OWNER'S MANUAL 2008
450‘SMR
ART. NO. 3211243en
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DEAR KTM CUSTOMER
1
'($5 .70 &86720(5
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 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
Engine number
(
P. 9)
P. 9)
Dealer's stamp
(
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 of our motorcycles can however not be completely excluded.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-
tions, 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 prudction of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes
that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria
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CONTENTS
2
&217(176
Adjusting compression damping of fork ........................... 25
Adjusting rebound damping of fork.................................. 26
Bleeding fork legs.......................................................... 26
Cleaning dust boots of fork legs ...................................... 26
Removing the fork protector............................................ 27
Installing the fork protector ............................................ 27
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
VIEW OF VEHICLE............................................................... 7
View of vehicle, front left side........................................... 7
View of vehicle, rear right side .......................................... 8
LOCATION OF SERIAL NUMBERS........................................ 9
Chassis number............................................................... 9
Type label....................................................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
OPERATING ELEMENTS.................................................... 10
Clutch lever .................................................................. 10
Hot start lever ............................................................... 10
Hand brake lever ........................................................... 10
Short circuit button ....................................................... 10
Electric starter button .................................................... 10
Fuel tap........................................................................ 11
Opening filler cap.......................................................... 11
Closing filler cap ........................................................... 11
Choke........................................................................... 11
Shift lever..................................................................... 12
Foot brake pedal ........................................................... 12
Plug-in stand ................................................................ 12
Adjusting play of steering head bearing‘
Checking play of steering head bearing.x........................... 27
....................... 28
Fork offset .................................................................... 28
Setting the fork offset‘x............................................... 29
Removing the fork legs‘x
............................................... 29
Installing the fork legs‘
x.............................................. 29
Removing the lower triple clamp‘x
Installing the lower triple clamp‘
x ................................ 30
................................. 30
Greasing the steering head bearing‘x............................. 31
Dismounting the front fender.......................................... 31
Installing the front fender............................................... 31
Dismount the start number plate..................................... 32
Fitting the start number plate ......................................... 32
Handlebar position ........................................................ 32
Adjusting handlebar position‘x...................................... 32
Checking gas Bowden cable route ................................... 33
Checking play in the gas Bowden cable ........................... 33
Adjusting the gas Bowden cable play‘x.......................... 33
Checking chain dirt ....................................................... 34
Cleaning the chain......................................................... 34
Checking the chain tension ............................................ 34
Checking the chain tension when fitting rear wheel........... 35
Checking the rear sprocket / engine sprocket for wear ....... 35
Checking chain wear...................................................... 35
Adjusting the chain tension ............................................ 36
Adjusting chain tension - after checking .......................... 37
Adjusting chain tension - fitting rear wheel ...................... 37
Adjusting chain guide‘x............................................... 38
Brake fluid reservoir....................................................... 38
Brake calipers ............................................................... 38
Checking brake discs ..................................................... 38
Checking free play of hand brake lever............................. 39
Adjusting basic position of handbrake lever...................... 39
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 .......................................................... 16
Refueling...................................................................... 17
GREASING AND SERVICE TABLE....................................... 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
Important checks and maintenance work to be carried
out by the rider. ............................................................ 19
Topping up the front brake fluid‘
Checking the front brake linings...................................... 40
Checking front brake fluid level..x..................................... 39
................................. 40
Removing front brake linings‘x
Mounting front brake linings‘
x...................................... 41
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 21
Jacking up the motorcycle.............................................. 21
Removing the motorcycle from the work stand.................. 21
Changing the front brake linings‘
Checking free play of foot brake lever .............................. 43
.x..................................... 41
................................. 42
Checking the basic chassis setting with the rider's
weight .......................................................................... 21
Compression damping of shock absorber.......................... 21
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 21
Adjusting the low-speed compression damping of the
shock absorber.............................................................. 22
Adjusting rebound damping of the shock absorber ............ 22
Measuring rear wheel sag unloaded ................................. 23
Checking static sag of the shock absorber........................ 23
Check the riding sag of the shock absorber. ..................... 23
Adjusting spring preload of the shock absorber‘x............ 24
Adjusting riding sag‘x.................................................. 24
Removing the shock absorber‘x..................................... 25
Installing shock absorber‘x........................................... 25
Checking basic setting of fork......................................... 25
Adjusting basic position of footbrake lever‘x................... 43
Adding rear brake fluid‘
Checking the rear brakexfluid level .................................. 43
.............................................. 44
Removing rear brake linings‘
Checking rear brake linings .x........................................... 44
....................................... 45
Installing the rear brake linings‘x
Changing the rear brake linings‘
x.................................. 45
.................................. 46
Removing front wheel‘x................................................ 46
Fitting front wheel‘x.................................................... 47
Removing rear wheel‘x................................................. 48
Fitting rear wheel‘x...................................................... 48
Tire condition checking.................................................. 49
Checking tire air pressure............................................... 49
Checking spoke tension.................................................. 50
Removing the battery‘x................................................ 50
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CONTENTS
3
STANDARDS..................................................................... 86
INDEX .............................................................................. 87
Installing the battery‘x................................................. 50
Recharging the battery‘x.............................................. 51
Removing a fuse............................................................ 52
Replacing the fuse......................................................... 52
Ignition curve plug connection........................................ 52
Changing the ignition curve ............................................ 52
Removing the seat......................................................... 53
Mounting the seat ......................................................... 53
x
......................................... 53
.............................................. 54
Installing the fuel tank‘
Dismounting the fuel taxnk‘
Cooling system.............................................................. 55
Checking antifreeze and coolant level.............................. 55
x....................................................... 56
Draining coolant‘
Refilling coolant‘
Removing main silencer ................................................. 57
Checking the cooxlant level.............................................. 55
....................................................... 56
Fitting the main silencer ................................................ 57
Removing glass fiber yarn filling of main silencer‘
Glass fiber yarn filling of main silencer...............x............. 57
......... 57
Fitting glass fiber yarn filling of main silencer‘x.............. 58
Changing glass fiber yarn filling of main silencer‘x.......... 58
Dismounting the air filter box lid..................................... 58
Installing the air filter box lid.......................................... 58
Removing the air filter‘x
............................................... 59
Installing the air filter‘
x............................................... 58
Cleaning air filter‘x...................................................... 59
Adjusting basic position of clutch lever............................ 59
Checking fluid level of hydraulic clutch ........................... 60
Changing fluid level of hydraulic clutch‘x...................... 60
Carburetor - idle ............................................................ 61
Carburetor - adjusting idle‘x......................................... 61
Emptying the carburetor float chamber‘x....................... 62
Checking engine oil level................................................ 62
Changing engine oil and oil filter, cleaning oil screen‘x... 63
Draining engine oil‘x
..x.................................................. 63
Removing the oil filter‘
Cleaning the oil screenx‘ .............................................. 63
............................................... 64
Mounting oil filter‘x..................................................... 64
Filling up with engine oil‘x........................................... 64
Topping up engine oil .................................................... 65
TROUBLESHOOTING......................................................... 66
CLEANING........................................................................ 68
Cleaning motorcycle ...................................................... 68
STORAGE ......................................................................... 69
Storage......................................................................... 69
Putting into operation after storage ................................. 69
TECHNICAL DATA - ENGINE.............................................. 70
Capacity - engine oil ...................................................... 70
Capacity - coolant.......................................................... 70
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 71
TECHNICAL DATA - CARBURETOR..................................... 73
TECHNICAL DATA - CHASSIS ............................................ 74
Capacity - fuel............................................................... 75
TECHNICAL DATA - FORK.................................................. 76
Capacity - fork oil .......................................................... 76
TECHNICAL DATA - SHOCK ABSORBER ............................. 77
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 78
WIRING DIAGRAM ............................................................ 80
Wiring diagram.............................................................. 80
SUBSTANCES................................................................... 82
AUXILIARY SUBSTANCES.................................................. 84
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MEANS OF REPRESENTATION
4
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Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your 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.
Specific name
Identifies a specific name.
Name®
Identifies a protected name.
Brand™
Identifies a brand in merchandise traffic.
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IMPORTANT NOTES
5
ꢁ,03257$17 127(6
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only on secluded property 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 break-
age 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 greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your motorcycle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the motorcycle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any re-
sulting damage or loss.
Transport
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥ
Always place the vehicle on a firm and even surface.
Note
Fire hazardಗSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ಥ
Do not place the vehicle where there are flammable or explosive substances.
ಥ
ಥ
ಥ
switch off engine.
Turn the handle‘ꢀ of the fuel tap to the‘OFF position.
Use straps or other suitable devices to secure the motorcycle against accidents or falling over.
Environment
Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten-
tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can en-
sure that such problems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your mo-
torcycle legally, display environmental consciousness, and respect the rights of others.
Warning notes
In your own interest, read the specified warning notes.
Info
Various warning labels are attached to your vehicle. Do not remove any warning labels. If they are missing, you or others may
not recognize dangers and may therefore be injured.
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IMPORTANT NOTES
6
Grades of risks
Danger
Danger that leads immediately and certainly to severe and permanent injury or death.
Warning
Danger that will probably lead to severe and permanent injury or death.
Note
Danger of serious damage to machine or material.
Warning
Risk of environmental damage.
OWNER'S MANUAL
ಥ
Read this owner's manual carefully and completely before making your first trip. It contains a lot of information and tips to help
you operate and handle your motorcycle. Only then will you find out how to customize the motorcycle ideally for your own use and
how you can protect yourself from injury. The owner's manual also contains important information on servicing the motorcycle.
ಥ
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.
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VIEW OF VEHICLE
7
ꢂ9,(: 2) 9(+,&/(
V
iew of vehicle, front left side
500182-10
1
Hand brake lever
Start number plate
Front fender
2
3
4
5
6
7
8
9
Front wheel
Fork part number
Oil filter cover
Plug-in stand
Shift lever
Choke button
10
11
12
Air filter
Filler cap
Clutch lever
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VIEW OF VEHICLE
8
ꢂ
ꢃꢁ
iew of vehicle, rear right side
500183-10
1
2
3
4
5
6
7
8
Main silencer
Shock absorber
Brake caliper of rear wheel brake
Rear wheel
Foot brake pedal
Manifold
Chassis number/type label
Throttle grip
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LOCATION OF SERIAL NUMBERS
9
ꢄ/2&$7,21 2) 6(5,$/ 180%(56
Cꢄꢃꢀ hassis number
The chassis number‘ꢀ is stamped on the steering head on the right.
400193-10
400284-10
400194-10
500175-10
500083-10
ꢄ
ꢃꢁ
ype label
The type label‘ꢀ is fixed to the front of the steering head.
ꢄ
ngine number
The engine number‘ꢀ is stamped on the left side of the engine under the engine
sprocket.
ꢄ
The fork part number‘ꢀ is stamped on the inner side of the fork stub.
ꢄ
The shock absorber part number‘ꢀ is stamped on the top of the shock absorber above
the adjusting ring on the engine side.
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OPERATING ELEMENTS
10
ꢅ23(5$7,1* (/(0(176
Cꢅꢃꢀ lutch lever
The clutch lever‘ꢀ is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
400195-10
400195-12
500176-10
400197-10
500177-10
ꢅ
ꢃꢁ
ot start lever
The hot start lever‘ꢀ is fitted on the left side of the handlebar.
If you pull the hot start lever to the handlebar during the start procedure, a bore is
opened in the carburetor through which the engine can draw in extra air. This gives a
leaner fuel-air mixture, which is needed for a hot start.
Possible states
•
•
Hot start function activated ಥ‘Hot start lever is pulled out to the stop.
Hot start function deactivated ಥ‘Hot start lever is pushed back to the stop.
ꢅ
The hand brake lever‘ꢀ is located on the right side of the handlebar and operates the
front wheel brake.
ꢅꢃꢄ
The short circuit button‘ꢀ is fitted on the left side of the handlebar.
Possible states
•
•
Short circuit button‘ in basic position ಥ‘In this position, the ignition circuit is
closed, and the engine can be started.
Short circuit button‘ pressed ಥ‘In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
ꢅꢃꢅ
The electric starter button‘ꢀ is fitted on the right side of the handlebar.
Possible states
•
•
Electric starter button‘ in basic position
Electric starter button‘ pressed ಥ‘In this position, the electric starter is actuated.
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OPERATING ELEMENTS
11
ꢅ
ꢃꢆ
With the tap handle‘ꢀ on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
•
•
Fuel supply closed OFF ಥ‘No fuel can flow from the tank to the carburetor.
Fuel supply open ON ಥ‘Fuel can flow from the tank to the carburetor. The fuel tank
empties completely.
500178-10
400199-10
400199-11
500179-10
ꢅ
ꢃꢇ
pening filler cap
losing filler cap
hoke
ಥ
Press release button‘ꢀ, turn filler cap counterclockwise and lift it free.
ꢅꢃꢈ
ಥ
Replace the filler cap and turn clockwise until the release button‘ꢀ locks in place.
Info
Run the fuel tank breather hose‘ꢁ without kinks.
ꢅꢃꢉ
The choke‘ꢀ is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw ex-
tra 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 ಥ‘The choke lever is pulled out to the stop.
Choke function activated ಥ‘The choke lever is pushed in to the stop.
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OPERATING ELEMENTS
12
ꢅ
ꢃꢀꢊ
hift lever
The shift lever‘ꢀ is mounted on the left side of the engine.
400204-12
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
400204-11
ꢅ
ꢃꢀꢀ
oot brake pedal
The foot brake pedal‘ꢀ is located in front of the right footrest and operates the rear
wheel brake.
400205-10
ꢅ
ꢃꢀꢁ
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥ
Always place the vehicle on a firm and even surface.
To stand the motorcycle, plug the plug-in stand‘ꢀ into the left side of the wheel spin-
dle.
Info
Before riding, remove the plug-in stand.
500180-10
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
13
ꢆ*(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21
A
dvice on first use
Danger
Danger of accidentsಗDanger from inadequate traffic experience.
ಥ
Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injuryಗRisk of injury by missing/inadequate protective clothing.
ಥ
Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle.
Warning
Danger of accidentsಗCritical riding behavior due to inappropriate riding.
ಥ
Adapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidentsಗAccident risk caused by presence of a passenger.
ಥ
Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidentsಗBrake system failure.
ಥ
If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake pedal if you do not want to brake.
Warning
Danger of accidentsಗUnstable riding behavior.
ಥ
Do not exceed the maximum permitted weight and axle loads.
Warning
Risk of misappropriationಗUsage by unauthorized persons.
ಥ
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.
ಥ
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.
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Before your first trip, read the entire operating instructions carefully.
Get to know the operating elements.
adjust the basic position of clutch lever. ( P. 59)
adjust the basic position of handbrake lever. ( P. 39)
Adjust the basic position of the footbrake lever. ( P. 43)
Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Your motorcycle is not licensed for use on public roads.
