screw .

Guideline

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

700442-10

9.81Removing the glass fiber yarn filling of the main silencer x

Warning

Danger of burns The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down. Do not touch hot components.

– Remove the main silencer. ( p. 51)
– Remove screws  of locking cap . Remove locking cap and outer tube .
– Pull the glass fiber yarn filling  from the inner tube.
– Clean the parts that are to be reinstalled.

700443-01

9.82Installing the glass fiber yarn filling of the main silencer x

– Slide the glass fiber yarn filling  over the inner tube.
– Slide the outer tube  over the glass fiber yarn filling.
– Insert the locking cap  into the outer tube. Mount the screws  with toothed

wheels and tighten.
Guideline

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

– Install the main silencer. ( p. 51)

700443-10

9.83Removing the air filter x

Note

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

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

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

700441-01

– Remove the seat. ( p. 48)
– Unhook the air filter holder  and swing it to the side. Remove the air filter with

the air filter support.

– Remove the air filter from the air filter support.

MAINTENANCE WORK ON CHASSIS AND ENGINE 53

9.84Installing the air filter x

– Mount the clean air filter onto the air filter support.
– Put in both parts together, position them and fix them with the air filter support .

Info

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

– Mount the seat. ( p. 48)

700441-01

9.85Cleaning air filter x

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

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

–

Remove the air filter. x ( p. 52)

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

Air filter cleaner ( p. 70)

Info

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

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

Oil for foam air filter ( p. 71)

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

–

Install the air filter. x ( p. 53)

9.86Carburetor - idle

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

Info

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

700457-01

The idle speed is adjusted with adjusting screw .
The idle mixture is adjusted with idle air adjusting screw .

9.87Carburetor - adjusting the idle speed x

700457-01

– Screw in idle air adjusting screw  all the way and turn it to the specified basic

position.
Guideline

Idle air adjusting screw

Open 3.5 turns

– Run the engine until warm.

Guideline

Warm-up time ≥ 5 min

MAINTENANCE WORK ON CHASSIS AND ENGINE 54

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

– When running the engine, always make sure there is sufficient venti-

lation, and do not start or run the engine in a closed space without an
effective exhaust extraction system.

– Adjust the idle speed with the adjusting screw .

Guideline

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

( p. 11)

Idle speed 1,400… 1,500 rpm

– Turn idle air adjusting screw  slowly in a clockwise direction until the idle speed

begins to fall.

– Note the position and turn the idle air adjusting screw slowly counterclockwise until

the idle speed falls again.

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

Info

If the engine speed rises considerably, reduce the idle speed to a normal
level and repeat the above steps.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle air adjusting screw to the end without any change of
engine speed, you need to install a smaller idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
Following extreme air temperature or altitude changes, adjust the idle speed
again.

9.88Emptying the carburetor float chamber x

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 between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con­tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Warning

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

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

Info

Carry out this work with a cold engine.
Water in the float chamber results in malfunctioning.

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

No more fuel flows from the tank to the carburetor.

MAINTENANCE WORK ON CHASSIS AND ENGINE 55

– Place a cloth beneath the carburetor to soak up emerging fuel.
– Remove plug .
– Completely drain the fuel.
– Mount and tighten the plug.

700458-01

9.89Checking gear oil level

Info

The gear oil level must be checked when the engine is cold.

– Stand the motorcycle upright on a horizontal surface.
– Remove gear oil level check screw . Stand the vehicle upright.
– Check the gear oil level.

A small amount of gear oil should flow out of the hole.

» If no gear oil flows out:

–

Add gear oil. x ( p. 56)

– Mount and tighten the gear oil level check screw.

Guideline

300661-10

Screw, gear oil level check M6 6 Nm (4.4 lbf ft)

9.90Changing the gear oil x

–

Drain the gear oil. x ( p. 55)

–

Fill up with gear oil. x ( p. 56)

9.91Draining the gear oil x

Warning

Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven.

