KTM SXC 400 User Manual

OWNERS HANDBOOK

MANUALE D’USO

MANUEL D’UTILISATION

MANUAL DE INSTRUCCIONES

2002

BEDIENUNGSANLEITUNG

Art.Nr. 3.210.17 06/2001

400/520 SX, MXC, EXC RACING

ENGLISH

IMPORTANT

WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL

CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST

RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND

ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE

PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR

ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS:



WARNING



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

CAUTION

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

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

Frame number

Engine number

Stamp of dealer

Tampering with noise control system prohibited

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

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

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

inoperative by any person.

COMSUMER INFORMATION FOR AUSTRALIA ONLY

KTM S

PORTMOTORCYCLE

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

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

PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS

OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTI

TUTING THEM WITH OTHERS

. I

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

ANNOUNCEMENT

. I

N THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL

KTM

DEALER FOR INFORMATION

E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS

Introduction

We would like to congratulate you on your purchase of a KTM motorcycle.

You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual

carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorbike to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date

with the latest state of this production series. It cannot be completely ruled out, however, that there may exist minor discrepancies resulting from further design upgrades of these motorcycles. This manual is an important part of your motorbike and should be passed on to any subsequent owner in case you decide to sell it.

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

For your own safety use only KTM-approved parts and accessories. KTM is not liable for damage that arises in connection with the use of other products.

Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Have services carried out by a KTM dealer so that your warranty claim remains intact.

We wish you a lot of fun when driving !

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

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

ENGLISH

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Compression damping of fork . . . . . . . . . . . . . . . . . . . . .9

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

Damping action during compression of shock absorber (SX) 9

Compression damping of shock absorber (MXC, EXC) .10

Rebound damping of shock absorber (SX, MXC, EXC) .10

Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .11

PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE

. .14

MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .16

Changing the original position of the clutch lever . . . . .16

Checking and adjusting the steering head bearing . . . . .16

Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .17

Cleaning the dust sleeves of the telescopic fork . . . . . . .17

Adjusting the spring preload on the fork (SX) . . . . . . . .17

How to change the handlebar position . . . . . . . . . . . . .18

Changing the spring preload of shock absorber . . . . . . .18

Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .19

Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

General informations about KTM disc brakes . . . . . . . .20

Adjusting of free travel at the hand brake lever . . . . . . .21

Page

Checking of brake fluid level - front brake . . . . . . . . . . .21

Refilling the front brake fluid reservoir . . . . . . . . . . . . . .21

Checking the front brake pads . . . . . . . . . . . . . . . . . . .21

Replacing the front brake pads . . . . . . . . . . . . . . . . . . .22

Changing the basic position of the brake pedal . . . . . .22

Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .22

Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .22

Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .23

Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .23

Dismounting and mounting the front wheel . . . . . . . . .23

Dismounting and mounting the rear wheel . . . . . . . . .24

Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .25

Replacing the battery of the digital speedometer . . . . .25

Adjusting digital speedometer . . . . . . . . . . . . . . . . . . .26

Check/set distance of magnetic sensor . . . . . . . . . . . . .27

Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Replacing head light/parking light lamp . . . . . . . . . . .29

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .30

Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . .30

Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .31

Replacing the glass fiber yarn packing of the silencer

. .31

Cleaning the spark arrestor (MXC/EXC USA) . . . . . . . .31

Checking adjustment of the hand decompression release cable

.32

Adjust the throttle cables . . . . . . . . . . . . . . . . . . . . . . .32

Checking the oil level of the hydraulic clutch . . . . . . . .32

Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .32

Carburetor adjust idling . . . . . . . . . . . . . . . . . . . . . . . .33

Adjusting the mixture control screw . . . . . . . . . . . . . . .33

Checking the float level . . . . . . . . . . . . . . . . . . . . . . . .33

Draining of float chamber of the carburetor . . . . . . . . .34

Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Checking engin oil level . . . . . . . . . . . . . . . . . . . . . . . .34

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .35

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .37

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

CONSERVATION FOR WINTER OPERARION . . . . . . . . .39

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Re-initiation after time of storage . . . . . . . . . . . . . . . . .39

TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . .40

TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .43

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

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

INDEX

ENGLISH

Chassis number

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

Engine number, engine type

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

SERIAL NUMBER LOCATIONS

OPERATION INSTRUMENTS

Clutch lever

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

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

maintenance work on chassis and engine).