ಥ
ಥ
ಥ
ಥ
ಥ
Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
Do not make any trips that over-stress your ability and experience.
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
Do not make any changes to the motorcycle, and use only KTM approved parts.
Do not carry any baggage.
Info
Motorcycles react sensitively to any changes of weight distribution.
ಥ
ಥ
Do not exceed the overall maximum permitted weight and the axle loads.
Specification
Maximum permissible overall weight
Maximum permissible front axle load
Maximum permissible rear axle load
335‘kg (738.54‘lb.)
145‘kg (319.67‘lb.)
190‘kg (418.87‘lb.)
Run the engine in.
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GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION
14
ꢆ
ꢃꢁ
unning in the engine
ಥ
During the running-in phase, do not exceed the specified engine speed and engine performance.
Specification
Maximum engine speed
During the first 3 service hours
7000‘rpm
Maximum engine performance during the running-in period
During the first 3 service hours
싨‘50‘%
During the next 12 service hours
싨‘75‘%
ಥ
Avoid fully opening the throttle!
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RIDING INSTRUCTIONS
15
ꢇ5,',1* ,16758&7,216
C
hecks 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 a habit of making a general check before you ride.
ಥ
Check the engine oil level. ( P. 62)
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Check the chain tension. ( P. 34)
Check the chain dirt accumulation. ( P. 34)
Check the tire condition. ( P. 49)
Checking the tire air pressure. ( P. 49)
Check the front brake brake fluid level. ( P. 39)
Check the rear brake fluid level. ( P. 43)
Check the front brake linings. ( P. 40)
Check the rear brake linings. ( P. 44)
Check brake system function.
Check the coolant level. ( P. 55)
Check that all operating elements are correctly adjusted and free to move.
ꢇ
ꢃꢁ
tarting
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in unconsciousness and/or death.
ಥ
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed
space.
Note
Engine failureಗHigh engine speeds in cold engines have a negative effect on the service life of the engine.
ಥ
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.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.
Conditions
Motorcycle standing still: 싩‘1‘week
Empty the carburetor float chamber. ( P. 62)
ಥ
ಥ
Turn the handle‘ꢀ of the fuel tap to the‘ON position. (Figure‘500178-10‘ P. 11)
Fuel can flow from the tank to the carburetor.
ಥ
ಥ
Remove the motorcycle from the stand.
Shift gear to neutral.
Conditions
Engine cold
Pull choke lever out as far as possible.
Conditions
Engine warm
Pull the hot start lever out to the stop.
ಥ
ಥ
ಥ
Press the electric starter button.‘
Info
Don't open the throttle.
Conditions
Engine hot and running
Push back the hot start lever to the stop with the engine running.
ಥ
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RIDING INSTRUCTIONS
16
ꢇ
ꢃꢂ
tarting up
ಥ
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
ꢇ
ꢃꢄ
hifting, riding
Warning
Danger of accidentsಗIf you change down at high engine speed, the rear wheel can lock up.
ಥ
Do not change into a low gear at high engine speed. The engine races and the rear wheel can block.
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.
ಥ
When conditions allow (incline, road situation, etc.), you can shift into a higher gear. To do so, release the throttle while simulta-
neously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
ಥ
ಥ
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 3/4 of its range; the speed hardly
drops, but the fuel consumption falls considerably.
ಥ
ಥ
ಥ
ಥ
Always open the throttle only as much as the engine can handle ಥ abrupt throttle opening increases fuel consumption.
To shift down, brake if necessary 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.
Switch off the engine if you expect to be standing for a long time.
Specification
싩‘2‘min
ಥ
ಥ
Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine and the cooling system.
Ride with a lower engine speed instead of with a high engine speed and a slipping clutch.
ꢇ
ꢃꢅ
raking
Warning
Danger of accidentsಗIf you brake too hard, the wheels can lock.
ಥ
Adapt your braking to the traffic situation and the road conditions.
Warning
Danger of accidentsಗReduced braking caused by spongy pressure point of front or rear brake.
ಥ
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidentsಗReduced braking due to wet or dirty brakes.
ಥ
Clean or dry dirty or wet brakes by riding and braking gently.
ಥ
ಥ
ಥ
On sandy, wet or slippery surfaces, use the rear brake.
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not overstress the engine.
In this way, you have to brake far less and the brakes do not overheat.
ꢇ
ꢃꢆ
topping, parking
Warning
Danger of burnsಗSome vehicle components get very hot when the machine is driven.
ಥ
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 damageಗDanger of damage by the vehicle running away or falling over.
Always place the vehicle on a firm and even surface.
ಥ
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RIDING INSTRUCTIONS
17
Note
Fire hazardಗSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ಥ
Do not place the vehicle where there are flammable or explosive substances.
ಥ
ಥ
ಥ
ಥ
ಥ
Brake the motorcycle.
Shift gear to neutral.
Press the short circuit button‘ when the engine is idling until the engine stops.
Turn the handle‘ꢀ of the fuel tap to the‘OFF position. (Figure‘500178-10‘ P. 11)
Stand the motorcycle on a hard surface.
ꢇ
ꢃꢇ
efueling
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
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.
ಥ
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 poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
Warning
Environmental hazardಗImproper handling of fuel is a danger to the environment.
ಥ
Do not allow fuel to get into the ground water, the ground, or the sewage system.
ಥ
ಥ
Open the filler cap. ( P. 11)
Fill the fuel tank with fuel up to measurement‘ꢂ.
Specification
Measurement of‘ꢂ
35‘mm (1.38‘in)
A
Tank capacity
8.2‘l
(2.17‘US‘gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( P. 82)
ಥ
Close the filler cap. ( P. 11)
400382-10
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GREASING AND SERVICE TABLE
18
ꢈ*5($6,1* $1' 6(59,&( 7$%/(
Iꢈꢃꢀ mportant maintenance work to be carried out by an authorized KTM workshop.
S3N
S10A
S30A
Engine
Change the engine oil and oil filter, and clean the oil screen. ( P. 63)
Replace spark plug.
•
•
•
Check and adjust valve clearance.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check engine mounting screws for tightness.
Clean spark plug connectors and check for tightness.
Check screw of shift lever for tightness.
Carburetor
Check carburetor connection boots for cracks and leakage.
Check vent hoses for damage and routing without sharp bends.
Check idle.
•
•
•
•
Attachments
Check the cooling system for leakage.
Check the antifreeze and coolant level. ( P. 55)
Check the exhaust system for leakage and looseness.
Check Bowden cables for damage, smooth operation and routing without sharp
bends.
•
•
Check the fluid level of the hydraulic clutch. ( P. 60)
Clean the air filter. ( P. 59)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check cables for damage and routing without sharp bends.
Check the front brake linings. ( P. 40)
Check the rear brake linings. ( P. 44)
Check the brake discs. ( P. 38)
Brakes
•
•
•
•
•
•
•
•
•
•
•
Check the front brake brake fluid level. ( P. 39)
Check the rear brake fluid level. ( P. 43)
Check brake lines for damage and leakage.
Check the free play of the hand brake lever. ( P. 39)
Check the free play of the foot brake lever. ( P. 43)
Check brake system function.
Check screws and guide bolts of brake system for tightness.
Check shock absorber and fork for leakage and functioning.
Clean dust boots of fork legs. ( P. 26)
Bleed fork legs. ( P. 26)
Chassis
Wheels
Check swingarm bearing.
Check play of steering head bearing. ( P. 27)
Check all screws to see if they are tight.
Check the spoke tension. ( P. 50)
•
•
•
•
•
•
•
•
•
•
•
Check rim run-out.
Check the tire condition. ( P. 49)
Checking the tire air pressure. ( P. 49)
Check the chain wear. ( P. 35)
Check the chain tension. ( P. 34)
Clean the chain. ( P. 34)
Check wheel bearing for play.
Clean and grease adjusting screws of chain adjuster.
S3N: After 3 service hours - corresponds to about 21 liters of fuel
S10A: Every 10 service hours - corresponds to about 70 liters of fuel / after every race
S30A: Every 30 service hours - corresponds to about 210 liters of fuel
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GREASING AND SERVICE TABLE
19
ꢈ
ꢃꢁ
S10A
S20N
S40N
J1A
J2A
Carry out a complete fork service.
•
Carry out a complete shock absorber service.
Grease the steering head bearing. ( P. 31)
Clean and adjust carburetor.
•
•
•
•
•
•
Treat electric contacts with contact spray.
Change hydraulic clutch fluid.
Change brake fluid.
Check wear of clutch discs.
•
•
•
•
Check long clutch springs.
Check clutch slave cylinder for dents.
Check outer clutch hub for dents.
Check cylinder wear and change pistons.
Check camshaft wear. (visual check)
Check wear of valve spring seat.
•
•
•
•
•
•
•
•
•
•
•
•
•
Check wear of valve guides.
Change valves.
Change valve springs.
Check the timing-chain tensioner function.
Check crankshaft and crankshaft journal for run-out.
Change conrod bearing.
Check piston pin bearing.
Change the crankshaft main bearing.
Check wear of all transmission components including shafts and bearings.
Check the spring length of the oil pressure regulator valve.
Change glass fiber yarn filling of main silencer. ( P. 58)
Replace foot brake cylinder seals.
Check carburetor components.
•
•
•
S10A: Every 10 service hours - corresponds to about 70 liters of fuel / after every race
S20N: After 20 service hours - corresponds to about 140 liters of fuel
S40N: After 40 service hours - corresponds to about 280 liters of fuel
J1A: annually
J2A: every 2 years
ꢈ
ꢃꢂ
NB1A
Check the engine oil level. ( P. 62)
Check the front brake brake fluid level. ( P. 39)
Check the rear brake fluid level. ( P. 43)
Check the front brake linings. ( P. 40)
Check the rear brake linings. ( P. 44)
Check and adjust Bowden cables.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Bleed fork legs. ( P. 26)
Clean dust boots of fork legs. ( P. 26)
Clean the chain. ( P. 34)
Check the chain tension. ( P. 34)
Check the chain wear. ( P. 35)
Check the rear sprocket / engine sprocket for wear. ( P. 35)
Clean the air filter. ( P. 59)
Checking the tire air pressure. ( P. 49)
Check the tire condition. ( P. 49)
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GREASING AND SERVICE TABLE
20
NB1A
Check the coolant level. ( P. 55)
•
•
•
•
•
Empty the carburetor float chamber. ( P. 62)
Check that all operating elements for smooth operation.
Check braking.
Check all screws, nuts and hose clamps regularly for tightness.
NB1A: Depending on conditions of use according to requirements.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
21
ꢉ0$,17(1$1&( :25. 21 &+$66,6 $1' (1*,1(
Jꢉꢃꢀ acking up the motorcycle
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥ
Always place the vehicle on a firm and even surface.
ಥ
ಥ
Jack up the motorcycle underneath the engine. The wheels must no longer touch
the ground.
Work stand (59229055000)
Secure the motorcycle against falling over.
500181-01
ꢉ
ꢃꢁ
Note
Danger of damageಗDanger of damage by the vehicle running away or falling over.
ಥ
Always place the vehicle on a firm and even surface.
ಥ
ಥ
Remove the motorcycle from the work stand.
Remove the work stand.
ꢉ
ꢃꢂ
hecking the basic chassis setting with the rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings
of the suspension components must match your body weight.
As delivered, KTM motorcycles are adjusted for a standard rider weight (with full protective clothing).
Standard rider weight
75… 85‘kg (165.34… 187.39‘lb.)
If your weight is above or below the standard range, you have to adjust the basic setting of the suspension components accordingly.
Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs
must be replaced.
ꢉ
ꢃꢄ
The shock absorber can regulate compression damping in low- and high-speed range separately (Dual Compression Control).
The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motor-
cycle.
The low- and high-speed technology works non-specifically.
ꢉ
ꢃꢅ
djusting high-speed compression damping of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-
tenance on it yourself.
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
ಥ
Turn the adjusting screw‘ꢀ clockwise with a ring wrench until it stops.
Info
Do not loosen nut‘ꢁ!
500184-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
22
ಥ
Turn back counterclockwise the number of turns corresponding to the shock ab-
sorber type.
Specification
Compression damping, high-speed
Standard
1.5‘turns
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
ꢉ
ꢃꢆ
djusting the low-speed compression damping of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-
tenance on it yourself.
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
ಥ
Turn the adjusting screw‘ꢀ clockwise with a screwdriver until it stops.
Info
Do not loosen nut‘ꢁ!
ಥ
Turn back counterclockwise the number of clicks corresponding to the shock ab-
sorber type.
Specification
Compression damping, low-speed
Standard
10‘clicks
500184-11
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
ꢉ
ꢃꢇ
djusting rebound damping of the shock absorber
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-
tenance on it yourself.
ಥ
Turn the adjusting screw‘ꢀ clockwise until it stops.
Info
Do not loosen nut‘ꢁ!
ಥ
Turn back counterclockwise the number of clicks corresponding to the shock ab-
sorber type.
Specification
Rebound damping
Standard
20‘clicks
500185-10
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
23
ꢉ
ꢃꢈ
easuring rear wheel sag unloaded
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Measure the distance ಥ as vertical as possible ಥ between the rear axle and a fixed
point, for example, a mark on the side cover.
ಥ
ಥ
Make a note of the value as measurement‘ꢂ.
Remove the motorcycle from the work stand. ( P. 21)
0A
400389-10
ꢉ
ꢃꢉ
hecking static sag of the shock absorber
ಥ
ಥ
ಥ
Measure distance‘ꢂ of rear wheel unloaded. ( P. 23)
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‘ꢃ.
ಥ
0A
Info
The static sag is the difference between measurements‘ꢂ and‘ꢃ.
ಥ
Check the static sag.
Static sag
15… 20‘mm (0.59… 0.79‘in)
»
If the static sag is less or more than the specified value:
ಥ
Adjust the spring preload of the shock absorber. ( P. 24)
0B
400383-10
ꢉ
ꢃꢀꢊ
heck the riding sag of the shock absorber.
ಥ
ಥ
Measure distance‘ꢂ of rear wheel unloaded. ( P. 23)
With another person holding the motorcycle, sit on the saddle with full protective
clothing in a normal sitting position (feet on footrests) and bounce up and down a
few times until the rear suspension levels out.
0A
ಥ
ಥ
The other person now has to measure the distance between the rear axle and a
fixed point.
Make a note of the value as measurement‘ꢄ.
Info
The riding sag is the difference between measurements‘ꢂ and‘ꢄ.
ಥ
Check the riding sag.