– Wear suitable protective clothing and protective gloves. If you get scalded, immediately flush the affected areas with luke-

warm water.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

Drain the gear oil only when the engine is warm.

– Stand the motorcycle on its side stand on a horizontal surface.
– Place a suitable container under the engine.
– Remove the gear oil drain plug with magnet .
– Completely drain the gear oil.
– Thoroughly clean gear oil drain plug with magnet.
– Clean the sealing area on the engine.
– Mount the gear oil drain plug with magnet and the seal ring and tighten it.

Guideline

300659-10

Oil drain plug with magnet M12x1.5 20 Nm

(14.8 lbf ft)

MAINTENANCE WORK ON CHASSIS AND ENGINE 56

9.92Filling up with gear oil x

Info

Too little gear oil or poor-quality oil results in premature wear of the transmission.

– Remove screw cap  and fill up with gear oil.

Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 68)

– Mount and tighten screw cap.

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

300660-10

– Start the engine and check that it is oil-tight.
– Check the gear oil level. ( p. 55)

9.93Adding gear oil x

– When running the engine, always make sure there is sufficient venti-

lation, and do not start or run the engine in a closed space without an
effective exhaust extraction system.

Info

Too little gear oil or poor-quality oil results in premature wear of the transmission.

– Remove gear oil level check screw .

300661-10

– Remove screw cap . Stand the vehicle upright.
– Add gear oil until it flows out of the bore of the gear oil level screw.

Engine oil (15W/50) ( p. 68)

– Mount and tighten the gear oil level check screw.

Guideline

Screw, gear oil level check M6 6 Nm (4.4 lbf ft)

– Mount and tighten screw cap .

300660-11

Danger

Danger of poisoning Exhaust gases are poisonous and can result in uncon-

sciousness and/or death.

– When running the engine, always make sure there is sufficient venti-

lation, and do not start or run the engine in a closed space without an
effective exhaust extraction system.

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

TROUBLESHOOTING 57

Faults Possible cause Action

Engine turns but does not start Operating error – Go through the steps of starting the engine.

( p. 15)

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

Fuel feed interrupted – Check the fuel tank breather.

Engine flooded – Clean and dry the spark plug, or change it if

Spark plug oily or wet – Clean and dry the spark plug, or change it if

Electrode distance (plug gap) of spark
plug too wide

Fault in ignition system –

Short-circuit cable in cable harness
frayed, short-circuit button defective

Socket connector or ignition coil is
loose or oxidized

Water in carburetor or jets blocked –

Engine has no idle Idling jet blocked –

Adjusting screws on carburetor dis­torted

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

Engine does not speed up Carburetor running over because float

needle dirty or worn
Loose carburetor jets –
Fault in ignition system –

Engine has too little power Fuel feed interrupted – Check the fuel tank breather.

Air filter very dirty –
Exhaust system leaky, deformed or

too little glass fiber yarn filling in
main silencer

Fault in ignition system –

Diaphragm or reed valve housing
damaged

Noticeable wear – Overhaul the engine.

Engine stalls or is popping into the
carburetor

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

Lack of fuel – Turn the knurled screw on the fuel tap all the

Engine takes in bad air – Check the intake flange and carburetor for

Socket connector or ignition coil is
loose or oxidized

–

Empty the carburetor float chamber. x

( p. 54)

– Clean the fuel tap.

–

Check/set the carburetor components. x

necessary.

necessary.

– Adjust the plug gap.

Guideline
Spark plug electrode gap

0.60 mm (0.0236 in)

Check the ignition system. x

–

Adjust the ignition. x

–

Check the short circuit button. x

– Clean the socket connector and treat it with

contact spray.

Check/set the carburetor components. x
Check/set the carburetor components. x

–

Carburetor - adjust the idle speed. x

( p. 53)

Check the ignition coil. x

–

Check the spark plug connector. x

–

Check/set the carburetor components. x
Check/set the carburetor components. x

Check the ignition system. x

–

Adjust the ignition. x

– Clean the fuel tap.