Hand decompression lever

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

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

CAUTION

–NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE. RATHER,

USE THE SHORT-CIRCUIT BUTTON OR THE EMERGENCY-OFF BUTTON.

–T

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

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

Hand brake lever

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

B can be used to

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



WARNING



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

(

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

BRAKE SYSTEM

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

BRAKE SYSTEM LOOKED OVER BY A

KTM DEALER.

ENGLISH

Digital speedometer, indicator lamps (EXC)

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

The blue control lamp

2 lights up when the high beam is on.

Speedometer – digital (EXC)

Some models are equipped with a digital speedometer 3.

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

Aside from speed indication the following indications can be selected:

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

See maintenance work for change of battery and basic setting.

Odometer (EXC USA)

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

Speedometer, indicator lamps (EXC AUS)

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

6 will be flashing in

the same rhythm. The blue indicator lamp

7 will be lit when the high beam is on

Short circuit button (SX/MXC)

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

TRP

STP

DST

CLK

ENGLISH

Combination switch (EXC)

The light switch has 2, respetively 3 switch positions.

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

You may use button

1 to actuate the horn.

The red short circuit button

2 serves to switch off the engine. Leave the

switch pressed until the engine stops.

Headlamp switch (EXC USA)

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

Flasher switch

Flasher left

Flasher right

Emergency OFF button (EXC)

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

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



WARNING



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

ACTUATING THE STARTER BUTTON

. IF YOU START THE MOTORCYCLE WITH A GEAR

ENGAGED

, THE MOTORCYCLE WILL MOVE FORWARD.

Emergency OFF switch (EXC Australia)

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

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

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

Pushing of the black starter button

5 actuates the E-starter.



WARNING



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

ACTUATING THE STARTER BUTTON

. IF YOU START THE MOTORCYCLE WITH A GEAR

ENGAGED

, THE MOTORCYCLE WILL MOVE FORWARD.

ENGLISH

Filler cap

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

Install tank breather hose

1 without kinks.

Fuel

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

CAUTION

SE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY

GASOLINE HAVING LESS THAN

95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE.



WARNING



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

WHEN HANDLING GASOLINE

. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR

BURNING CIGARETTES

. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE

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

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

SEEK A DOCTOR’S ADVICE IMMEDIATELY.

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

Fuel tap

OFF

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

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

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

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

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

Reserve MXC...........................3.0 l (0,8 US gallons)

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

CAUTION

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

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

35 mm

ON RESOFF

MXC EXC

ENGLISH

Choke

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

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

Shift lever

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

Kickstarter

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



WARNING



–I

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

MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

. YOU MIGHT SLIP OFF THE KICK-

STARTER,

OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH

GREAT VEHEMENCE

–A

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

ICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM

, AND AN OPENED

THROTTLE GRIP INCREASE THE KICK

-BACK HAZARD.

Foot brake pedal

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



WARNING



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

(

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

BRAKE SYSTEM

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

BRAKE SYSTEM LOOKED OVER BY A

KTM DEALER.

Side stand

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

2 to

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

CAUTION

–T

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

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

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

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

STAND AS FAR AS POSSIBLE

. IF THE STAND TOUCHES THE GROUND WHILE YOU ARE

DRIVING

, YOU MAY LOSE CONTROLL OF YOUR MOTORCYCLE.

2,3,4 (5,6)

ENGLISH

Compression damping of fork

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

Turn the adjusting screws 2 clockwise to increase damping, turn it counterclockwise to reduce damping during compression.

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

fork

WP 1418W710 . . . . . . . . . . . . . . . 20 clicks (SX)

WP 0518W712 . . . . . . . . . . . . . . . 20 clicks (EXC/MXC)

Rebound damping of fork

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

1 (REB), the degree of damping of

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

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

fork

WP 1418W710 . . . . . 16 clicks (SX)

WP 0518W712 . . . . . 12 clicks (MXC/EXC)

Damping action during compression of shock absorber (SX)

The shock absorber on the SX models can synchronize the compression damping in the low and high-speed range separately (Dual Compression Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber compression rates. The high-speed setting is effective at fast compression rates. Turning in a clockwise direction will increase the damping, turning counterclockwise will decrease the damping.