Riding sag
80… 90‘mm (3.15… 3.54‘in)
»
If the riding sag differs from the specified measurement:
ಥ
Adjust the riding sag. ( P. 24)
C
400384-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
24
ꢉ
ꢃꢀꢀ
djusting spring preload of the shock absorber‘x
Danger
Danger of accidentsಗThe shock absorber is under high pressure.
ಥ
The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main-
tenance on it yourself.
Info
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
ಥ
ಥ
ಥ
ಥ
Remove shock absorber. ( P. 25)
After removing the shock absorber, clean it thoroughly.
Loosen screw‘ꢀ.
Turn adjusting ring‘ꢁ until the spring is no longer under tension.
Combination wrench (50329080000)
Hook wrench (T106S)
2
1
A
ಥ
ಥ
Measure the overall spring length when not under tension.
Tighten the spring by turning adjusting ring‘ꢀ to measurement‘ꢂ.
Specification
Spring preload
11‘mm (0.43‘in)
ಥ
ಥ
Tighten screw‘ꢁ.
Specification
Screw, shock absorber adjusting ring
Installing shock absorber. ( P. 25)
M6
5‘Nm (3.69‘lbf‘ft)
400216-10
ꢉ
ꢃꢀꢁ
djusting riding sag‘x
ಥ
ಥ
ಥ
Remove shock absorber. ( P. 25)
After removing the shock absorber, clean it thoroughly.
Choose and fit a suitable spring.
Specification
Spring rate
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
Weight of rider: 85… 95‘kg (187.39… 209.44‘lb.)
76‘N/mm (433.97‘lb/in)
80‘N/mm (456.81‘lb/in)
84‘N/mm (479.65‘lb/in)
Info
The spring rate is shown on the outside of the spring.
ಥ
ಥ
ಥ
Installing shock absorber. ( P. 25)
Check the static sag of the shock absorber. ( P. 23)
Adjust the rebound damping of the shock absorber. ( P. 22)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
25
ꢉ
ꢃꢀꢂ
emoving the shock absorber‘x
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
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.
ಥ
Remove screw‘ꢁ, push splash protector‘ꢅ to the side, and remove the shock ab-
sorber.
500186-10
ꢉ
ꢃꢀꢄ
nstalling shock absorber‘x
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Push splash protector‘ꢀ to the side and position the shock absorber. Mount and
tighten screw‘ꢁ.
Specification
Screw, top shock absorber M12
80‘Nm
Loctite® 243™
Loctite® 243™
(59.01‘lbf‘ft)
ಥ
Mount and tighten screw‘ꢅ.
Specification
Screw, bottom shock ab-
sorber
M12
80‘Nm
(59.01‘lbf‘ft)
500186-11
Info
The heim joint for the shock absorber at the swing arm is Teflon coated. It
must not be greased with grease or with other lubricants. Lubricants dis-
solve the Teflon coating, thereby drastically reducing the service life.
ಥ
Remove the motorcycle from the work stand. ( P. 21)
ꢉ
ꢃꢀꢅ
hecking basic setting of fork
Info
For various reasons, no exact riding sag can be determined for the forks.
As with the shock absorber, smaller weight differences can be compensated by the
spring preload.
However, if your fork is often overloaded (hard end stop on compression), you must fit
harder springs to avoid damage to the fork and frame.
400386-01
ꢉ
ꢃꢀꢆ
djusting compression damping of fork
Info
The hydraulic compression damping determines the fork suspension behavior.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
26
ಥ
Turn adjusting screws‘ꢀ clockwise until they stop.
Info
The adjusting screws‘ꢀ are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
ಥ
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Compression damping
Standard
15‘clicks
400206-10
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
ꢉ
ꢃꢀꢇ
Info
The hydraulic rebound damping determines the fork suspension behavior.
ಥ
ಥ
Remove protection covers‘ꢀ.
Turn adjusting screws‘ꢁ clockwise until they stop.
Info
The adjusting screws‘ꢁ are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
ಥ
Turn back counterclockwise the number of clicks corresponding to the fork type.
Specification
Rebound damping
500189-10
Standard
15‘clicks
Info
Turn clockwise to increase damping, turn counterclockwise to reduce sus-
pension damping.
ಥ
Mount protection covers‘ꢀ.
ꢉ
ꢃꢀꢈ
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Remove bleeder screws‘ꢀ briefly.
Any excess pressure escapes from the interior of the fork.
ಥ
ಥ
Mount and tighten bleeder screws.
Remove the motorcycle from the work stand. ( P. 21)
400248-10
ꢉ
ꢃꢀꢉ
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Remove the fork protector. ( P. 27)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
27
ಥ
Push dust boots‘ꢀ of both fork legs downwards.
Info
The dust boots should 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 can start to leak.
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake
discs.
500188-10
ಥ
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
ಥ
Clean and oil the dust boots and inner fork tube of both fork legs.
Universal oil spray ( P. 84)
ಥ
ಥ
ಥ
ಥ
Press the dust boots back into their normal position.
Remove excess oil.
Install the fork protector ( P. 27)
Remove the motorcycle from the work stand. ( P. 21)
ꢉ
ꢃꢁꢊ
ಥ
ಥ
ಥ
Remove screws‘ꢀ and take off clamp.
Remove screws‘ꢁ on left fork leg. Remove the fork protector.
Remove the screws on the right fork leg. Remove the fork protector.
500187-11
ꢉ
ꢃꢁꢀ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Position the fork protection on the left fork leg. Mount and tighten screws‘ꢀ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
ಥ
ಥ
Position the brake line. Put the clamp on, mount and tighten screws‘ꢁ.
Position the fork protection on the right fork leg. Mount and tighten screws.
Specification
500187-10
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
ꢉ
ꢃꢁꢁ
hecking play of steering head bearing
Warning
Danger of accidentsಗUnsafe riding behavior due to incorrect steering head bearing play.
ಥ
The steering head bearing play should be adjusted immediately in an authorized KTM workshop.
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.
ಥ
Jack up the motorcycle. ( P. 21)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
28
ಥ
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 ( P. 28)
ಥ
ಥ
Move the handlebar to and fro over the entire steering range.
The handlebar must be able to move easily over the entire steering range. No
resting locations should be noticeable.
400387-10
»
If click positions are noticeable:
ಥ
Adjust play of the steering head bearing ( P. 28)
ಥ
Check the steering head bearing and replace if required.
ಥ
Remove the motorcycle from the work stand. ( P. 21)
ꢉ
ꢃꢁꢂ
djusting play of steering head bearing‘x
ಥ
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Loosen screw‘ꢀ. Remove screw‘ꢁ.
Loosen and retighten screw‘ꢅ.
Specification
Screw, top steering head
M20x1,5
10‘Nm
(7.38‘lbf‘ft)
ಥ
ಥ
Using a plastic hammer, tap lightly on the upper triple clamp to avoid strains.
Fully tighten screw‘ꢀ.
Specification
500103-11
Screw, top triple clamp
M8
17‘Nm
(12.54‘lbf‘ft)
ಥ
Mount and tighten screw‘ꢁ.
Specification
Screw, top steering stem
M8
17‘Nm
(12.54‘lbf‘ft)
Loctite® 243™
ಥ
Check play of steering head bearing. ( P. 27)
ꢉ
ꢃꢁꢄ
ork offset
You can see the currently set offset if you remove screw‘ꢀ.
The fork offset‘ꢂ has an impact on the handling of the vehicle. It is calculated from
the center of the fork leg to the center of the steering head bearing.
The fork offset can optionally be adjusted.
0B
Marking‘ꢃ to the front gives greater stability on fast racetracks.
Fork offset
0AA
Front marking
14‘mm (0.55‘in)
Marking‘ꢃ to the rear gives better handling in bends.
Fork offset
Rear marking
16‘mm (0.63‘in)
01
400188-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
29
ꢉ
ꢃꢁꢅ
etting the fork offset‘x
ಥ
ಥ
ಥ
ಥ
Remove the lower triple clamp. ( P. 30)
Remove screw‘ꢀ. Remove the steering stem.
Clean the parts and check for damage.
Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten
screw‘ꢀ.
Specification
Screw, bottom steering
head
M20x1,5
60‘Nm
(44.26‘lbf‘ft)
Loctite® 243™
ಥ
Install the lower triple clamp. ( P. 30)
500104-10
ꢉ
ꢃꢁꢆ
emoving the fork legs‘x
ಥ
ಥ
ಥ
Remove front wheel. ( P. 46)
Remove screws‘ꢀ and take off clamp.
Hang the brake caliper‘ꢁ and the brake line loosely to the side.
500200-12
ಥ
ಥ
Loosen screw‘ꢅ. Remove the fork leg on the left.
Loosen screw‘ꢆ. Remove the fork leg on the right.
500094-12
ꢉ
ꢃꢁꢇ
nstalling the fork legs‘x
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Position the fork legs.
Info
The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position the bleeder screw‘ꢀ to the front.
400248-10
ಥ
ಥ
Fully tighten screw‘ꢁ.
Specification
Screw, top triple clamp
M8
M8
17‘Nm
(12.54‘lbf‘ft)
Fully tighten screw‘ꢅ.
Specification
Screw, bottom triple clamp
12‘Nm
(8.85‘lbf‘ft)
500094-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
30
ಥ
ಥ
Position the brake line. Put the clamp on, mount and tighten screws‘ꢅ.
Fit front wheel. ( P. 47)
500200-13
ꢉ
ꢃꢁꢈ
emoving the lower triple clamp‘x
ಥ
ಥ
ಥ
ಥ
Remove the fork legs. ( P. 29)
Dismount the start number plate ( P. 32)
Dismount the front fender. ( P. 31)
Remove screws‘ꢀ and hang the CDI control unit to the side.
Info
Do not unplug the CDI control unit.
ಥ
Remove screw‘ꢁ. Remove screw‘ꢅ, 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.
500099-10
ಥ
ಥ
ಥ
Remove o-ring‘ꢆ. Remove protector ring‘ꢇ.
Remove the lower triple clamp with the steering stem.
Remove the upper steering head bearing.
500100-10
ꢉ
ꢃꢁꢉ
nstalling the lower triple clamp‘x
ಥ
ಥ
Clean the bearing and sealing elements, check for damage, and grease. Replace
damaged or worn parts.
Long-life grease ( P. 84)
03
02
01
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.
ಥ
Push up protective ring‘ꢁ and o-ring‘ꢅ.
500098-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
31
ಥ
ಥ
Position the upper triple clamp with the steering.
Mount and tighten screw‘ꢆ.
Specification
Screw, top steering head
M20x1,5
10‘Nm
(7.38‘lbf‘ft)
ಥ
Position the clutch line, wiring harness and CDI control unit. Mount and tighten
screws‘ꢇ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
500099-11
ಥ
ಥ
ಥ
ಥ
Install front fender. ( P. 31)
Fit the start number plate. ( P. 32)
Install the fork legs. ( P. 29)
Mount and tighten screw‘
.
Specification
Screw, top steering stem
M8
17‘Nm
(12.54‘lbf‘ft)
Loctite® 243™
ಥ
ಥ
Check the cable harness, cable, brake and clutch line for free movement and free
laying.
Check play of steering head bearing. ( P. 27)
500103-10
ꢉ
ꢃꢂꢊ
reasing the steering head bearing‘x
ಥ
ಥ
Remove the lower triple clamp. ( P. 30)
Install the lower triple clamp. ( P. 30)
ꢉ
ꢃꢂꢀ
ismounting the front fender
ಥ
ಥ
Remove screws‘ꢀ. Remove the front fender.
Make sure that the distance bushings remain in place.
500190-10
ꢉ
ꢃꢂꢁ
ಥ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Make sure that the spacing sleeves are mounted in the fender.
Position the front fender. Mount and tighten screws‘ꢀ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
Info
Take care with the contact of the holding lugs to the start number plate.
500190-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
32
ꢉ
ꢃꢂꢂ
ಥ
ಥ
Remove screw‘ꢀ and take off clamp.
Remove screw‘ꢁ. Remove the start number plate.
500191-10
ꢉ
ꢃꢂꢄ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Position the start number plate. Mount and tighten screw‘ꢀ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
Info
Take care with the contact of the holding lug at the fender.
500191-11
ಥ
Position brake line. Put the clamp on, mount and tighten screw‘ꢁ.
ꢉ
ꢃꢂꢅ
andlebar position
On the upper triple clamp, there are 2 holes at a distance of‘ꢂ to each other.
Drilling distance A 15‘mm (0.59‘in)
The holes on the handlebar support are placed at a distance of‘ꢃ from the center.
Drilling distance B 3.5‘mm (0.14‘in)
0AA
The handlebar can be mounted in 4 different positions. This enables you to mount the
handlebar in the position most suitable for the rider.
0B
400271-11
ꢉ
ꢃꢂꢆ
djusting handlebar position‘x
ಥ
Remove the four screws‘ꢀ. Remove the handlebar clamp. Remove the handlebar
and lay it to one side.
01
02
Info
Protect the motorcycle and its attachments from damage by covering them.
Do not bend the cables and lines.
ಥ
ಥ
Remove the two screws‘ꢁ. Remove the handlebar support.
Place the handlebar support in the required position. Fit and tighten the two
screws‘ꢁ.
Specification
400271-10
Screw, handlebar support
M10
40‘Nm
(29.5‘lbf‘ft)
Loctite® 243™
Info
Position the left and right handlebar supports evenly.
ಥ
ಥ
Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
Position the handlebar clamp. Fit and evenly tighten the four screws‘ꢀ.
Specification
Screw, handlebar clamp
M8
20‘Nm
(14.75‘lbf‘ft)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
33
ꢉ
ꢃꢂꢇ
ಥ
ಥ
ಥ
The two gas Bowden cables must run parallel behind the handlebar down to the
frame. They must be routed directly on the frame above the tank bearing to the car-
buretor.
500201-10
ꢉ
ꢃꢂꢈ
hecking play in the gas Bowden cable
Move the handlebar to the straight-ahead position. Move the throttle grip back and
forth slightly to ascertain the play in the gas Bowden cable.
Play in gas Bowden cable
3… 5‘mm (0.12… 0.2‘in)
»
If the gas Bowden cable play does not meet specifications:
ಥ
Adjust the gas Bowden cable play. ( P. 33)
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in uncon-
sciousness and/or death.
400192-10
ಥ
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in a closed space.
Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
»
If the idle speed changes:
Adjust the gas Bowden cable play. ( P. 33)
ಥ
ꢉ
ꢃꢂꢉ
djusting the gas Bowden cable play‘x
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Dismount the fuel tank. ( P. 53)
Check gas Bowden cable route. ( P. 33)
Move the handlebar to the straight-ahead position.
Push back bellows‘ꢀ.
Loosen nut‘ꢁ. Turn adjusting screw‘ꢅ in as far as possible.
Loosen nut‘ꢆ. Turn adjusting screw‘ꢇ so that there is play in the gas Bowden ca-
ble at the throttle grip.