–

Check/set the carburetor components. x
Clean the air filter. x ( p. 53)

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

silencer. x
Check the ignition system. x

–

Adjust the ignition. x

– Check the diaphragm and reed valve housing.

way counterclockwise.

– Fill up with fuel. ( p. 17)

tightness.

– Clean the socket connector and treat it with

contact spray.

– Check the coolant level. ( p. 50)

TROUBLESHOOTING 58

Faults Possible cause Action

Engine overheats Too little air stream – Switch off engine when standing.

Radiator fins very dirty – Clean radiator fins.
Foam formation in cooling system –

Damaged cylinder head or cylinder
head gasket

Bent radiator hose –
Incorrect ignition point due to loose

stator

White smoke emission (steam in
exhaust gas)

Gear oil exits at the vent hose Too much gear oil added – Check the gear oil level. ( p. 55)
Water in the gear oil Damaged shaft seal ring or water

Damaged cylinder head or cylinder
head gasket

pump

Drain the coolant. x ( p. 50)

–

Refill the coolant. x ( p. 51)

– Check the cylinder head or cylinder head gas-

ket.

Change the radiator hose. x

–

Adjust the ignition. x

– Check the cylinder head or cylinder head gas-

ket.

– Check the shaft seal ring and water pump.

CLEANING 59

11.1Cleaning motorcycle

Note

Material damage Damage and destruction of components by high-pressure cleaning equipment.

– Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-

cal components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts.

Warning

Environmental hazard Hazardous substances cause environmental damage.

– Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

Info

If you clean the motorcycle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.

– Before you clean the motorcycle, seal the exhaust system to prevent penetration by water.
– First remove coarse dirt particles with a gentle water spray.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush.

Motorcycle cleaner ( p. 70)

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

– After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.

–

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

Warning

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

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

– After cleaning, let your child ride the vehicle a short distance until the engine warms up and the brakes are dried.

Info

The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.

– Push back the protection covers on the handlebar instruments to allow water to evaporate.
– After the motorcycle has cooled off, oil or grease all moving parts and bearings.
– Clean the chain. ( p. 32)
– Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.

Cleaning and polishing materials for metal, rubber and plastic ( p. 70)

– Treat all painted parts with a mild paint polish.

High-luster polish for paint ( p. 70)

– To prevent electrical problems, treat electric contacts and switches with contact spray.

Contact spray ( p. 70)

STORAGE 60

12.1Storage

Warning

Danger of poisoning Fuel is poisonous and a health hazard.

– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immedi-

ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con­tact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.

Info

If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you
should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the
start of the new season.

– Clean the motorcycle. ( p. 59)

–

Change the gear oil. x ( p. 55)

– Check the antifreeze and coolant level. ( p. 49)
– Drain the fuel from the tank into a suitable container.

–

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

– Check the tire air pressure. ( p. 47)
– The storage place should be dry and not subject to large temperature fluctuations.

Info

KTM recommends jacking up the motorcycle.

– Jack up the motorcycle. ( p. 20)
– Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping,

thus causing corrosion.

Info

Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during
combustion condenses and causes valves and exhaust system to rust.

12.2Putting into operation after storage

– Remove the motorcycle from the work stand. ( p. 20)
– Fill up with fuel. ( p. 17)
– Checks before putting into operation. ( p. 15)
– Take a test ride.