Standard low-speed setting: – Turn the adjusting screw 4 to the limit in a clockwise direction using a

screwdriver .

– Unscrew the respective number of clicks for the specific type of shock

absorber in a counterclockwise direction.

Type White Power 1218W738 . . . . . . .15 clicks

Standard high-speed setting: – Turn the adjusting screw 5 to the limit in a counterclockwise direction

using a box wrench.

– Unscrew the respective number of turns for the specific type of shock

absorber in a clockwise direction.

Type White Power 1218W738 . . . . . . . 2 turns



WARNING



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

NITROGEN

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

ANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

EVER UNSCREW THE BLACK SCREW CONNECTION 6 (24MM).

ENGLISH

Compression damping of shock absorber (MXC, EXC)

The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping.

STANDARD ADJUSTMENT: – Turn the adjusting screw clockwise to the stop. – Then turn the adjusting screw counterclockwise, counting the number of

clicks that corresponds to the respective type of shock absorber.

Type White Power 1218W739.............15 clicks



WARNING



HE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH

-COMPRESSION

NITROGEN

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

ANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT

EVER UNSCREW THE BLACK SCREW CONNECTION 2 (24MM).

Rebound damping of shock absorber (SX, MXC, EXC)

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

clicks that corresponds to the respective type of shock absorber.

Type White Power 1218W738.............25 clicks

Type White Power 1218W739.............25 clicks



WARNING



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

NITROGEN

. N

EVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTEN-

ANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

NEVER UNSCREW THE BLACK SCREW CONNECTION 4 (15MM

Steering lock

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

CAUTION

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

TO THE LEFT THE KEY COULD GET DAMAGED

ENGLISH

DRIVING INSTRUCTIONS



WARNING



–THE SX MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS AND

FREEWAYS

–W

HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT

OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE

Instructions for initial operation

– Verify that your KTM dealer performed the PREPARATION

OF VEHICLE jobs (see Customer Service Manual).

– Read these operating instructions carefully before your first

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

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

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

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

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

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

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

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

pads rub continuously and the braking system is over-

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

use ORIGINAL KTM SPARE PARTS. Spare parts from other

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

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

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

tribute the weight evenly between the front and rear wheel.

Never exceed the maximum permissible laden weight and

the axle weights. The maximum permissible laden weight is

made up of the following components:

– Motorcycle ready for operation and tank full

– Luggage

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

Running in the Racing models

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

CAUTION

THE 400/520 SC/MXC/EXC RACING MODELS WERE UNCOMPRO-

MISINGLY DESIGNED FOR OFF-ROAD COMPETITION PURPOSES ONLY. EVEN THOUGH THE

EXC MODELS ARE APPROVED FOR USE ON PUBLIC ROADS,

THEIR USE ON ROADS IS RECOMMENDABLE ONLY TO A VERY LIMITED EXTENT

. AVOID EXTENDED ON-ROAD RIDES AT FULL THROTTLE.

Check the following before each start

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

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

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

2 FUEL

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

3 CHAIN

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

4 TIRES

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

5 BRAKES

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

6 CABLES

Check correct setting and easy running of all control cables.

7 COOLING FLUID

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

8 ELECTRICAL SYSTEM

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

9 LUGGAGE

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



WARNING



–WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER

KTM

DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A

JACKET

, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A

SHORT TRIP

. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLO-

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

–ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS

BECOME AWARE OF YOU AS EARLY AS POSSIBLE

–D

O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.

–O

NLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR

EXAMPLE

, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF

THE MOTORCYCLE

. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT

DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES

–T

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

TIRES THAT HAVE THE SAME PROFILE TYPE

–T

HE RACING MODELS ARE DESIGNED AND DIMENSIONED FOR 1 PER-

SON ONLY. NEVER TAKE ANOTHER RIDER ALONG.

ENGLISH

Starting when the engine is cold

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

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

actuate the E-starter.