Specification
Play in gas Bowden cable
3… 5‘mm (0.12… 0.2‘in)
ಥ
ಥ
Tighten nut‘ꢆ.
400269-10
Press and hold the throttle grip in the closed setting. Turn adjusting screw‘ꢅ out
until there is no play in the Bowden cable‘
.
ಥ
ಥ
ಥ
ಥ
Tighten nut‘ꢁ.
Push bellows‘ꢀ on. Check the throttle grip for smooth operation.
Install the fuel tank. ( P. 54)
Check play in the gas Bowden cable. ( P. 33)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
34
ꢉ
ꢃꢄꢊ
hecking chain dirt
ಥ
Check the chain for coarse dirt accumulation.
»
If the chain is very dirty:
Clean the chain. ( P. 34)
ಥ
ꢉ
ꢃꢄꢀ
leaning the chain
Warning
Danger of accidentsಗOil or grease on the tires reduces their grip.
ಥ
Remove oil and grease with a suitable cleaning material.
Warning
Danger of accidentsಗReduced braking due to oil or grease on the brake discs.
ಥ
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
The service life of the chain depends largely on its maintenance.
ಥ
Clean the chain regularly and then treat with chain spray.
Chain cleaner ( P. 84)
Offroad chain spray ( P. 84)
ꢉ
ꢃꢄꢁ
hecking the chain tension
Warning
Danger of accidentsಗDanger caused by incorrect chain tension.
ಥ
If the chain tension is too high, 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 can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Push the chain at the end of the chain sliding component upwards to measure the
chain tension‘ꢂ.
Info
The upper chain section‘ꢀ must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
8… 10‘mm (0.31… 0.39‘in)
»
If the chain tension does not meet specifications:
500192-10
ಥ
Adjusting chain tension - after checking. ( P. 37)
ಥ
Remove the motorcycle from the work stand. ( P. 21)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
35
ꢉ
ꢃꢄꢂ
hecking the chain tension when fitting rear wheel
Warning
Danger of accidentsಗDanger caused by incorrect chain tension.
ಥ
If the chain tension is too high, 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 can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ಥ
ಥ
Make sure that the chain adjusters are fitted correctly on the adjusting screws.
Push the chain at the end of the chain sliding component upwards to measure
chain tension‘ꢂ.
Info
The upper chain section‘ꢀ must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
8… 10‘mm (0.31… 0.39‘in)
500192-10
»
If the chain tension does not meet specifications:
ಥ
Adjust the chain tension when fitting rear wheel. ( P. 37)
ꢉ
ꢃꢄꢄ
ಥ
ಥ
Check the rear sprocket / engine sprocket for wear.
If the rear sprocket / engine sprocket are worn:
»
ಥ
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 re-
placed together.
400227-01
Check that the chain guide is firmly seated and not worn.
ꢉ
ꢃꢄꢅ
hecking chain wear
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Shift to neutral and pull the upper chain length with the specified tension‘ꢂ.
Specification
Chain tension
10… 15‘kg (22.05… 33.07‘lb.)
0A
ಥ
Measure distance‘ꢃ of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance‘ꢃ at the longest
chain section
272‘mm (10.71‘in)
»
If distance‘ꢃ is greater than the specified measurement:
ಥ
Replace the chain.
Info
When you replace the chain, you should also replace the rear and
engine sprockets.
B
0
New chains wear out faster on old, worn sprockets.
ಥ
Remove the motorcycle from the work stand. ( P. 21)
1 2 3
16 17 18
400385-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
36
ꢉ
ꢃꢄꢆ
djusting the chain tension
Warning
Danger of accidentsಗDanger caused by incorrect chain tension.
ಥ
If the chain tension is too high, 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 can
rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine
sprocket or the rear sprocket and block the rear wheel or damage the engine. Check for correct chain tension and adjust if
necessary.
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Push the chain at the end of the chain sliding component upwards to measure
chain tension‘ꢂ.
Info
The upper chain section‘ꢀ must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
500192-10
ಥ
ಥ
ಥ
Loosen nut‘ꢁ.
Loosen nuts‘ꢅ.
Adjust the chain tension by turning the left and right adjusting screws‘ꢆ.
Specification
Chain tension
8… 10‘mm (0.31… 0.39‘in)
Turn the left and right adjusting screws‘ꢆ so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks‘ꢃ.
The rear wheel is then correctly aligned.
ಥ
ಥ
ಥ
Tighten nuts‘ꢅ.
Make sure that chain adjusters‘ꢇ are fitted correctly on the adjusting screws‘ꢆ.
Tighten nut‘ꢁ.
Specification
Nut, rear wheel spindle
M20x1,5
80‘Nm
(59.01‘lbf‘ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
Chain adjusters‘ꢇ can be turned by 180°.
500193-10
ಥ
Remove the motorcycle from the work stand. ( P. 21)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
37
ꢉ
ꢃꢄꢇ
djusting chain tension - after checking
ಥ
ಥ
ಥ
Loosen nut‘ꢀ.
Loosen nuts‘ꢁ.
Adjust the chain tension by turning the adjusting screws‘ꢅ left and right.
Specification
Chain tension
8… 10‘mm (0.31… 0.39‘in)
Turn the adjusting screws‘ꢅ left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks‘ꢂ.
The rear wheel is then correctly aligned.
ಥ
ಥ
Tighten nuts‘ꢁ.
Make sure that the chain adjusters‘ꢆ are fitted correctly on the adjusting
screws‘ꢅ.
ಥ
Tighten nut‘ꢀ.
Specification
Nut, rear wheel spindle
M20x1,5
80‘Nm
(59.01‘lbf‘ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
500193-13
The chain adjusters‘ꢆ can be turned by 180°.
ꢉ
ꢃꢄꢈ
djusting chain tension - fitting rear wheel
ಥ
ಥ
Loosen nuts‘ꢀ.
Adjust the chain tension by turning the adjusting screws‘ꢁ left and right.
Specification
Chain tension
8… 10‘mm (0.31… 0.39‘in)
Turn the adjusting screws‘ꢁ left and right so that the markings on the left and
right chain adjusters are in the same position relative to the reference marks‘ꢂ.
The rear wheel is then correctly aligned.
ಥ
Tighten nuts‘ꢀ.
500193-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
38
ꢉ
ꢃꢄꢉ
djusting chain guide‘x
ಥ
Remove screws‘ꢀ and‘ꢁ. Take off the chain guide.
Conditions
Number of teeth: 싨‘44‘teeth
ಥ
ಥ
Insert nut‘ꢅ in hole‘ꢂ. Position the chain guide.
Mount and tighten screws‘ꢀ and‘ꢁ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
Conditions
Number of teeth: 싩‘45‘teeth
ಥ
ಥ
Insert nut‘ꢅ in hole‘ꢃ. Position the chain guide.
Mount and tighten screws‘ꢀ and‘ꢁ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
500194-10
ꢉ
ꢃꢅꢊ
rake fluid reservoir
Warning
Danger of accidentsಗBrake system failure.
ಥ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the
brake linings are worn.
ꢉ
ꢃꢅꢀ
The brake calipers of this series are "floating", which means that they are not fixed to the brake caliper support.
The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc.
ꢉ
ꢃꢅꢁ
hecking brake discs
Warning
Danger of accidentsಗReduced braking due to worn brake discs.
ಥ
Worn brake discs should be replaced immediately by an authorized KTM workshop.
ಥ
Check the thickness of the front and rear brake discs at several places on the disc
to see if it conforms to measurement‘ꢂ.
Info
0A
Wear reduces the thickness of the brake disc around the area used by the
brake linings.
Wear limit of brake discs
front
Rear
4.5‘mm (0.18‘in)
3.5‘mm (0.14‘in)
400388-10
»
The brake disc thickness is less than the specified value.
Replace the brake disc.
ಥ
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MAINTENANCE WORK ON CHASSIS AND ENGINE
39
ꢉ
ꢃꢅꢂ
hecking free play of hand brake lever
Warning
Danger of accidentsಗBrake system failure.
ಥ
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.
ಥ
Push the hand brake lever forwards and check free play.‘ꢂ.
Free play of hand brake lever 싩‘3‘mm (싩‘0.12‘in)
If the free travel does not meet specifications:
adjust the basic position of handbrake lever. ( P. 39)
»
ಥ
500176-11
ꢉ
ꢃꢅꢄ
djusting basic position of handbrake lever
ಥ
Adjust the basic setting of the handbrake lever to your hand size by turning adjust-
ing screw‘ꢀ.
Info
If you turn the adjusting screw clockwise (as seen in the direction of travel),
the handbrake lever moves nearer to the handlebar.
If you turn the adjusting screw counterclockwise (as seen in the direction of
travel), the handbrake lever moves away from the handlebar.
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!
500176-12
ಥ
Check the free play of the hand brake lever. ( P. 39)
ꢉ
ꢃꢅꢅ
hecking front brake fluid level
Warning
Danger of accidentsಗBrake system failure.
ಥ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidentsಗReduced braking due to old brake fluid.
ಥ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
ಥ
ಥ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Check the brake fluid level in the brake fluid reservoir‘ꢀ.
»
If the brake fluid is below the MIN mark:
ಥ
Top up the brake fluid of the front brake. ( P. 40)
500195-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
40
ꢉ
ꢃꢅꢆ
opping up the front brake fluid‘x
Warning
Danger of accidentsಗBrake system failure.
ಥ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಗReduced braking due to old brake fluid.
ಥ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends DOT‘5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT‘4 brake fluid and provides
greater safety for high demands.
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!
ಥ
ಥ
ಥ
ಥ
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screw cap‘ꢀ.
Remove the plastic ring‘ꢁ with membrane‘ꢅ.
Top up the brake fluid to level‘MAX.
Brake fluid DOT 5.1 ( P. 82)
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Fit the membrane and the plastic ring. Mount and tighten the screw cap.
500196-10
Info
Clean up overflowed or spilt brake fluid immediately with water.
ꢉ
ꢃꢅꢇ
Warning
Danger of accidentsಗReduced braking due to worn brake linings.
Worn brake linings should be replaced immediately in an authorized KTM workshop.
ಥ
ಥ
Check the brake linings for minimum thickness‘ꢂ.
»
Minimum thickness‘ꢂ: 싩‘1‘mm (싩‘0.04‘in)
If the minimum thickness is less than specified:
ಥ
Change the front brake linings. ( P. 42)
500202-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
41
ꢉ
ꢃꢅꢈ
emoving front brake linings‘x
Warning
Danger of accidentsಗImproper brake maintenance and repair.
ಥ
Always have your brake system maintained and repaired in an authorized KTM workshop.
ಥ
Remove locking split pins‘ꢀ.
500203-11
500204-10
500205-10
ಥ
ಥ
Press the spring hanger of the spring‘ꢁ forwards and withdraw the bolt‘ꢅ.
Take off the springs‘ꢁ. Remove the brake linings.
ಥ
ಥ
Remove screws‘ꢆ with washers‘ꢇ and take off the brake caliper.
Clean the brake caliper.
ꢉ
ꢃꢅꢉ
ounting front brake linings‘x
Warning
Danger of accidentsಗReduced braking 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.
ಥ
Warning
Danger of accidentsಗReduced braking due to use of non-approved brake linings.
ಥ
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 origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
ಥ
ಥ
ಥ
Check the brake discs. ( P. 38)
Check parts for damage and wear. Replace damaged or worn parts.
Position the brake caliper. Fit and tighten screws‘ꢀ with washers‘ꢁ.
Specification
Screw, front brake caliper
M10x1,25
40‘Nm
(29.5‘lbf‘ft)
Loctite® 243™
500205-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
42
ಥ
Fit the brake linings. Position the springs‘ꢅ and mount the bolts‘ꢆ.
Info
The spring hanger of the springs‘ꢅ must be positioned upwards.
500204-11
ಥ
ಥ
Fit the locking splint pins‘ꢇ.
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
500203-12
ꢉ
ꢃꢆꢊ
hanging the front brake linings‘x
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಗReduced braking due to old brake fluid.
ಥ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends DOT‘5.1 brake fluid from Motorex®. This has a higher wet boiling point than DOT‘4 brake fluid and provides
greater safety for high demands.
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!
ಥ
ಥ
ಥ
ಥ
ಥ
Remove the front brake linings. ( P. 41)
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screw cap‘ꢀ.
Remove the plastic ring‘ꢁ with membrane‘ꢅ.
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the reservoir.
ಥ
ಥ
Mount the front brake linings. ( P. 41)
Top up the brake fluid to level‘MAX.
Brake fluid DOT 5.1 ( P. 82)
500196-10
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Fit the membrane and the plastic ring. Mount and tighten the screw cap.
Info
Clean up overflowed or spilt brake fluid immediately with water.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
43
ꢉ
ꢃꢆꢀ
hecking free play of foot brake lever
Warning
Danger of accidentsಗBrake system failure.
ಥ
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.
ಥ
ಥ
Disconnect spring‘ꢀ.
Move the foot brake lever backwards and forwards between the end stop and the
foot brake cylinder piston bracket and check free play‘ꢂ.
Specification
Free play at foot brake lever
3… 5‘mm (0.12… 0.2‘in)
»
If the free travel does not meet specifications:
ಥ
Adjust the basic position of the footbrake lever. ( P. 43)
ಥ
Reconnect spring‘ꢀ.
400205-11
ꢉ
ꢃꢆꢁ
djusting basic position of footbrake lever‘x
Warning
Danger of accidentsಗBrake system failure.
ಥ
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.
ಥ
ಥ
ಥ
Disconnect spring‘ꢀ.
Loosen nut‘ꢆ and with push rod‘ꢇ, turn it back until you have maximum free play.
To adjust the basic position of the footbrake lever individually, lossen nut‘ꢁ and
turn screw‘ꢅ accordingly.
Info
The range of adjustment is limited.
ಥ
ಥ
ಥ
ಥ
Turn push rod‘ꢇ accordingly until you have free play‘ꢂ. If necessary, adjust the
basic position of the footbrake lever.
Specification
400232-10
Free play at foot brake lever
3… 5‘mm (0.12… 0.2‘in)
Hold screw‘ꢅ and tighten nut‘ꢁ.
Specification
Remaining nuts, chassis
M8
M6
30‘Nm
(22.13‘lbf‘ft)
Hold push rod‘ꢇ and tighten nut‘ꢆ.
Specification
Remaining nuts, chassis
15‘Nm
(11.06‘lbf‘ft)
Reconnect spring‘ꢀ.
ꢉ
ꢃꢆꢂ
hecking the rear brake fluid level
Warning
Danger of accidentsಗBrake system failure.
ಥ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Danger of accidentsಗReduced braking due to old brake fluid.