TECHNICAL DATA - ENGINE 61

Design 1-cylinder 2-stroke engine, water-cooled, with reed intake and

exhaust control
Displacement 64.85 cm³ (3.9574 cu in)
Stroke 40.8 mm (1.606 in)
Bore 45 mm (1.77 in)
Control Exhaust control PCEV
Crankshaft bearing 2 grooved ball bearings
Conrod bearing Needle bearing
Piston pin bearing Needle bearing
Pistons Aluminum cast
Piston rings 1 rectangular ring
Engine lubrication Mixture oil lubrication
Primary transmission 23:75 straight cut spur gear
Clutch Multidisc clutch in oil bath/hydraulically activated
Gearbox 6-gear, claw shifted
Transmission ratio

1st gear 13:37
2nd gear 16:34
3rd gear 18:31
4th gear 21:30
5th gear 23:28

6th gear 24:26
Ignition AET digital
Spark plug NGK LR 8 B
Spark plug electrode gap 0.60 mm (0.0236 in)
Cooling Water-cooled
Starting aid Kickstarter

13.1Capacity - gear oil

Gear oil 0.50 l (0.53 qt.) Engine oil (15W/50) ( p. 68)

13.2Capacity - coolant

Coolant 0.55 l (0.58 qt.) Coolant ( p. 68)

Coolant (mixed ready to use) ( p. 68)

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 62

Bearing retainer, main shafts M5
Nut, exhaust control diaphragm M5 3 Nm (2.2 lbf ft) –
Screw, clutch line holder M5 5 Nm (3.7 lbf ft)
Screw, diaphragm cover of exhaust

control
Screw, ignition system/stator M5 5 Nm (3.7 lbf ft)
Screw, reed valve housing of exhaust

control
Screw, retaining bracket for return

spring of shift shaft
Screw, shift drum locating M5 6 Nm (4.4 lbf ft)
Screw, water pump wheel M5 5 Nm (3.7 lbf ft)
Bearing retainer, shift drum M6 8 Nm (5.9 lbf ft)
Drain plug, water pump cover M6 6 Nm (4.4 lbf ft) –
Exhaust control, lower part of control

valve
Screw, clutch intermediate cover M6 10 Nm (7.4 lbf ft) –
Screw, clutch slave cylinder M6 10 Nm (7.4 lbf ft)
Screw, clutch springs M6 10 Nm (7.4 lbf ft) –
Screw, engine housing M6 10 Nm (7.4 lbf ft) –
Screw, engine sprocket cover M6 10 Nm (7.4 lbf ft) –
Screw, exhaust flange M6 10 Nm (7.4 lbf ft)
Screw, gear oil level check M6 6 Nm (4.4 lbf ft) –
Screw, generator cover M6 8 Nm (5.9 lbf ft) –
Screw, intake flange/reed valve housing M6 10 Nm (7.4 lbf ft) –
Screw, kickstarter stop piece M6 10 Nm (7.4 lbf ft)
Screw, outer clutch cover M6 10 Nm (7.4 lbf ft) –
Screw, reed valve housing of exhaust

control
Screw, shift drum locating M6 10 Nm (7.4 lbf ft)
Screw, shift lever M6 14 Nm (10.3 lbf ft)
Screw, water pump cover M6 8 Nm (5.9 lbf ft) –
Vacuum connection/vent connection M6 5 Nm (3.7 lbf ft)
Screw, cylinder head M7 18 Nm (13.3 lbf ft) –
Nuts, cylinder base M8 20 Nm (14.8 lbf ft) –
Screw, kickstarter M8 25 Nm (18.4 lbf ft)
Stud, cylinder base (left section of the

engine case)

Stud, cylinder base (left section of the
engine case)

Screw, inner clutch hub M10 60 Nm (44.3 lbf ft)
Spark plug M10x1 10… 12 Nm (7.4…

Nut, rotor M10x1.25 50 Nm (36.9 lbf ft) –
Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –
Nut, primary gear M14x1.25 40 Nm (29.5 lbf ft)

M5 4 Nm (3 lbf ft) –

M5 5 Nm (3.7 lbf ft) –

M5 6 Nm (4.4 lbf ft)

M6

M6 10 Nm (7.4 lbf ft) –

M8 Tightening sequence:

screw in until it projects by
27 mm (1.063 in)