WARNING



–I

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

MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES

. YOU MIGHT SLIP OFF THE KICK-

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

–A

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

ICKING THE KICKSTARTER WITH NOT ENOUGH MOMENTUM

, AND AN OPENED

THROTTLE GRIP INCREASE THE KICK

-BACK HAZARD.

–D

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

. EXHAUST

FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH

LWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING

CAUTION

–M

AXIMAL PERIOD FOR CONTINUOUS STARTING

: 5 SECONDS. WAIT AT LEAST 5

SECONDS BEFORE TRYING AGAIN.

–D

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

COLD

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

CYLINDER

, IT CAN CAUSE ENGINE DAMAGE.

Starting when the engine is warm

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

actuate the E-starter.

What to do when the engine is „flooded”

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

Starting off

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



WARNING



–B

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

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

CONTROL

–A

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

OF YOU AS EARLY AS POSSIBLE

Shifting/Riding

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

ENGLISH

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

NOTE: D

EDICATED TO NOTHING BUT OFFROAD RACING, 400/520

SX/MXC/EXC R

ACING MODELS MAKE NO COMPROMISES IN THEIR

DESIGN

. AS SUCH, THEY DO NOT INCLUDE ANY RADIATOR FAN, AND THE

SIZE OF THE RADIATOR IS DIMENSIONED FOR OPTIMUM ERGONOMICS

N NORMAL RACING, THE COOLING SYSTEM IS SUFFICIENT.

IF YOU USE YOUR MOTORBIKE IN OTHER CONDITIONS, PLEASE NOTE THAT – THE E-

STARTER ALLOWS YOU TO START MXC/EXC RACING MODELS

AGAIN AT ANY TIME

. THEREFORE, TURN OFF THE ENGINE IF YOU

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

(MORE THAN 2 MINUTES).

–AVOID LETTING THE CLUTCH SLIP FREQUENTLY AND FOR EXTENDED

PERIODS

. THIS WOULD CAUSE THE ENGINE OIL TO HEAT UP

, THEREBY

HEATING UP THE ENGINE AND THE COOLING SYSTEM

. RATHER,

YOU

SHOULD DRIVE AT LOW SPEEDS

(4-STROKE STYLE - LETTING THE

ENGINE PULL YOU

) AND NOT AT HIGH SPEEDS NOT BY LETTING THE

CLUTCH SLIP

(2-STROKE STYLE).



WARNING



–O

BSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING

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

–A

DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

. –DRIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS. –W

HEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY

SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE

–R

EPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR

DAMAGED

IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR

LENS

THE OPERATOR WILL BE BLINDED.

–AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

–A

TWISTED HANDLEBAR MUST ALWAYS BE REPLACED. DO NOT ADJUST

THE HANDLEBAR

, IT WILL LOSE STA-BILITY.

CAUTION

–H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. WE RECOMMEND YOU RUN

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

. AFTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

. THE ENGINE HAS REACHED ITS OPERA-

TING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM.

–N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

ALOWER GEAR

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

N ADDITION, THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

–I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT

–I

N THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU

NOTICE ANY UNUSUAL OPERATION

-RELATED NOISE, STOP IMMEDIA-

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

–N

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

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

Braking

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



WARNING



–I

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

THROUGH WATER AND IN CASE OF RIDES ON WET OFF

-ROAD TRACKS,

HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT. THE BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN

–R

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

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

–D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS

–W

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

AND BRAKE FLUID HEAT UP

. THE HOTTER THESE PARTS GET, THE WEA-

KER THE BREAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL

Stopping and parking

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



WARNING



–N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING

–MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE

RUNNING

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

SHOCK ABSORBERS CAN BECOME VERY HOT

. DO NOT TOUCH ANY OF

THESE PARTS AFTER OPERATING THE MOTORCYCLE

, AND TAKE CARE TO

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

CAUTION

–N

EVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE

ENGINE

. R

ATHER, USE THE SHORT

CIRCUIT BUTTON OR THE EMER-

GENCY-OFF BUTTON.

–C

LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE

CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE

–N

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

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

CAUTION

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

MOTORCYCLE

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

AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR

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

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