ಥ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
44
ಥ
ಥ
Stand the vehicle upright.
Check the brake fluid level in the viewer‘ꢀ.
»
When in the viewer‘ꢀ an air bubble is visible:
ಥ
Add rear brake fluid. ( P. 44)
400234-10
ꢉ
ꢃꢆꢄ
dding rear brake fluid‘x
Warning
Danger of accidentsಗBrake system failure.
ಥ
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings.
Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಗReduced braking due to old brake fluid.
ಥ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from‘Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
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!
ಥ
ಥ
ಥ
Stand the vehicle upright.
Remove screw cap‘ꢀ with membrane‘ꢁ and the O-ring.
Add brake fluid to level‘ꢂ.
Brake fluid DOT 5.1 ( P. 82)
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Mount the screw cap with the membrane‘and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
400233-10
ꢉ
ꢃꢆꢅ
hecking rear brake linings
Warning
Danger of accidentsಗReduced braking due to worn brake linings.
ಥ
Worn brake linings should be replaced immediately in an authorized KTM workshop.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
45
ಥ
Check the brake linings for minimum thickness‘ꢂ.
»
Minimum thickness‘ꢂ: 싩‘1‘mm (싩‘0.04‘in)
If the minimum thickness is less than specified:
ಥ
Change the rear brake linings. ( P. 46)
500206-11
ꢉ
ꢃꢆꢆ
emoving rear brake linings‘x
Warning
Danger of accidentsಗImproper brake maintenance and repair.
Always have your brake system maintained and repaired in an authorized KTM workshop.
ಥ
ಥ
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
ಥ
ಥ
Remove the locking split pins‘ꢀ, withdraw the bolt‘ꢁ, and take out the brake
pads.
Clean brake caliper and brake caliper support.
500206-10
ꢉ
ꢃꢆꢇ
nstalling the rear brake linings‘x
Warning
Danger of accidentsಗReduced braking 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.
ಥ
Warning
Danger of accidentsಗReduced braking due to use of non-approved brake linings.
ಥ
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 origi-
nal license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
ಥ
ಥ
ಥ
Check the brake discs. ( P. 38)
Check parts for damage and wear. Replace damaged or worn parts.
Check that leaf spring‘ꢀ in the brake caliper and sliding plate‘ꢁ in the brake
caliper support are seated correctly.
Info
The arrow on the leaf spring points in the rotation direction of the brake
disc.
500122-10
ಥ
ಥ
Fit the brake linings, insert bolt‘ꢅ, and mount locking split pins‘ꢆ.
Info
Make sure that the decoupling plate‘ꢇ is mounted on the piston side of the
brake pad.
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
500207-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
46
ꢉ
ꢃꢆꢈ
hanging the rear brake linings‘x
Warning
Skin irritationsಗBrake fluid can cause skin irritation on contact.
ಥ
ಥ
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Danger of accidentsಗReduced braking due to old brake fluid.
ಥ
Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
KTM recommends brake fluid DOT‘5.1 from Motorex®. This brake fluid has a higher wet boiling point than brake fluid DOT‘4
and offers more protection under high load.
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!
ಥ
ಥ
ಥ
ಥ
Remove the rear brake linings. ( P. 45)
Stand the vehicle upright.
Remove screw cap‘ꢀ with membrane‘ꢁ and the O-ring.
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
ಥ
ಥ
Install the rear brake linings. ( P. 45)
Add brake fluid to level‘ꢂ.
Brake fluid DOT 5.1 ( P. 82)
400233-10
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Mount the screw cap with the membrane‘and the O-ring.
Info
Clean up overflowed or spilt brake fluid immediately with water.
ꢉ
ꢃꢆꢉ
emoving front wheel‘x
ಥ
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Remove screw‘ꢀ.
Loosen screw‘ꢁ.
500209-10
ಥ
Remove screws‘ꢅ with washers‘ꢆ and take off the brake caliper.
Info
Do not pull the handbrake lever when the brake claiper is removed.
500208-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
47
ಥ
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of
the fork.
Info
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
500210-10
ಥ
Remove the spacing sleeves‘ꢇ.
500211-10
ꢉ
ꢃꢇꢊ
itting front wheel‘x
Warning
Danger of accidentsಗReduced braking 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.
ಥ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Clean and grease shaft seal rings‘ꢀ and bearing surface‘ꢂ of the spacing sleeves.
Long-life grease ( P. 84)
ಥ
Fit the spacing sleeves.
500211-11
500212-10
500208-10
ಥ
ಥ
Lift the front wheel into the fork, position it, and insert the wheel spindle.
Mount and tighten screw‘ꢁ.
Specification
Screw, front wheel spindle
M24x1,5
40‘Nm
(29.5‘lbf‘ft)
ಥ
Position the brake caliper. Fit and tighten screws‘ꢅ with washers‘ꢆ.
Specification
Screw, front brake caliper
M10x1,25
40‘Nm
(29.5‘lbf‘ft)
Loctite® 243™
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MAINTENANCE WORK ON CHASSIS AND ENGINE
48
ಥ
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
ಥ
ಥ
Remove the motorcycle from the work stand. ( P. 21)
Pull the front wheel brake and push down hard on the fork several times to align
the fork legs.
ಥ
Fully tighten screw‘ꢇ.
Specification
Screw, fork stub
M8
15‘Nm
(11.06‘lbf‘ft)
500209-11
ꢉ
ꢃꢇꢀ
emoving rear wheel‘x
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
Info
Make sure when pushing back the brake piston that you do not press the
brake caliper against the spokes.
ಥ
ಥ
Remove nut‘ꢀ.
Remove chain adjuster‘ꢁ. Withdraw the wheel spindle‘ꢅ only enough to allow the
rear wheel to be pushed forward.
ಥ
ಥ
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
swing arm.
Info
Do not operate the foot brake when the rear wheel is removed.
Always lay the wheel down in such a way that the brake disc is not dam-
aged.
500213-10
ಥ
Remove the spacing sleeves‘ꢆ.
500214-11
ꢉ
ꢃꢇꢁ
itting rear wheel‘x
Warning
Danger of accidentsಗReduced braking 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.
ಥ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Clean and grease shaft seal rings‘ꢀ and bearing surface‘ꢂ of the spacing sleeves.
Long-life grease ( P. 84)
ಥ
Fit the spacing sleeves.
500214-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
49
ಥ
ಥ
Lift the rear wheel into the swing arm, position it, and insert the wheel spindle‘ꢁ.
Put the chain on.
500215-10
ಥ
ಥ
ಥ
Position the chain adjuster‘ꢅ. Fit nut‘ꢆ, but do not tighten it yet.
Check the chain tension when fitting rear wheel. ( P. 35)
Make sure that the chain adjusters‘ꢅ are fitted correctly on the adjusting
screws‘ꢇ.
ಥ
Tighten nut‘ꢆ.
Specification
Nut, rear wheel spindle
M20x1,5
80‘Nm
(59.01‘lbf‘ft)
Info
The wide adjustment range of the chain adjusters (32 mm) enables different
secondary transmissions with the same chain length.
The chain adjusters‘ꢅ can be turned by 180°.
ಥ
ಥ
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
Remove the motorcycle from the work stand. ( P. 21)
500193-12
ꢉ
ꢃꢇꢂ
ire condition checking
Info
Fit only tires approved by KTM.
Other tires could have a negative effect on riding behavior.
The type, condition and air pressure of the tires all have an important impact on the riding behavior of the motorcycle.
The front and rear wheels must be fitted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
ಥ
Examine the tires for cuts, foreign bodies and other damage.
ꢉ
ꢃꢇꢄ
hecking 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.
ಥ
ಥ
Remove dust cap.
Check tire air pressure when tires are cold.
Tire air pressure
front
1.6‘bar (23.21‘psi)
Rear
1.6‘bar (23.21‘psi)
»
If the tire pressure does not meet specifications:
Correct tire pressure.
Mount dust cap.
ಥ
ಥ
500216-01
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MAINTENANCE WORK ON CHASSIS AND ENGINE
50
ꢉ
ꢃꢇꢅ
hecking spoke tension
Warning
Danger of accidentsಗUnstable riding behavior due to loose spokes.
ಥ
If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop.
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.
ಥ
To check spoke tension, tap each spoke with a screwdriver.
Specification
You should hear a high note.
Spoke nipple, front wheel
Spoke nipple, rear wheel
M4,5
M5
5‘Nm (3.69‘lbf‘ft)
5‘Nm (3.69‘lbf‘ft)
Info
If you hear different tone frequencies from different spokes, this is an indi-
cation of different spoke tensions.
500217-01
ꢉ
ꢃꢇꢆ
emoving the battery‘x
Warning
Risk of injuryಗBattery acid and battery gases cause serious cauterization.
ಥ
ಥ
ಥ
ಥ
ಥ
Keep batteries out of the reach of children.
Wear suitable protective clothing and goggles.
Avoid contact with battery acid and battery gases.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
ಥ
ಥ
ಥ
ಥ
Switch off all power-consuming components and switch off the engine.
Remove the seat. ( P. 53)
Disconnect the negative (minus) cable‘ꢀ of the battery.
Pull back the plus pole cover‘ꢁ and disconnect the positive (plus) cable of the bat-
tery.
ಥ
ಥ
Hang the rubber band‘ꢅ out to the bottom.
Lift the battery up.
500069-10
ꢉ
ꢃꢇꢇ
nstalling the battery‘x
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Place the battery in the battery holder.
Condition
Outdoor temperature: 싩‘10‘°C (싩‘50‘°F)
3Ah battery‘(YTX4L-BS) ( P. 74)
Condition
Outdoor temperature: 싨‘10‘°C (싨‘50‘°F)
4Ah battery‘(YTX5L-BS) ( P. 74)
500069-11
ಥ
ಥ
ಥ
Reconnect the rubber band‘ꢀ.
Attach the plus cable and replace the plus pole cover‘ꢁ.
Attach the minus cable‘ꢅ.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
51
ಥ
Mount the seat. ( P. 53)
ꢉ
ꢃꢇꢈ
echarging the battery‘x
Warning
Risk of injuryಗBattery acid and battery gases cause serious cauterization.
ಥ
ಥ
ಥ
ಥ
ಥ
Keep batteries out of the reach of children.
Wear suitable protective clothing and goggles.
Avoid contact with battery acid and battery gases.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Warning
Environmental hazardಗComponents and battery acid are a danger to the environment.
ಥ
Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Even if there is no load on the battery, it loses power every day.
The charge state and the type of charge are very important for the service life of the battery.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
ಥ
ಥ
ಥ
Switch off all power-consuming components and switch off the engine.
Remove the seat. ( P. 53)
Disconnect the minus (negative) cable of the battery to avoid damage to the motor-
cycle's electronics.
ಥ
Connect the battery charger to the battery. Switch on the battery charger.
Battery charger‘(58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid‘ꢀ.
Charge the battery according to the instructions‘ꢁ on the battery casing.
400240-10
ಥ
ಥ
Switch off the charger after charging. Disconnect the battery.
Specification
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use.
3‘months
Mount the seat. ( P. 53)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
52
ꢉ
ꢃꢇꢉ
emoving a fuse
ಥ
ಥ
ಥ
Switch off all power-consuming components and switch off the engine.
Dismount the air filter box lid. ( P. 58)
Remove the protection cover‘ꢀ.
Info
The fuse‘ꢁ is located in the starter relay‘ꢅ under the filter box cover.
ಥ
Remove the fuse‘ꢁ.
400270-10
ꢉ
ꢃꢈꢊ
eplacing the fuse
Warning
Fire hazardಗThe electrical system can be overloaded by the use of incorrect fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Info
A reserve fuse‘ꢀ is located in the starter relay.
Replace a burned-out fuse‘ꢁ only by an equivalent fuse.
ಥ
Refit the fuse.
Fuse‘(58011109110)
Info
400273-10
If the new fuse burns out, contact an authorized KTM workshop.
ಥ
ಥ
Replace the protection cover.
Install the air filter box lid. ( P. 58)
ꢉ
ꢃꢈꢀ
The plug connection‘ꢀ is located in front of the fuel tank on the left of the frame.
Possible states
•
•
Soft ಥ‘If the plug connection is separated, riding is more flexible.
Performance ಥ‘If the plug connection is connected, higher performance is
achieved.
500218-10
ꢉ
ꢃꢈꢁ
Changing the ignition curve from Performance to Soft.
Separate plug connection‘ꢀ. (Figure‘500218-10‘ P. 52)
Soft ಥ‘Greater flexibility
Changing the ignition curve from Soft to Performance.
ಥ
ಥ
Connect plug connection‘ꢀ. (Figure‘500218-10‘ P. 52)
Performance ಥ‘Higher performance
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MAINTENANCE WORK ON CHASSIS AND ENGINE
53
ꢉ
ꢃꢈꢂ
ಥ
Remove screw‘ꢀ. Lift up the seat at the rear, pull it back and then remove from
above.
500080-10
ꢉ
ꢃꢈꢄ
ounting the seat
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Hook the front of the seat into the flange adapter of the fuel tank, lower the rear of
the seat and simultaneously push it forwards.
ಥ
ಥ
Make sure that the seat is correctly locked in.
Mount and tighten the screw of the seat fixing.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
500068-01
ꢉ
ꢃꢈꢅ
ismounting the fuel tank‘x
ಥ
Remove the seat. ( P. 53)
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
ಥ
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, espe-
cially 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
500219-10
Danger of poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale
fuel vapors. If fuel gets into your eyes, rinse immediately with water and
contact a doctor. Wash affected skin areas immediately with soap and
water. If fuel is swallowed, contact a doctor immediately. Change cloth-
ing 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.
ಥ
ಥ
ಥ
ಥ
Turn off the fuel tap and pull off the fuel hose.
Remove screws‘ꢀ with collar sleeve.
Remove screw‘ꢁ with collar sleeve.
Remove the tube from the fuel tank vent line.
500066-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
54
ಥ
Pull both spoilers to the side of the radiator bracket‘ꢅ and take the fuel tank away
upwards.
500220-10
ꢉ
ꢃꢈꢆ
nstalling the fuel tank‘x
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
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.
ಥ
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 poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.
ಥ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Position the fuel tank and fit the two spoilers to the side of the radiator fixing.
Make sure that no cables or Bowden cables are trapped or damaged.
500220-01
500066-11
500219-11
ಥ
ಥ
Mount the fuel tank vent hose.
Fit and tighten screw‘ꢀ with collar sleeve.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
ಥ
Fit and tighten screws‘ꢁ with collar sleeve.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
ಥ
ಥ
Connect fuel hose.
Mount the seat. ( P. 53)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
55
ꢉ
ꢃꢈꢇ
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 with-
out danger of function problems.
120‘°C (248‘°F)
Coolant ( P. 82)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cool-
ing effect.
