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ENGLISH

12

What to do when the engine is „flooded”

The throttle must be fully opened when starting.

Kickstart instructions

Start as described above, then push the kickstarter hard ALL
THE WAY.

WARNING

A

LWAYS WEAR BOOTS WHEN USING THE KICKSTARTER TO AVOID INJURY

.

Starting off

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

WARNING

B

EFORE YOU START OFF

CHECK THAT THE MAIN OR SIDE STAND HAS BEEN

SWUNG UP FULLY

. I

F THE STAND DRAGS ON THE GROUND

THE

MOTORCYCLE CAN GO OUT OF CONTROL

.

Shifting/Riding

You are now in first gear, refered to as the drive or uphill gear.
Depending on the conditions (traffic, road gradient, etc.), you
can shift to a higher gear. Close throttle, at the same time pull
clutch lever and shift to the next higher gear. Let clutch lever
go again and open throttle. If you turned on the choke, make
sure you turn it off again as soon as engine is warm.
When you reach full speed through turning the throttle grip all
the way, turn throttle back to 3/4; the speed hardly decreases
although the engine will use less gas. Never open the throttle
wider than the engine can handle. Excessive turning of the
throttle grip will increase full consumption. 

By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.
If the engine is killed f.ex. at a crossing, simply pull the clutch
lever and start. It is not necessary to switch the gear to NEUTRAL.

WARNING

– O

BSERVE THE TRAFFIC REGULATIONS

DRIVE DEFENSIVELY AND TRYING

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

.

– A

DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

.

– D

RIVE CAREFULLY ON UNKNOWN ROADS

– W

HEN DRIVING OFF

-

ROAD

ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY

SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE

.

– R

EPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY

OF TIME

. W

HEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR

GOGGLES

YOU WILL BE PRACTICALLY BLIND

.

– A

FTER FALLING WITH THE MOTORCYCLE

CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

.

!

CAUTION

!

– H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. W

E RECOMMEND YOU RUN

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

. A

FTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

. T

HE ENGINE HAS REACHED ITS OPERATING

TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM

– N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A

LOWER GEAR

. T

HE ENGINE WILL OVERSPEED

DAMAGING THE VALVES

.

I

N ADDITION

THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

.

– L

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

LEAD TO ENGINE DAMAGE

.

– I

F THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE

YOU ARE DRIVING

THIS INDICATES COOLING SYSTEM TROUBLE

. I

MME

-

DIATELY STOP AND TURN OFF THE ENGINE

. D

RIVING WITH THE WAR

-

NING LAMP ON WILL CAUSE ENGINE DAMAGE

.

– 

PLACE A CLOTH ON THE RADIATOR CAP

. O

PEN THE CAP SLOWLY

,

SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE

. - 

CAUTION SCALDING HAZARD! - 

AND CHECK THE COOLING

LIQUID LEVEL

.

– 

D

O NOT DRIVE ON

UNTIL THERE IS SUFFICIENT LIQUID IN THE COO

-

LING SYSTEM

. H

OWEVER

CALL ON ONE OF

KTM’

S DEALERS AS

SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED

– I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING

CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT

.

Braking

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

WARNING

W

HEN YOU BRAKE

THE BRAKE DISCS

BRAKE PADS

BRAKE CALIPER AND

BRAKE FLUID HEAT UP

. T

HE HOTTER THESE PARTS GET

THE WEAKER THE

BRAKING EFFECT

. I

N EXTREME CASES

THE ENTIRE BRAKING SYSTEM CAN FAIL

.

Stopping and parking

Apply the brakes fully and put the engine into neutral. To stop
the engine, switch off the ignition. Turn the fuel tap to the
OFF position, park on an area where the ground is firm, and
lock the motorcycle.

WARNING

– N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS

THE ENGINE IS RUNNING

.

– M

OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE

RUNNING

. T

HE ENGINE RADIATORS

EXHAUST

EXHAUST SYSTEM

BRAKE

DISCS

AND SHOCK ABSORBERS CAN BECOME VERY HOT

. D

O NOT

TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE

AND

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

– N

EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE

HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS

.

!

CAUTION

!

– C

LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE

.O

THERWISE THE

CARBURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE

.

– A

LWAYS

TAKE

OUT

THE

IGNITION

KEY

WHEN

PARKING

YOUR

MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PER

-

SONS

.

– D

O NOT LEAVE THE PARKING LIGHT ON FOR MORE THAN THREE

HOURS WITH THE ENGINE OFF

. O

THERWISE YOU WILL NOT BE ABLE TO

START THE ENGINE WITH THE ELECTRIC STARTER

.

Summary of Contents for 1998 400 R

Page 1: ...98 OWNER S HANDBOOK 11 97 400 620 R XC e...

Page 2: ......

Page 3: ...ETELY BEFORE YOU TAKE YOUR FIRST RIDE IT CONTAINS INFOR MATION AND TIPS THAT WILL BE ABLE YOU TO OPE RATE AND HANDLE YOUR MOTORCYCLE PROPERLY PAY ATTENTION ESPECIALLY TO THE FOLLOWING INSTRUCTIONS WAR...

Page 4: ...e to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform th...

Page 5: ...uid level front brake 19 Refilling the front brake fluid reservoir 19 Checking the front brake pads 19 Changing the basic position of the foot brake pedal 20 Checking rear brake fluid level 20 Refilli...

Page 6: ...UTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS Hand decompression lever The hand decompression lever 2 is only used in two special cases a When the engine stalled It is possible that the starte...

Page 7: ...indicator B in the speedometer 2 indicates overall mileage The day mileage indicator C can be set to 0 by means of the setting wheel D Turn the seatting wheel forward until only zeros can be seen in t...

