KTM 2002 400 EXC Racing Owner'S Handbook Manual Download | Manualshive

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Introduction

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

You are now the owner of a state-of-the-art sports motorcycle that guarantees to
bring you lots of fun and enjoyment, provided that you clean and maintain it
appropriately.

Before you go for your first ride, be sure to read this manual

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

At the time this manual was typeset, it was up-to-date

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

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

Chassis and Engine” of this manual.

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

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

We wish you a lot of fun when driving !

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

KTM SPORTMOTORCYCLE AG

5230 MATTIGHOFEN, AUSTRIA

Attachments: Spare parts manual chassis & engine

ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.

©

by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved

ENGLISH

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Summary of Contents for 2002 400 EXC Racing

Page 1: ...OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG Art Nr 3 210 17 06 2001 400 520 SX MXC EXC RACING ...

Page 2: ... by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person COMSUMER INFORMATION...

Page 3: ... in case you decide to sell it Many motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform those steps marked described in the chapter entitled M...

Page 4: ...el at the hand brake lever 21 Page Checking of brake fluid level front brake 21 Refilling the front brake fluid reservoir 21 Checking the front brake pads 21 Replacing the front brake pads 22 Changing the basic position of the brake pedal 22 Checking rear brake fluid level 22 Refilling the rear brake fluid reservoir 22 Checking the rear brake pads 23 Replacing the rear brake pads 23 Dismounting an...

Page 5: ...re The outer end of the lever must at all times provide for a backlash of approx 10mm 0 4 in Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompression level encounters CAUTION NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE RATHER USE THE SHORT CIRCUIT BUTTON OR THE EMERGENCY OFF BUTTON THE SETTING OF THE DECOMPRESSION CABLE SH...

Page 6: ... stop function DST Total distance up to 99 999 km CLK Clock See maintenance work for change of battery and basic setting Odometer EXC USA The odometer is a mileage indicator and can be set to 0 by means of the adjustment wheel 4 Speedometer indicator lamps EXC AUS The mileage indicator A in the speedometer 5 indicates overall mileage When the turn indicator is on the green indicator lamp 6 will be...

Page 7: ...tton 5 actuates the E starter WARNING ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE WILL MOVE FORWARD Emergency OFF switch EXC Australia The red emergency OFF switch 6 is arranged adjacent to the throttle grip In this position the E starter is operational and the engine can be star...

Page 8: ...PTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in th...

Page 9: ...LE GRIP INCREASE THE KICK BACK HAZARD Foot brake pedal The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to your seat position see maintenance work WARNING IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE W...

Page 10: ...er on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber com pression rates The high speed sett...

Page 11: ... of shock absorber SX MXC EXC By using the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respe...

Page 12: ...cha 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 OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of ki...

Page 13: ...tuate the E starter What to do when the engine is flooded In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decompression lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark p...

Page 14: ...E ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER NEVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN TED OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Al...

Page 15: ...d lamp setting Check function of electric systems low high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks Check smooth operation and adjust free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork ...

Page 16: ...htness of screws nuts and hose clamps regular For cross country use After every cleaning Befor each start Continued tests of the 400 520 racing motor for KTM s specialized workshop additional order for KTM s specialized workshop a 100 l fuel consumption is equivalent to approx 15 operating hours Force fit of clutch drive shaftestsitz Clutch disk wear Cylinder and piston wear Groove piston pin reta...

Page 17: ...E WORK ON CHASSIS AND ENGINE Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclock wise...

Page 18: ...me time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push dust pro tec...

Page 19: ...smount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 5 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 6 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired ...

Page 20: ... to 80 Nm 60 ft lb WARNING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE NOTE The large adjusting range of the c...

Page 21: ... ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases At their thinnest point A the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location B outside the contact face...

Page 22: ...voir 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 clean brake fluid DOT 5 1 i e Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A P...

Page 23: ...in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking rear brake fluid level The reservoir for the rear disc brake is disposed on the engine in the vicini...

Page 24: ...ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 5 on the ...

Page 25: ...n the collar nut 1 remove chain tensioner 2 hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED MAKE SURE THE B...

Page 26: ...have come loose Check spoke tension especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer WARNING SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN U...

Page 27: ...3 by pushing the right but ton you jump to the next figure 4 repeat nos 2 3 until correct time is indicated 5 push the button on the back approx 1 second to terminate the setting procedure 2 push the left button until the right figure is showed in the display 3 by pushing the right but ton you jump to the next figure 4 repeat nos 2 3 until the previously noted total mileage is indicated 5 push the...

Page 28: ...he indication TRP is active and push the but ton on the back approx 5 seconds WS appears 2 use the right button to select the position to be changed 3 push the left button until the right figure is showed in the display 4 repeat nos 2 3 until correct wheel circumfe rence is indicated 5 push the button on the back for approx 1 second to terminate the setting procedure 5 sec 1 sec mm x 3 14 km h WS ...

Page 29: ...NE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C 30 95 F Do not expose to direct sun radiation Charging the battery Remove ...