400242-10
ꢉ
ꢃꢈꢈ
hecking antifreeze and coolant level
Warning
Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ಥ
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
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 im-
mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
ಥ
ಥ
Stand the motorcycle upright on a horizontal surface.
Remove the radiator cap.
Check antifreeze of coolant.
-25… -45‘°C (-13… -49‘°F)
»
If the antifreeze of the cooling liquid does not meet specifications:
Correct antifreeze of coolant.
ಥ
ಥ
Check the coolant level in the radiator.
Coolant level‘ꢂ above radiator fins.
10‘mm (0.39‘in)
400243-10
»
If the level of the cooling liquid does not meet specifications:
ಥ
Correct the coolant level.
Alternative 1
Coolant ( P. 82)
Alternative 2
Coolant (mixed ready to use) ( P. 82)
Refit the radiator cap.
ಥ
ꢉ
ꢃꢈꢉ
hecking the coolant level
Warning
Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ಥ
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
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 im-
mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
56
ಥ
ಥ
ಥ
Stand the motorcycle upright on a horizontal surface.
Remove the radiator cap.
Check the coolant level in the radiator.
Coolant level‘ꢂ above radiator fins.
10‘mm (0.39‘in)
»
If the level of the cooling liquid does not meet specifications:
ಥ
Correct the coolant level.
Alternative 1
Coolant ( P. 82)
400243-10
Alternative 2
Coolant (mixed ready to use) ( P. 82)
Refit the radiator cap.
ಥ
ꢉ
ꢃꢉꢊ
raining coolant‘x
Warning
Danger of scaldingಗThe coolant gets very hot when the motorcycle is driven and is under high pressure.
ಥ
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
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 im-
mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
ಥ
ಥ
ಥ
ಥ
Stand the vehicle upright.
Place a suitable container under the water pump cover.
Remove screw‘ꢀ. Remove the radiator cap‘ꢁ.
Completely drain the coolant.
Fit screw‘ꢀ with a new seal and tighten it.
Specification
Screw, water pump cover
M6
10‘Nm
(7.38‘lbf‘ft)
400242-11
ꢉ
ꢃꢉꢀ
efilling coolant‘x
Warning
Danger of poisoningಗCoolants are poisonous and a health hazard.
ಥ
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 im-
mediately. Change clothes that have come into contact with coolants. Keep coolants out of the reach of children.
ಥ
ಥ
ಥ
Make sure that the screw‘ꢀ is tightened.
Stand the vehicle upright.
Pour coolant in up to measurement‘ꢂ above the radiator fins.
Specification
10‘mm (0.39‘in)
Coolant
1.2‘l (1.27‘qt.)
Coolant ( P. 82)
Coolant (mixed ready to use)
(
P. 82)
400244-10
ಥ
ಥ
ಥ
Refit the radiator cap.
Make a short test ride.
Check the coolant level. ( P. 55)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
57
ꢉ
ꢃꢉꢁ
emoving main silencer
Warning
Danger of burnsಗThe exhaust system gets very hot when the vehicle is driven.
ಥ
Allow the exhaust system to cool down. Do not touch hot components.
ಥ
ಥ
Disconnect spring‘ꢀ.
Remove screws‘ꢁ and take off main silencer.
500221-10
ꢉ
ꢃꢉꢂ
itting the main silencer
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Mount the main silencer. Mount and tighten screws‘ꢀ.
Specification
Remaining screws, chassis
M6
10‘Nm
(7.38‘lbf‘ft)
ಥ
Reconnect spring‘ꢁ.
500221-11
ꢉ
ꢃꢉꢄ
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.
ꢉ
ꢃꢉꢅ
emoving glass fiber yarn filling of main silencer‘x
Warning
Danger of burnsಗThe exhaust system gets very hot when the vehicle is driven.
ಥ
Allow the exhaust system to cool down. Do not touch hot components.
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Remove the main silencer. ( P. 57)
Remove screws of end cap‘ꢀ. Remove the end cap.
Remove screws of insert‘ꢁ. Remove insert.
Remove screws of cap‘ꢅ. Remove cap.
Remove inner-tube‘ꢆ.
Remove glass fiber yarn filling from insert‘ꢅ and inner-tube‘ꢆ.
Clean parts to be refitted.
500226-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
58
ꢉ
ꢃꢉꢆ
itting glass fiber yarn filling of main silencer‘x
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Attach the glass fiber yarn filling to inner tube‘ꢀ. Fit the inner tube into the outer
tube‘ꢁ.
ಥ
ಥ
Insert cap‘ꢅ. Mount and tighten screws.
Attach the glass fiber yarn filling to insert‘ꢆ. Fit the insert into the outer tube‘ꢁ.
Mount and tighten screws.
ಥ
ಥ
Insert end cap‘ꢇ. Mount and tighten screws.
Fit the main silencer. ( P. 57)
500226-11
ꢉ
ꢃꢉꢇ
hanging glass fiber yarn filling of main silencer‘x
ಥ
ಥ
Remove glass fiber yarn filling of main silencer. ( P. 57)
Fit the glass fiber yarn filling of the main silencer. ( P. 58)
ꢉ
ꢃꢉꢈ
ismounting the air filter box lid
ಥ
Pull off the air filter box lid in area‘ꢂ to the side and remove to the front.
500222-10
ꢉ
ꢃꢉꢉ
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Insert the air filter box lid into the rear area‘ꢂ and clip it into the front area‘ꢃ.
500222-11
ꢉ
ꢃꢀꢊꢊ
emoving the air filter‘x
Note
Engine failureಗUnfiltered intake air has a negative effect on the service life of the engine.
ಥ
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ಥ
ಥ
ಥ
Dismount the air filter box lid. ( P. 58)
Undo the hose clip‘ꢀ.
Remove the air filter.
500223-10
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MAINTENANCE WORK ON CHASSIS AND ENGINE
59
ꢉ
ꢃꢀꢊꢀ
nstalling the air filter‘x
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Fit a clean air filter.
Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
ಥ
ಥ
Position and tighten the hose clip‘ꢀ.
Install the air filter box lid. ( P. 58)
500223-10
ꢉ
ꢃꢀꢊꢁ
leaning air filter‘x
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Do not use fuel or kerosene for cleaning the air filter.
ಥ
ಥ
ಥ
Remove the air filter. ( P. 58)
Remove large pieces of dirt by shaking. Use a soft brush to clean the air filter.
Spray on the cleaner and let it penetrate for 10 minutes.
Air filter cleaner ( P. 84)
ಥ
ಥ
Rinse the air filter from the inside with a soft jet of water.
Shake off remaining water. Allow the air filter to dry.
Info
Do not use compressed air for drying!
500225-01
ಥ
Spray the dry air filter carefully with filter oil.
Air filter oil ( P. 84)
ಥ
ಥ
ಥ
Allow the filter oil to penetrate for 20 minutes.
Clean the air filter box.
Check the distribution of the filter oil.
»
If unoiled areas are visible:
Oil the air filter again.
ಥ
ಥ
Wipe off excess filter oil.
Info
Do not over-oil the air filter.
ಥ
ಥ
Check carburetor connection boot for damage and tightness.
Install the air filter. ( P. 59)
ꢉ
ꢃꢀꢊꢂ
djusting basic position of clutch lever
ಥ
Adjust the basic setting of the clutch lever to your hand size by turning 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.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
400195-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
60
ꢉ
ꢃꢀꢊꢄ
hecking fluid level of hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
ಥ
ಥ
ಥ
ಥ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws‘ꢀ.
Remove the cover‘ꢁ with membrane‘ꢅ.
Check the fluid level.
Fluid level under top level of container. 4‘mm (0.16‘in)
»
If the level of the cooling liquid does not meet specifications:
ಥ
Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) ( P. 82)
400245-10
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Position the cover with the membrane. Mount and tighten screws.
ꢉ
ꢃꢀꢊꢅ
hanging fluid level of hydraulic clutch‘x
Warning
Environmental hazardಗProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ಥ
ಥ
ಥ
ಥ
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws‘ꢀ.
Remove the cover‘ꢁ with membrane‘ꢅ.
400245-10
500224-10
400247-10
ಥ
ಥ
Fill the bleeding syringe‘ꢆ with the appropriate hydraulic fluid.
Bleed syringe (50329050000)
Hydraulic fluid (15) ( P. 82)
On the slave cylinder, remove the bleeder screw‘ꢇ and fit the bleeding syringe‘ꢆ.
ಥ
Inject the liquid into the system until it escapes from the bore hole‘ of the mas-
ter cylinder without bubbles.
ಥ
ಥ
ಥ
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.
Specification
Fluid level under top level of container. 4‘mm (0.16‘in)
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Position the cover with the membrane. Mount and tighten screws.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
61
ꢉ
ꢃꢀꢊꢆ
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 en-
gine vibration. Wear can result in malfunctioning.
The idle speed is adjusted with the adjustment screw‘ꢀ.
The idle mixture is adjusted with the idle mixture adjustment screw‘ꢁ.
400266-10
ꢉ
ꢃꢀꢊꢇ
arburetor - adjusting idle‘x
ಥ
Screw in the idle adjusting screw‘ꢁ until it stops and then to the prescribed basic
setting.
Specification
Idle mixture adjusting screw
Open
1.5‘turns
Adjustment tool for mixture control screw (77329034000)
ಥ
ಥ
Run the engine until warm.
Specification
400266-10
Warm-up time
싩‘5‘min
Adjust the idle speed with the adjusting screw‘ꢀ.
Specification
Choke function activated ಥ‘The choke lever is pushed in to the stop. ( P. 11)
Idle speed
1600… 1650‘rpm
ಥ
ಥ
Turn the idle adjusting screw‘ꢁ slowly until the idle speed begins to fall.
Note the position and turn the idle adjusting screw slowly counterclockwise until
the idle speed falls.
ಥ
Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extreme sport motocyclist will set the mixture about 1/4 of a turn back
from this ideal value (leaner, in a clockwise direction) since the engine be-
comes hotter in sporting use.
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 adjusting screw to the end without any change of
engine speed, you have to fit a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
ಥ
Adjust the idle speed with the adjusting screw‘ꢀ.
Specification
Choke function activated ಥ‘The choke lever is pushed in to the stop. ( P. 11)
Idle speed
1600… 1650‘rpm
Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
62
ꢉ
ꢃꢀꢊꢈ
mptying the carburetor float chamber‘x
Danger
Fire hazardಗFuel can easily catch fire.
ಥ
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.
ಥ
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 poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister ac-
cording to regulations and keep it out of the reach of children.
Warning
Environmental hazardಗImproper handling of fuel is a danger to the environment.
ಥ
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.
ಥ
ಥ
Turn the handle‘ꢀ of the fuel tap to the‘OFF position. (Figure‘500178-10‘ P. 11)
No more fuel flows from the tank to the carburetor.
Guide the hose coming down behind the engine into a suitable container.
Info
Water in the float chamber results in malfunctioning.
ಥ
ಥ
Undo the screw‘ꢀ (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.
Tighten screw‘ꢀ.
400239-10
ꢉ
ꢃꢀꢊꢉ
hecking engine oil level
Info
The engine oil level can be checked on a cold or hot engine.
ಥ Stand the motorcycle upright on a horizontal surface.
Condition
The engine is at operating temperature.
ಥ
Check the engine oil level.
The engine oil reaches the top of the viewer‘ꢃ.
»
When the engine oil does not reach the top of the viewer:
Top up the engine oil. ( P. 65)
ಥ
Condition
Engine is cold.
Check the engine oil level.
ಥ
400212-10
The engine oil reaches the bottom of the viewer‘ꢂ.
»
When the engine oil does not reach the bottom of the viewer:
ಥ
Top up the engine oil. ( P. 65)
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MAINTENANCE WORK ON CHASSIS AND ENGINE
63
ꢉ
ꢃꢀꢀꢊ
hanging engine oil and oil filter, cleaning oil screen‘x
ಥ
ಥ
ಥ
ಥ
Drain the engine oil. ( P. 63)
Remove the oil filter. ( P. 64)
Mount the oil filter. ( P. 64)
Fill up with engine oil. ( P. 64)
ꢉ
ꢃꢀꢀꢀ
raining engine oil‘x
Warning
Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven.
ಥ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the engine oil only when the engine is warm.
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Stand the motorcycle on its side stand on a horizontal surface.
Place a suitable container under the engine.
Remove the oil drain plug‘ꢀ with the seal ring.
Completely drain the engine oil.
Thoroughly clean the oil drain plug with a magnet.
Clean the sealing area on the engine.
Check parts for damage and wear. Replace damaged or worn parts.
Refit oil drain plug‘ꢀ with seal ring and tighten it.
Specification
400261-10
Oil drain plug with magnet
M12x1,5
20‘Nm
(14.75‘lbf‘ft)
ಥ
Clean the oil screen. ( P. 63)
ꢉ
ꢃꢀꢀꢁ
leaning the oil screen‘x
Warning
Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven.
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
ಥ
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Place a suitable container under the engine.
Loosen the plug‘ꢀ with a few light hammer blows.
Remove plug‘ꢀ with oil screen‘ꢁ and O-rings.
Completely drain the remaining engine oil.
Thoroughly clean parts and sealing area.
Check parts for damage and wear. Replace damaged or worn parts.
Fit and tighten plug‘ꢀ with oil screen‘ꢁ and O-rings.
Specification
Plug, oil screen
M32x1,5
30‘Nm
(22.13‘lbf‘ft)
400261-11
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MAINTENANCE WORK ON CHASSIS AND ENGINE
64
ꢉ
ꢃꢀꢀꢂ
emoving the oil filter‘x
Warning
Danger of scaldingಗEngine oil and gear oil get very hot when the motocycle is driven.
ಥ
Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
ಥ
ಥ
Place a suitable container under the engine.
Remove screws‘ꢀ. Remove oil filter cover with O-ring.
400262-10
ಥ
Pull the oil filter insert‘ꢁ out of the oil filter casing.
Circlip pliers reverse (51012011000)
ಥ
ಥ
Completely drain the engine oil.
Thoroughly clean parts and sealing area.
400263-10
ꢉ
ꢃꢀꢀꢄ
ounting oil filter‘x
ಥ
ಥ
Check parts for damage and wear. Replace damaged or worn parts.
Lay the motorcycle on its side and fill the oil filter housing to about ൜ full with en-
gine oil.
ಥ
ಥ
ಥ
Fill the oil filter with engine oil and place it in the oil filter container.
Oil the O-ring of the oil filter cover and assemble it with the oil filter cover‘ꢀ.
Mount and tighten screws.
Specification
Screw, oil filter cover
M6
10‘Nm
(7.38‘lbf‘ft)
400264-10
ಥ
Stand the motorcycle up.