Page 8: ...this symbol is visible on the switch the engine can not be started i e the ignition circuit and the starter circuit are interrupted Filler cap To open filler cap Turn the filler cap counter clockwise...

Page 9: ...k as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time too CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKE...

Page 10: ...THE KEY COULD GET DAMAGED Compression damping of fork The compression damping mechanism is built into the left fork tube It only regulates the degree of damping during compression By using the knob 1...

Page 11: ...be adjusted to 11 positions Turn the knob to the left side to increase dam ping turn it to the right side to reduce damping during rebounding BASIC SETTING WP 01 18 Q7 81 K4T96S position 4 WARNING NE...

Page 12: ...e in a perfect tech nical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE...

Page 13: ...ULL LOAD UNTIL THE ENGINE IS WARM IF THE ENGINE DOES NOT CRANK WHEN YOU ACTUATE THE STARTER TIP SWITCH the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignitio...

Page 14: ...TORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVERSPEED DAMAGING THE VALVES IN ADDITION THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY...

Page 15: ...and that your motorcycle is standing securely NOTE REGARDING THE SIDE STAND Use your foot to kick side stand forward up to the stop and lean the motorcycle sideways Make sure that the ground is solid...

Page 16: ...eeder screws at fork legs overpressure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance ad...

Page 17: ...LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OIL GREASE FILTERS FUELS CLEANING AGENTS ETC ACCORDING TO YOUR LOCAL REGULA...

Page 18: ...damaged With a plastic hammer lightly rap on the triple clamp to avoid tension Re tighten the five clamp screws with 15 Nm 11 ft lb WARNING IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF P...

Page 19: ...ain tension if necessary WARNING IF CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY POWER TRANSMIS SION CHAIN CHAIN SPROCKETS TRANSMISSION AND REAR WHEEL BEARINGS WILL BE SUBJECTED TO UNNECESSAR...

Page 20: ...The brake calipers of this series float This means that the brake calipers are not solidly attached to the caliper support Thus the brake pads are always in optimum contact with the brake disc BRAKE P...

Page 21: ...ir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with brake fluid DOT 5 1 Shell Adv...

Page 22: ...IN mark you need to refill the brake fluid reservoir For better access to the brake fluid reservoir remove the seat and the right side cover Remove plug 3 with rubber boot 4 and add brake liquid DOT 5...

Page 23: ...MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE FOOTBRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE OTHERWISE THE BRAKING EFFEC...

Page 24: ...res and nails or other sharp objects that might have become embedded in the tire Refer to the specific regulations in your country for minimum tire tread requirements We recommend replacing tires at t...

Page 25: ...DAMAGE DO NOT REMOVE THE LOCKING BAR 2 NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DEST ROY THE RECTIFIER REGULATOR BATTERY STORAGE When preparing the motorcycle for a longer pe...

Page 26: ...use that has just been set in gets blown again you are strongly advised to have it ins pected by a KTM dealer Fuse capacity 5 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET...

Page 27: ...ID CAUTION SCALDING HAZARD DO NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM WARNING IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE R...

Page 28: ...vering of the cable 3 5 mm from the adju sting screw 4 until resistance is felt To adjust loosen the counter nut 5 and turn the adjusting screw accor dingly Finally tighten counter nut and slide the p...

Page 29: ...oil level should be between the two marks on the dipstick Add engine oil i e Shell Advance Ultra if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHEC...

Page 30: ...tart engine and let it run in idle 1 2 minutes until oil escapes at the bore B As soon as oil starts to escape turn off the engine and mount plug together with the gasket CAUTION DO NOT REV UP THE ENG...

Page 31: ...er Clean fil ter housing oil filter cover and sealing surfaces Check oil duct in oil filter cover if clogged Check the O ring 3 for damage O rings need not be replaced unless damaged Press the O ring...

Page 32: ...o neutral and switch the emergency OFF switch on swing up side stand Recharge the battery and investigate the causes for dischar ging contact a KTM dealer Check ignition lock and emergency OFF switch...

Page 33: ...eck fuel system as well as carburetor Replace or abrade the float Clean or replace air filter contact a KTM dealer Check if exhaust system is damaged Have valve clearance adjusted Check setting of the...

Page 34: ...eans carburetor jets are preven ted from becoming resinous by the old fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times...

Page 35: ...40t Chain O Ring 5 8 x 1 4 Battery maintenance free battery 12V 8Ah Steering angle 62 5 Wheel base 1510 10 mm 59 4 0 4 in Seat high 940 mm 37 in Ground clearance 350 mm 13 8 in Dead weight without fue...

Page 36: ...9 64 mm 101 76 mm Ratio 10 8 1 10 4 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft camshaft drive through single chain Camshaft 249...

Page 37: ...0 35 Nm 26 ft lb Allen head screws outer race M6x12 M6x12 5 Loctite 648 18 Nm 13 ft lb Allen head screw cylinder head top sect M6x50 M6x55 12 9 20 Nm 15 ft lb Allen head screw cylinder head top sect M...

Page 38: ...ENGLISH 36 Schal...

Page 39: ...ENGLISH 37 ltplan...

Page 40: ...val or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise co...

Page 41: ...MEETS EPA NOISE EMISSION REQUIREMENTS OF 80 dBA FOR MODEL SPECIFIC CODE KTM 5760398 INSTALLATION OF THIS EXHAUST SYSTEM ON MOTORCYCLES NOT SPECIFIED MAY VIOLATE FEDERAL LAW 400 R XC O 2 6 K O 2 6 K O...

Page 42: ...K T M S P O R T M O T O R C Y C L E A G A 5230 Mattighofen Postfach 91 Austria I n t e r n e t h t t p w w w k t m c o a t FN 102019 d Landesgericht Ried im Innkreis...

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