M8 Tightening sequence:

screw in until it projects by
29 mm (1.142 in)

8.9 lbf ft)

Loctite®648™

Loctite®243™

Loctite®222

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

–

Loctite®243™

TECHNICAL DATA - CARBURETOR 63

Carburetor type MIKUNI TM 24
Needle position 2nd position from top
Idle air adjusting screw

Open 3.5 turns
Main jet 210
Jet needle 51 PL 43-2
Idling jet 20
Needle jet Q-O (454)
Throttle slide 2.5

TECHNICAL DATA - CHASSIS 64

Frame Central tube frame of chrome molybdenum steel tubing, powder-

coated
Fork Marzocchi Upside down
Shock absorber WP Suspension 3614 BAVP
Suspension travel

Front 220 mm (8.66 in)

Rear 270 mm (10.63 in)
Fork offset 18 mm (0.71 in)
Brake system

Front Disc brake, brake caliper, fixed

Rear Disc brake, brake caliper, fixed
Brake disc diameters

Front 198 mm (7.8 in)

Rear 160 mm (6.3 in)
Brake discs - wear limits

Front 2.5 mm (0.098 in)

Rear 2.5 mm (0.098 in)
Tire air pressure off road

Front 1.0 bar (15 psi)

Rear 1.0 bar (15 psi)
Secondary drive ratio 14:50
Chain 1/2 x 1/4” O‑ring
Rear sprockets available 46, 48, 50
Steering head angle 64.5°
Wheelbase 1,137 mm (44.76 in)
Seat height unloaded 750 mm (29.53 in)
Ground clearance unloaded 280 mm (11.02 in)
Weight without fuel, approx. 55.4 kg (122.1 lb.)
Maximum rider weight < 50 kg (< 110 lb.)

16.1Tires

Front tire Rear tire

60/100 - 14 29M TT

Pirelli SCORPION MX Mid Soft 32 NHS

80/100 - 12 50M TT

Pirelli SCORPION MX Mid Soft 32 NHS

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

16.2Capacity - fuel

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

( p. 69)

TECHNICAL DATA - FORK 65

17.1SX

Fork part number 46201000033
Fork Marzocchi Upside down
Compression damping

Standard 10 clicks
Rebound damping

Standard 10 clicks
Spring rate

Weight of rider: 35… 45 kg (77… 99 lb.) 3.4 N/mm (19.4 lb/in)
Air chamber length 100±2.5 mm (3.94±0.098 in)
Fork length 735 mm (28.94 in)

Fork oil Fork oil (SAE 5) ( p. 68)

17.2XC

Fork part number 46201000133
Fork Marzocchi Upside down
Compression damping

Standard 10 clicks
Rebound damping

Standard 10 clicks
Spring rate

Weight of rider: 35… 45 kg (77… 99 lb.) 3.4 N/mm (19.4 lb/in)
Air chamber length 100±2.5 mm (3.94±0.098 in)
Fork length 735 mm (28.94 in)

Fork oil Fork oil (SAE 5) ( p. 68)

TECHNICAL DATA - SHOCK ABSORBER 66

18.1SX

Shock absorber part number 03.18.7E.03
Shock absorber WP Suspension 3614 BAVP
Compression damping

Comfort 10 clicks

Standard 9 clicks

Sport 3 clicks
Rebound damping

Comfort 10 clicks

Standard 9 clicks

Sport 6 clicks
Spring preload

Comfort 7 mm (0.28 in)

Standard 7 mm (0.28 in)

Sport 7 mm (0.28 in)
Spring rate

Weight of rider: < 35 kg (< 77 lb.) 35 N/mm (200 lb/in)

Weight of rider: 35… 45 kg (77… 99 lb.) 40 N/mm (228 lb/in)

Weight of rider: > 45 kg (> 99 lb.) 45 N/mm (257 lb/in)
Spring length 220 mm (8.66 in)
Gas pressure 10 bar (145 psi)
Static sag 12 mm (0.47 in)
Riding sag 90 mm (3.54 in)
Fitted length 347 mm (13.66 in)

Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 69)

18.2XC

Shock absorber part number 03.18.7E.05
Shock absorber WP Suspension 3614 BAVP
Compression damping

Comfort 10 clicks

Standard 9 clicks

Sport 3 clicks
Rebound damping

Comfort 10 clicks

Standard 9 clicks

Sport 6 clicks
Spring preload

Comfort 7 mm (0.28 in)

Standard 7 mm (0.28 in)

Sport 7 mm (0.28 in)
Spring rate

Weight of rider: < 35 kg (< 77 lb.) 35 N/mm (200 lb/in)

Weight of rider: 35… 45 kg (77… 99 lb.) 40 N/mm (228 lb/in)

Weight of rider: > 45 kg (> 99 lb.) 45 N/mm (257 lb/in)
Spring length 220 mm (8.66 in)
Gas pressure 10 bar (145 psi)
Static sag 12 mm (0.47 in)
Riding sag 90 mm (3.54 in)
Fitted length 347 mm (13.66 in)

Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 69)

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 67

Spoke nipple M3.5 3 Nm (2.2 lbf ft) –
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw, ball joint, push rod on foot-

brake cylinder
Screw, footbrake cylinder M6 10 Nm (7.4 lbf ft)
Screw, fork stub M6 10 Nm (7.4 lbf ft) –
Screw, front brake disc M6 14 Nm (10.3 lbf ft) –
Screw, rear brake disc M6 14 Nm (10.3 lbf ft)
Screw, throttle grip M6 4.5 Nm (3.32 lbf ft) –
Nut, rim lock M8 10 Nm (7.4 lbf ft) –
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bottom triple clamp M8 25 Nm (18.4 lbf ft) –
Screw, brake caliper M8 20 Nm (14.8 lbf ft)
Screw, engine bracket M8 30 Nm (22.1 lbf ft) –
Screw, foot brake pedal M8 25 Nm (18.4 lbf ft) –
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, rear sprocket M8 25 Nm (18.4 lbf ft)
Screw, side stand fixing M8 40 Nm (29.5 lbf ft)
Screw, tail piece M8 35 Nm (25.8 lbf ft)
Screw, top triple clamp M8 25 Nm (18.4 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, bottom shock absorber M10 45 Nm (33.2 lbf ft) –
Screw, front wheel spindle M10 40 Nm (29.5 lbf ft) –
Screw, handlebar support M10 40 Nm (29.5 lbf ft)
Screw, top shock absorber M10 45 Nm (33.2 lbf ft) –
Nut, rear wheel spindle M12x1 40 Nm (29.5 lbf ft) –
Nut, swingarm pivot M12x1 40 Nm (29.5 lbf ft) –
Nut, steering stem M20x1.5 10 Nm (7.4 lbf ft) –

M6 10 Nm (7.4 lbf ft) –

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

Loctite®243™

SUBSTANCES 68

Brake fluid DOT 4 / DOT 5.1

According to

– DOT

Guideline

– Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-

sponding properties. KTM recommends Castrol and Motorex®products.

Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4

®

Motorex
– Brake Fluid DOT 5.1

Coolant

Guideline

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

ing. KTM recommends Motorex®products.

Mixture ratio

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

−49 °F)

50 % corrosion inhibitor/antifreeze
50 % distilled water

Coolant (mixed ready to use)

Antifreeze −40 °C (−40 °F)

Supplier

®

Motorex
– Anti Freeze

Engine oil (15W/50)

According to

– JASO T903 MA ( p. 72)
– SAE ( p. 72) (15W/50)

Guideline

– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-

sponding properties. KTM recommends Motorex®products.

Supplier

®

Motorex
– Top Speed 4T

Fork oil (SAE 5)

According to

– SAE ( p. 72) (SAE 5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties. KTM recommends Motorex®products.