ꢉ
ꢃꢀꢀꢅ
illing up with engine oil‘x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ಥ
ಥ
Remove the screw cap‘ꢀ on the clutch cover and fill up with engine oil.
Engine oil 1.35‘l (1.43‘qt.) Engine oil (SAE 10W/50) ( P. 82)
Mount and tighten screw cap‘ꢀ.
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in uncon-
sciousness and/or death.
ಥ
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in a closed space.
400265-10
ಥ
Start the engine and check that it is oil-tight.
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MAINTENANCE WORK ON CHASSIS AND ENGINE
65
ಥ
Check the engine oil level. ( P. 62)
ꢉ
ꢃꢀꢀꢆ
opping up engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
ಥ
ಥ
Remove the screw cap‘ꢀ on the clutch cover and fill up with engine oil.
Engine oil (SAE 10W/50) ( P. 82)
Mount and tighten screw cap‘ꢀ.
Danger
Danger of poisoningಗExhaust gases are poisonous and can result in uncon-
sciousness and/or death.
ಥ
When running the engine, always make sure there is sufficient ventila-
tion, and do not start or run the engine in a closed space.
400265-10
ಥ
Start the engine and check that it is oil-tight.
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TROUBLESHOOTING
66
ꢀ7ꢊ528%/(6+227,1*
Faults
Possible cause
Measure
The engine cannot be cranked (electric
starter).
Battery discharged
ಥ
ಥ
ಥ
ಥ
ಥ
Recharge the battery. ( P. 51)
Check the cause of discharging.
Remove the fuse. ( P. 52)
Replace the fuse. ( P. 52)
Fuse blown
Low external temperature
Use the battery supplied in the acces-
sories package.
4Ah battery‘(YTX5L-BS) ( P. 74)
Engine turns but does not start.
Operating error
ಥ
ಥ
Carry out the instructions for starting.
(
P. 15)
Empty the carburetor float chamber.
P. 62)
Motorcycle was out of use for a long time
and there is old fuel in the float chamber
(
Fuel feed interrupted
ಥ
ಥ
ಥ
ಥ
Check tank vent.
Clean fuel tap.
Clean carburetor.
Engine flooded
Clean and dry spark plug or replace if
necessary.
Spark plug oily or wet
ಥ
ಥ
Clean and dry spark plug or replace if
necessary.
Electrode distance (plug gap) of spark
plug too wide
Adjust plug gap.
Specification
spark plug electrode gap
0.7‘mm (0.03‘in)
Spark plug connector or spark plug defec-
tive
Warning
Risk of injuryಗThe ignition
system is under high voltage.
ಥ
Do not touch parts of the ig-
nition system. Have work on
the ignition system carried
out in an authorized KTM
workshop.
ಥ
Remove spark plug, connect ignition
cable, hold spark plug to ground (bare
metal area on engine), and try to start
the engine.
Specification
You should see a strong spark on the
spark plug.
ಥ
ಥ
If there is no spark, change the spark
plug.
If there is still no spark, remove the
spark plug cap from the ignition cable,
hold it at the specified distance from
the ground contact, and try to start the
engine.
Specification
5‘mm (0.2‘in)
ಥ
ಥ
If you now have a spark, replace the
spark plug connector.
If there is no spark, have the ignition
system checked.
Short-circuit cable in wiring harness
chafed, short-circuit button defective
ಥ
ಥ
ಥ
Check wiring harness. (visual check)
Check electrical system.
Socket connector of CDI control device,
pulse generator or ignition coil oxidized.
Clean socket connector and treat it
with contact spray.
Water in carburetor or jets blocked
Idling jet blocked
ಥ
ಥ
ಥ
ಥ
Clean carburetor.
Engine has no idle.
Clean carburetor.
Adjusting screws on carburetor distorted
Spark plug defective
Have the carburetor adjusted.
Change spark plug.
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TROUBLESHOOTING
67
Faults
Possible cause
Measure
Engine has no idle.
Engine does not speed up.
Ignition system defective
ಥ
ಥ
Have ignition system checked.
Carburetor running over because float
needle dirty or worn
Have carburetor checked.
Loose carburetor jets
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Have carburetor checked.
Have ignition system checked.
Check tank vent.
Electronic ignition adjustment defective
Fuel feed interrupted
Engine has too little power.
Clean fuel tap.
Clean carburetor.
Air filter very dirty
Clean the air filter. ( P. 59)
Check exhaust system for damage.
Exhaust system leaky, deformed or too lit-
tle glass fiber yarn filling in main silencer
Change glass fiber yarn filling of main
silencer. ( P. 58)
Valve clearance too little
ಥ
ಥ
ಥ
Have valve clearance adjusted.
Have ignition system checked.
Electronic ignition adjustment defective
Engine stalls or is popping into the carbu- Lack of fuel
retor
Clean and check the fuel system and
carburetor.
Engine takes in bad air
ಥ
Check rubber sleeves and carburetor
for tightness.
Engine overheats.
Too little coolant in cooling system
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Check the cooling system for leakage.
Check the coolant level. ( P. 55)
Switch off engine when standing.
Clean radiator fins.
Too little air stream
Radiator fins very dirty
Foam formation in cooling system
Drain the coolant. ( P. 56)
Refill the coolant. ( P. 56)
Replace the radiator hose.
Bent radiator hose
High oil consumption
Battery discharged
Engine vent hose bent
Route the vent hose without bends or
replace it if necessary.
Engine oil level too high
ಥ
ಥ
Check the engine oil level. ( P. 62)
Engine oil too thin (low viscosity)
Change the engine oil and oil filter,
and clean the oil screen. ( P. 63)
Battery is not charged by generator
ಥ
Check electrical system.
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CLEANING
68
ꢀ&ꢀ/($1,1*
Cꢀꢀꢃꢀ leaning motorcycle
Note
Material damageಗDamage and destruction of components by high-pressure cleaning equipment.
ಥ
Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri-
cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts.
Warning
Environmental hazardಗProblem materials cause environmental damage.
ಥ
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to 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.
ಥ
ಥ
ಥ
Before you clean the motocycle, 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 paintbrush.
Motorcycle cleaner ( P. 84)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
ಥ
ಥ
After rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly.
Empty the carburetor float chamber. ( P. 62)
Warning
Danger of accidentsಗReduced braking due to wet or dirty brakes.
ಥ
Clean or dry dirty or wet brakes by riding and braking gently.
ಥ
After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
ಥ
ಥ
ಥ
ಥ
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. 34)
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. 84)
ಥ
ಥ
Treat all painted parts with a mild paint polish.
High-luster polish for paint ( P. 85)
To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray ( P. 85)
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STORAGE
69
ꢀ6ꢁ725$*(
Sꢀꢁꢃꢀ torage
Warning
Danger of poisoningಗFuel is poisonous and a health hazard.
ಥ
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister ac-
cording 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.
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Clean the motorcycle. ( P. 68)
Change the engine oil and oil filter, and clean the oil screen. ( P. 63)
Check the antifreeze and coolant level. ( P. 55)
Drain the fuel from the tanks into a suitable container.
Empty the carburetor float chamber. ( P. 62)
Checking the tire air pressure. ( P. 49)
Remove the battery. ( P. 50)
Recharge the battery. ( P. 51)
Specification
Storage temperature of battery without direct sunshine.
0… 35‘°C (32… 95‘°F)
ಥ
The storage place should be dry and not subject to large temperature differences.
Info
KTM recommends jacking up the motorcycle.
ಥ
ಥ
Jack up the motorcycle. ( P. 21)
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.
ꢀ
ꢁꢃꢁ
utting into operation after storage
ಥ
ಥ
ಥ
ಥ
ಥ
Remove the motorcycle from the work stand. ( P. 21)
Install the battery. ( P. 50)
Fill up with fuel. ( P. 17)
Checks before putting into operation ( P. 15)
Make a test ride.
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TECHNICAL DATA - ENGINE
70
ꢀ7ꢂ(&+1,&$/ '$7$
ꢋ
(1*,1(
Design
1-cyliner 4-stroke engine, water-cooled
449.3‘cm³ (27.42‘cu‘in)
60.8‘mm (2.39‘in)
Displacement
Stroke
Bore
97‘mm (3.82‘in)
Compression ratio
Idle speed
Control
12,5:1
1600… 1650‘rpm
4 valves controlled by cam levers ad 2 camshafts, driven by heli-
cal gear pair and tooth-wheel chain
Valve diameter, intake
Valve diameter, exhaust
Valve clearance, cold, intake
Valve clearance, cold, exhaust
Crankshaft bearing
Conrod bearing
Piston pin bearing
Pistons
40.4‘mm (1.59‘in)
31.7‘mm (1.25‘in)
0.07… 0.13‘mm (0.0028… 0.01‘in)
0.12… 0.18‘mm (0.0047… 0.01‘in)
2 cylinder roller bearing
Needle bearing
Bronze bush
Forged light alloy
Piston rings
1 compression ring, 1 oil scraper ring
Pressure circulation lubrication with 3 rotor pumps
29:74
Engine lubrication
Primary transmission
Transmission ratio
1st gear
18:31
2nd gear
20:29
3rd gear
22:27
4th gear
24:25
5th gear
26:23
Generator
12‘V, 42‘W
Ignition
Contactless controlled fully electronic ignition with digital igni-
tion adjustment, type Kokusan
Spark plug
NGK CR 9 EKB
spark plug electrode gap
Cooling
0.7‘mm (0.03‘in)
Water cooling, permanent circulation of coolant by water pump
Electric starter
Starting aid
ꢀ
ꢂꢃꢀ
apacity - engine oil
Engine oil
1.35‘l (1.43‘qt.)
Engine oil (SAE 10W/50) ( P. 82)
ꢀ
ꢂꢃꢁ
apacity - coolant
Coolant
1.2‘l (1.27‘qt.)
Coolant ( P. 82)
Coolant (mixed ready to use) ( P. 82)
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
71
ꢀ7ꢄ(&+1,&$/ '$7$
ꢋ
(1*,1( 7,*+7(1,1* 72548(6
Engine housing vent jet
Oil jet, piston cooling
Oil jet, cam lever lubrication
Oil jet, clutch oil supply
Screw, locking lever
M4
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
M4
4‘Nm (2.95‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
M4
M5x1
M5
Screw, camshaft bearing retaining
bracket
M5
Screw, timing train axle retaining
bracket
M5
6‘Nm (4.43‘lbf‘ft)
Loctite® 243™
Screw, ignition pulse generator
M5
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Screw, ignition pulse generator adapter M5
Screw, stator cable holder
M5
M5
Screw, bearing bolt of oil pump idler
shaft
Locking screw for bearing
Screw, oil pump cover
Screw, stator bracket
Oil jet, timing chain tensioner
Nut, water-pump wheel
Nut, cylinder head
M5
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
6‘Nm (4.43‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Loctite® 243™
Engine oil (any)
Loctite® 243™
ಥ
M5
M5
M6x0,6
M6
M6
Screw, exhaust flange
Screw, starter motor
M6
M6
Screw, ignition pulse generator cable
holder
M6
Loctite® 243™
Screw, clutch cover
M6
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
8‘Nm (5.9‘lbf‘ft)
ಥ
ಥ
ಥ
ಥ
Screw, clutch spring
M6
Screw, clutch slave cylinder
Screw, engine housing
Screw, oil filter cover
Screw, oil pump casing
Screw, shift drum locating
Screw, shift lever
M6
M6
M6
ಥ
M6
Loctite® 243™
M6
Loctite® 243™
M6
Loctite® 243™
Screw, valve cover
M6
ಥ
Screw, water pump cover
Screw, ignition cover
Stud, cylinder head
M6
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
14‘Nm (10.33‘lbf‘ft)
14‘Nm (10.33‘lbf‘ft)
14‘Nm (10.33‘lbf‘ft)
20‘Nm (14.75‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
ಥ
ಥ
ಥ
ಥ
M6
M6
Screw, clutch cover
M7x1
M7x1
M7x1
M8
Screw, engine housing
Screw, camshaft bearing bridge
Plug, crankshaft location
ಥ
Engine oil (any)
ಥ
ಥ
Screw, unlocking of timing chain ten-
sioner
M10x1
Screw, camshaft gear
Screw, ignition rotor
Plug, oil channel
M10x1
M10x1
M10x1
M10x1
M10x1,25
50‘Nm (36.88‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
Tightening sequence:
Tighten in diagonal
sequence.
Engine oil (any)
Engine oil (any)
ಥ
ಥ
Plug, cam lever axle
Nut, cylinder head
Engine oil (any)
Tightening stage 1
10‘Nm (7.38‘lbf‘ft)
Tightening stage 2
30‘Nm (22.13‘lbf‘ft)
Tightening stage 3
50°
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TECHNICAL DATA - ENGINE TIGHTENING TORQUES
72
Stud, cylinder head
Screw, engine sprocket
Spark plug
M10x1,25
M10
20‘Nm (14.75‘lbf‘ft)
60‘Nm (44.26‘lbf‘ft)
10… 12‘Nm (7.38…
8.85‘lbf‘ft)
ಥ
Loctite® 243™
M10
ಥ
Screw-in studs for clutch cover
Oil drain plug with magnet
Axle guide rail for timing chain
Axle tension rail for timing chain
Nut, compensating sprocket
Oil suction pipe
M12x1,5
M12x1,5
M14x1
20‘Nm (14.75‘lbf‘ft)
20‘Nm (14.75‘lbf‘ft)
15‘Nm (11.06‘lbf‘ft)
15‘Nm (11.06‘lbf‘ft)
20‘Nm (14.75‘lbf‘ft)
15‘Nm (11.06‘lbf‘ft)
18‘Nm (13.28‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
25‘Nm (18.44‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
30‘Nm (22.13‘lbf‘ft)
ಥ
ಥ
ಥ
ಥ
M14x1
M14x1
Loctite® 243™
M14x1
Loctite® 243™
Oil pressure regulator valve plug
Nut, inner clutch hub
M14x1,5
M18x1,5
M24x1,5
M27x1
ಥ
Loctite® 243™
Plug, timing chain tensioner
Nut, freewheel hub
ಥ
Loctite® 243™
Loctite® 243™
ಥ
Nut, primary gear
M27x1
Plug, oil screen
M32x1,5
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TECHNICAL DATA - CARBURETOR
73
ꢀ7ꢅ(&+1,&$/ '$7$
ꢋ
&$5%85(725
Carburetor type
Carburetor identfication number
Needle position
Idle mixture adjusting screw
Open
KEIHIN FCR-MX 41
4125I
4th position from top
1.5‘turns
Pump membrane stop
Hot start button
Diameter of bore in carburetor body
Main jet
2.15‘mm (0.08‘in)
2.5‘mm (0.1‘in)
185
OBDTR
42
Jet needle
Idling jet
Main air jet
200
100
85
Idle air jet
Cold start jet
Throttle slide
15
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TECHNICAL DATA - CHASSIS
74
ꢀ7ꢆ(&+1,&$/ '$7$
ꢋ
&+$66,6
Frame
Central tube frame made of chrome molybdenum steel tubing
WP 4860 MXMA CC
Fork
Suspension travel
front
280‘mm (11.02‘in)
Rear
310‘mm (12.2‘in)
Fork offset
Front marking
Rear marking
Shock absorber
Brake system
front
14‘mm (0.55‘in)
16‘mm (0.63‘in)
WP PDS 5018 DCC
Single disc brake with radially screwed four-piston fixed caliper,
floating brake disc
Rear
Single disc brake with single-piston floating caliper, fixed brake
disc
Diameter of brake discs
front
310‘mm (12.2‘in)
Rear
220‘mm (8.66‘in)
Wear limit of brake discs
front
4.5‘mm (0.18‘in)
Rear
3.5‘mm (0.14‘in)
Tire air pressure
front
1.6‘bar (23.21‘psi)
1.6‘bar (23.21‘psi)
14:48
Rear
Rear wheel gearing
Chain
5/8 x 1/4"
Rear sprockets available
Steering head angle
Wheelbase
38, 40, 42, 45, 48, 49, 50, 51, 52
63.5°
1475¢10‘mm (58.07¢0.39‘in)
920‘mm (36.22‘in)
300‘mm (11.81‘in)
111.5‘kg (245.81‘lb.)