Page 30: ...XPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the par king light lamp with holder 4 carefully out of the reflector Pull connector 5 off the headlamp and remove rubber cap 6 Disengage retaining clip and take bulb out of reflector When changing the parking light lamp sim pl...

Page 31: ...SARY TO BLEED THE COOLING SYSTEM DURING FILLING SEE BELOW FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE I E SHELL ADVANCE COOLANT USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING EXTREM CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVERHEATING PROBLEMS TO AVOID THIS AN ELECTRIC BLOWER 4 IS OFFERED FOR MODELLS WITH ELECTRIC STARTERS ASK YOUR KTM DEALER ...

Page 32: ... with glass fiber yarn to muffle noise The effect of heat causes the glass fiber yarn to become loose This may lead to a loss of performance and reduce the silencer s muffling power By experi ence the front glass fiber yarn packing 5 needs to be replaced more often than the rear silencing mat 6 For this purpose remove the silencer from the vehicle and dismount the front cap 7 Pull the front glass ...

Page 33: ... together with the rubber boot 9 The oil level in the horizontal standing master cylin der should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS W...

Page 34: ... screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to be selected Naturally in cases of jet changes you have to start your adjusting work from the beginning 5 Then use the adjusting wheel to set the desired idle speed 6 In cases of grea...

Page 35: ... draws engine oil from the oil sump of the transmission This engine oil flows through an oil line 3 into the cylinder head for camshaft lubrication 4 the oil quantity is controlled by the jet screw 5 An oil duct branches off to the long oil filter 6 where the coarser particles contained in the engine oil are filtered away Then the engine oil arrives at the short oil filter 7 which also filters the...

Page 36: ...om Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dis mount the oil screen clean the components thoroughly and blow compres sed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and tigh ten the plug to 10 Nm 7 ft lb CLEANING THE LONG OIL S...

Page 37: ...orcycle on its side and fill the oil filter housings about halfway with engine oil Insert the long oil filter at the front and the short oil filter at the back of the housing Grease the O rings 4 of the oil filter covers and mount the covers Mount the screws and tighten them to 8 Nm 6 ft lb Position the brake fluid container and tighten the screw to 8 Nm 6 ft lb Return the motorcycle to its uprigh...

Page 38: ...ents of the new fuels evaporate during longer periods of standstill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start off when the float chamber is filled with new fuel Close fuel tap loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out the ca...

Page 39: ...elay The battery isn t charged by the generator because REMEDY Dismount carburettor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well as carburettor Replace the float Clean or replace air filter Check if exhaust is damaged replace glas fibre yarn in exhaust silencer Adjust valve gap Check setting of the hand decompression cable Have ignition system...

Page 40: ...beginning of the next biking season STORAGE Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A ...

Page 41: ...lve diameter Exhaust 30 mm Valve clearence cold Intake 0 10 mm Valve clearence cold Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy cast alluminium alloy forged Piston rings 1 compression ring 1 oil scraper ring Engine lubrication pressure circulation lubrication with two rotorpumps Engine oi...

Page 42: ...Nm 6 ft lb Allan head screw shift roller locking piece M6 Loctite 243 10 Nm 6 ft lb Hexagon collar screw locking lever M5 Loctite 243 6 Nm 6 ft lb Hexagon collar screw shift roller M5 Loctite 243 6 Nm 6 ft lb Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 8 Nm 6 ft lb Hexagon collar screw clip M5 Loctite 243 6 Nm 4 ft lb Hexagon collar screw chain adjuster M6 8 Nm 6...

Page 43: ...mm 0 04 in Valves seat sealing intake max 1 50 mm 0 06 in seat sealing exhaust max 2 00 mm 0 078 in run out of valve heads max 0 05 mm 0 002 in valve guides diameter max 6 05 mm 0 238 in spring washer min 0 4 mm 0 016 in new 0 5 mm 0 019 in valve spring Interior min 36 5 mm 1 423 in new 37 45 mm 1 46in Exterior min 39 7 mm 1 548 in new 40 2 mm 1 567 in balancer shaft Journal runout max 0 06 mm 0 0...

Page 44: ...b M 10 45 Nm 33ft lb Other collar nuts on chassis M 6 15 Nm 11ft lb M 8 30 Nm 22ft lb M 10 50 Nm 37ft lb TIGHTENING TORQUES CHASSIS Dead weight without fuel 400 520 SX RACING 400 520 EXC RACING 400 520 MXC EXC USA Frame Central tube chrom moly steel frame Fork WP USD 4860 MXMA WP Up Side Down 4357 MXMA Wheel travel front rear 295 320 mm Rear suspension WP Progressive Damping System shock absorber ...

Page 45: ...g system 30 Correct chain tension 19 Damping action during compression of shock absorber SX 9 Digital speedometer EXC 5 Digital speedometer indicator lamps EXC 5 Dismounting and mounting the front wheel 23 Page Dismounting and mounting the rear wheel 24 Draining of float chamber of the carburetor 34 Driving instructions 11 Emergency OFF button EXC 6 Emergency OFF switch EXC Australia 6 Engine numb...

Page 46: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321017 ...

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