Supplier

®

Motorex
– Racing Fork Oil

Hydraulic fluid (15)

According to

– ISO VG (15)

Guideline

– Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the

corresponding properties. KTM recommends Motorex®products.

Supplier

®

Motorex
– Hydraulic Fluid 75

SUBSTANCES 69

Shock absorber oil (SAE 2.5) (50180342S1)

According to

– SAE ( p. 72) (SAE 2.5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding

properties.

Super unleaded gasoline, mixed with 2-stroke engine oil

According to

– DIN EN 228
– JASO FC ( p. 72)

Mixture ratio

1:60 2-stroke engine oil

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

AUXILIARY SUBSTANCES 70

Air filter cleaner

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Twin Air Dirt Bio Remover

Chain cleaner

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Chain Clean 611

Cleaning and polishing materials for metal, rubber and plastic

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Protect & Shine 645

Contact spray

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Accu Contact

High-luster polish for paint

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Moto Polish

Long-life grease

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Fett 2000

Motorcycle cleaner

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Moto Clean 900

Offroad chain spray

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Chain Lube 622

AUXILIARY SUBSTANCES 71

Oil for foam air filter

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Twin Air Liquid Bio Power

Universal oil spray

Specification

–

KTM recommends Motorex®products.

Supplier

®

Motorex
– Joker 440 Universal

STANDARDS 72

JASO T903 MA

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

SAE

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

JASO FC

JASO FC is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first
rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.

INDEX 73

INDEX

A

Air filter

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Antifreeze

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

B

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Brake fluid

front brake fluid, adding . . . . . . . . . . . . . . . . . . . . . . 38

of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . 42

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 37

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 42

Brake linings

front brake linings, changing . . . . . . . . . . . . . . . . . . . 40

front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . 38

front brake, installing . . . . . . . . . . . . . . . . . . . . . . . . 39

front brake, removing . . . . . . . . . . . . . . . . . . . . . . . . 39

rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . . . 44

rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 43

rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . . . 43

rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . . . 43

C

Carburetor

float chamber, emptying . . . . . . . . . . . . . . . . . . . . . . 54

idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

idle speed, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chain

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Chain guide

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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

Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Clutch

fluid level, checking . . . . . . . . . . . . . . . . . . . . . . . . . 35

fluid, changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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

adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 35

Compression damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 20

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-50

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

E

Engine

running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

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

F

Filler cap

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

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

Filling up

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 41

free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 41

free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fork legs

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

dust boots, cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 25

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fork overhang

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fork protector

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Front fender

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

G

Gear oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Gear oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

H

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

basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . 37

free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . 36

Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

K

Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

L

Lower triple clamp

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

INDEX 74

M

Main silencer

glass fiber yarn filling, installing . . . . . . . . . . . . . . . . . 52

glass fiber yarn filling, removing . . . . . . . . . . . . . . . . . 52

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

O

Owner's manual

General information . . . . . . . . . . . . . . . . . . . . . . . . . . 6

P

Play in throttle cable

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Putting into operation

advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 13

after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

checks before putting into operation . . . . . . . . . . . . . . 15

R

Rear sprocket / engine sprocket

checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Rear wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Rebound damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 20

S

Seat

mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-19

Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Shock absorber

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

riding sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 21

static sag, checking . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

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

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Spare parts, accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Spoke tension

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Spring preload

shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . . 22

Start number plate

installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Steering head bearing

greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Steering head bearing play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

T

Technical data

carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 67

engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

engine tightening torques . . . . . . . . . . . . . . . . . . . . . 62

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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

Tire air pressure

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

Tire condition

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

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57-58

U

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

V

Vehicle level

View of vehicle

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

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

W

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

*3211345en*

3211345en

KTM-Sportmotorcycle AG

5230 Mattighofen/Austria

http://www.ktm.com

01/2009

Photo: Mitterbauer