145‘kg (319.67‘lb.)
190‘kg (418.87‘lb.)
335‘kg (738.54‘lb.)
Seat height unloaded
Ground clearance unloaded
Weight without fuel
Maximum permissible front axle load
Maximum permissible rear axle load
Maximum permissible overall weight
3Ah battery
YTX4L-BS
YTX5L-BS
Battery voltage: 12‘V
Nominal capacity: 3‘Ah
maintenance-free
4Ah battery
Battery voltage: 12‘V
Nominal capacity: 4‘Ah
maintenance-free
Front tire
Rear tire
125/80‘R‘420‘‘TL
Dunlop KR106
170/55‘R‘17‘‘TL
Dunlop KR108
For further information, see:
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TECHNICAL DATA - CHASSIS
75
ꢀ
ꢆꢃꢀ
Tank capacity
8.2‘l (2.17‘US‘gal)
Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 82)
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TECHNICAL DATA - FORK
76
ꢀ7ꢇ(&+1,&$/ '$7$
ꢋ
)25.
Fork part number
14.18.7D.18
Fork
WP 4860 MXMA CC
Compression damping
Standard
15‘clicks
Rebound damping
Standard
15‘clicks
Spring length with preload spacer(s)
Spring rate
482‘mm (18.98‘in)
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
Weight of rider: 85… 95‘kg (187.39… 209.44‘lb.)
Gas pressure
4.6‘N/mm (26.27‘lb/in)
4.8‘N/mm (27.41‘lb/in)
5‘N/mm (28.55‘lb/in)
1.2‘bar (17.4‘psi)
Fork length
920‘mm (36.22‘in)
ꢀ
ꢇꢃꢀ
apacity - fork oil
Oil capacity / cartridge
195‘ml (6.59‘fl.‘oz.)
Fork oil (SAE 5) ( P. 82)
Fork oil (SAE 5) ( P. 82)
Oil capacity / fork tube without 390‘ml (13.19‘fl.‘oz.)
cartridge
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TECHNICAL DATA - SHOCK ABSORBER
77
ꢀ7ꢈ(&+1,&$/ '$7$
ꢋ
6+2&. $%625%(5
Shock absorber part number
12.18.7D.15
Shock absorber
WP PDS 5018 DCC
Compression damping, low-speed
Standard
10‘clicks
Compression damping, high-speed
Standard
1.5‘turns
Rebound damping
Standard
20‘clicks
Spring preload
11‘mm (0.43‘in)
Spring rate
Weight of rider: 65… 75‘kg (143.3… 165.34‘lb.)
Weight of rider: 75… 85‘kg (165.34… 187.39‘lb.)
Weight of rider: 85… 95‘kg (187.39… 209.44‘lb.)
76‘N/mm (433.97‘lb/in)
80‘N/mm (456.81‘lb/in)
84‘N/mm (479.65‘lb/in)
250‘mm (9.84‘in)
Spring length
Gas pressure
Static sag
10‘bar (145.04‘psi)
15… 20‘mm (0.59… 0.79‘in)
80… 90‘mm (3.15… 3.54‘in)
403‘mm (15.87‘in)
Riding sag
Fitted length
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TECHNICAL DATA - CHASSIS TIGHTENING TORQUES
78
ꢀ7ꢉ(&+1,&$/ '$7$
ꢋ
&+$66,6 7,*+7(1,1* 72548(6
Spoke nipple, front wheel
Spoke nipple, rear wheel
Remaining nuts, chassis
Remaining screws, chassis
Screw, rear brake disc
M4,5
M5
M6
M6
M6
M6
M6
M6
5‘Nm (3.69‘lbf‘ft)
5‘Nm (3.69‘lbf‘ft)
15‘Nm (11.06‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
14‘Nm (10.33‘lbf‘ft)
14‘Nm (10.33‘lbf‘ft)
5‘Nm (3.69‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Screw, front brake disc
Screw, shock absorber adjusting ring
Screw, ball joint of push rod on foot-
brake cylinder
Nut, rear sprocket screw
Nut, rim lock
M8
35‘Nm (25.82‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
30‘Nm (22.13‘lbf‘ft)
25‘Nm (18.44‘lbf‘ft)
17‘Nm (12.54‘lbf‘ft)
12‘Nm (8.85‘lbf‘ft)
15‘Nm (11.06‘lbf‘ft)
17‘Nm (12.54‘lbf‘ft)
20‘Nm (14.75‘lbf‘ft)
33‘Nm (24.34‘lbf‘ft)
35‘Nm (25.82‘lbf‘ft)
40‘Nm (29.5‘lbf‘ft)
60‘Nm (44.26‘lbf‘ft)
50‘Nm (36.88‘lbf‘ft)
45‘Nm (33.19‘lbf‘ft)
40‘Nm (29.5‘lbf‘ft)
20‘Nm (14.75‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
100‘Nm (73.76‘lbf‘ft)
12‘Nm (8.85‘lbf‘ft)
80‘Nm (59.01‘lbf‘ft)
10‘Nm (7.38‘lbf‘ft)
60‘Nm (44.26‘lbf‘ft)
40‘Nm (29.5‘lbf‘ft)
Loctite® 243™
M8
ಥ
ಥ
ಥ
ಥ
ಥ
ಥ
Remaining nuts, chassis
Remaining screws, chassis
Screw, top triple clamp
Screw, bottom triple clamp
Screw, fork stub
M8
M8
M8
M8
M8
Screw, top steering stem
Screw, handlebar clamp
Screw, engine brace
M8
Loctite® 243™
M8
ಥ
ಥ
M8
Screw, subframe
M8
Loctite® 243™
Screw, front brake caliper
Engine carrying screw
Remaining nuts, chassis
Remaining screws, chassis
Screw, handlebar support
Nut, seat fixing
M10x1,25
M10
Loctite® 243™
ಥ
ಥ
ಥ
M10
M10
M10
Loctite® 243™
M12x1
M12
ಥ
Screw, top shock absorber
Screw, bottom shock absorber
Nut, swingarm pivot
Loctite® 243™
M12
Loctite® 243™
M16x1,5
M20x1,5
M20x1,5
M20x1,5
M20x1,5
M24x1,5
ಥ
Screw-in nozzles, cooling system
Nut, rear wheel spindle
Screw, top steering head
Screw, bottom steering head
Screw, front wheel spindle
Loctite® 243™
ಥ
ಥ
Loctite® 243™
ಥ
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79
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WIRING DIAGRAM
80
ꢁ:ꢊ,5,1* ',$*5$0
Wꢁꢊꢃꢀ iring diagram
yellow-black
blue-white
brown
yellow-black
red
green
blue
blue
yellow
yellow
black
black
red-white
white
red-white
black-white
grey-black
grey
brown
black
yellow
yellow
black
red-white
red-white
black-white
400277-10
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WIRING DIAGRAM
81
Components
1
Battery
2
Generator
3
Ignition coil
4
Pulse generator
Voltage regulator/rectifier
Starter button
5
6
7
Starter relay
8
Starter motor
9
Short circuit button
Throttle valve sensor TPS
Ignition curve plug connection
CDI controller
10
11
12
Cable colors
black
black
black-white black-white
brown brown
brown-white brown-white
blue blue
blue-white blue-white
green
grey
green
gray
grey-black gray-black
red
red
red-white
white
red-white
white
yellow
yellow
yellow-black yellow-black
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SUBSTANCES
82
ꢁ6ꢀ8%67$1&(6
Super unleaded (ROZ 95 / RON 95 / PON 91)
according to
DIN‘EN‘228 (ROZ 95 / RON 95 / PON 91)
ಥ
Brake fluid DOT 5.1
according to
DOT
Specification
Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre-
sponding properties. KTM recommends Motorex® products.
ಥ
ಥ
Supplier
Motorex
ಥ
Motorex®‘Brake‘Fluid‘DOT‘5.1
Coolant
Specification
ಥ
Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze: -25… -45‘°C (-13… -49‘°F)
50‘% Anti-corrosion/antifreeze
50‘% distilled water
Coolant (mixed ready to use)
Antifreeze
-40‘°C (-40‘°F)
Supplier
Motorex
ಥ
Motorex®‘Anti‘Freeze
Hydraulic fluid (15)
according to
ಥ ISO VG (15)
Specification
ಥ
Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the
corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex
ಥ
Motorex®‘Hydraulic‘Fluid‘75
Engine oil (SAE 10W/50)
according to
ಥ
ಥ
JASO‘T903‘MA ( P. 86)
SAE ( P. 86) (SAE 10W/50)
Specification
ಥ
Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corre-
sponding properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex
ಥ
Motorex®‘Cross‘Power‘4T
Fork oil (SAE 5)
according to
ಥ SAE (SAE 5)
Specification
ಥ
Use only oils that comply with the specified standards (see specifications on the container) and that possesses the corresponding
properties. KTM recommends Motorex® products.
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SUBSTANCES
83
Supplier
Motorex
ಥ
Motorex®‘Racing‘Fork‘Oil
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AUXILIARY SUBSTANCES
84
ꢁ$ꢁ8;,/,$5< 68%67$1&(6
Universal oil spray
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Joker‘440‘Universal
Long-life grease
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Long‘Therm‘2000
Chain cleaner
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Chain‘Clean‘611
Offroad chain spray
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Chain‘Lube‘622
Air filter cleaner
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Twin‘Air‘Dirt‘Bio‘Remover
Air filter oil
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Air‘Filter‘Oil‘Spray‘655
Motorcycle cleaner
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Moto‘Clean‘900
Cleaning and polishing materials for metal, rubber and plastic
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Protect‘&‘Shine‘645
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AUXILIARY SUBSTANCES
85
High-luster polish for paint
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Moto‘Polish
Contact spray
Specification
ಥ
Supplier
KTM recommends Motorex® products.
Motorex
ಥ
Motorex®‘Accu‘Contact
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STANDARDS
86
ꢁ6ꢂ7$1'$5'6
JASO‘T903‘MA
Different technical development directions required a new specification for 4-stroke motorcycles ಥ the JASO T903 MA Standard. Ear-
lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi-
cation. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the fore-
ground for motorcycle engines. With most motorcycles, the gearbox and the clutch are lubricated with the 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 vis-
cosity. The viscosity describes only one property of oil and says nothing about quality.
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INDEX
87
,1'(;
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
A
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 59
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air filter
Compression damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Compression damping, high-speed
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 21
Air filter box lid
Compression damping, low-speed
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 22
Coolant
Antifreeze
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
B
Coolant level
Basic chassis setting
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
checking with rider's weight . . . . . . . . . . . . . . . . . . . . 21
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Battery
D
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Dust boots
Cleaning, of fork legs . . . . . . . . . . . . . . . . . . . . . . . . 26
E
Brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brake discs
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake fluid
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil
of rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . 44
Topping up brake fluid of front brake . . . . . . . . . . . . . . 40
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
topping up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Brake fluid level
Checking the front brake brake fluid level . . . . . . . . . . 39
of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 43
Brake linings
Engine oil level
Changing the front brake linings . . . . . . . . . . . . . . . . . 42
Mounting front brake linings . . . . . . . . . . . . . . . . . . . 41
of front brake, checking . . . . . . . . . . . . . . . . . . . . . . . 40
of rear brake, changing . . . . . . . . . . . . . . . . . . . . . . . 46
of rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . 44
of rear brake, installing . . . . . . . . . . . . . . . . . . . . . . . 45
of rear brake, removing . . . . . . . . . . . . . . . . . . . . . . . 45
Removing front brake linings . . . . . . . . . . . . . . . . . . . 41
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Filling up
C
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Carburetor
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 43
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 43
adjusting idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
emptying the float chamber . . . . . . . . . . . . . . . . . . . . 62
idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fork
Chain
checking basic setting . . . . . . . . . . . . . . . . . . . . . . . . 25
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fork legs
Chain guide
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fork offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Chain wear
Fork protector
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clutch
Front fender
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
changing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Front wheel
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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INDEX
88
Fuel tank
Rear wheel
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuse
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 22
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
G
S
Gas Bowden cable route
Seat
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 39
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shock absorber
checking riding sag . . . . . . . . . . . . . . . . . . . . . . . . . . 23
checking static sag . . . . . . . . . . . . . . . . . . . . . . . . . . 23
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hot start lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Short circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spoke tension
I
Ignition curve
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Spring preload
L
of shock absorber, adjusting . . . . . . . . . . . . . . . . . . . . 24
Lower triple clamp
Start number plate
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
M
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steering head bearing
Main silencer
changing glass fiber yarn filling . . . . . . . . . . . . . . . . . 58
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fitting glass fiber yarn filling . . . . . . . . . . . . . . . . . . . 58
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removing glass fiber yarn filling . . . . . . . . . . . . . . . . . 57
greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Steering head bearing play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Motorcycle
T
Technical data
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-75
Chassis tightening torques . . . . . . . . . . . . . . . . . . . . . 78
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Engine tightening torques . . . . . . . . . . . . . . . . . . . 71-72
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Tire air pressure
OWNER'S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
P
Tire condition
Play in gas Bowden cable
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66-67
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Plug-in stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Putting into operation
W
Advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . 13
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Checks before putting into operation . . . . . . . . . . . . . . 15
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-81
R
Rear sprocket / engine sprocket
checking for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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*3211243en*
3211243en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
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