KTM 2012 505 SX Owner'S Manual Download Page 156

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MAINTENANCE WORK ON THE ENGINE

154

Warning

Environmental hazard

Hazardous substances cause environmental damage.

–

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

–

Place a suitable container under the engine.

301842-10

–

Loosen screw plug

by striking it lightly with a hammer a few times.

–

Remove plug

with oil screen

and the O-rings.

–

Drain the remaining engine oil.

–

Thoroughly clean the parts and sealing area.

–

Mount and tighten screw plug

with oil screen

and the O-rings.

Guideline

Plug, oil screen

M32x1.5

30 Nm
(22.1 lbf ft)

Lubricated with
engine oil

16.6

Installing the oil filter

301844-10

–

Fill oil filter

with engine oil and place it in the oil filter container.

Summary of Contents for 2012 505 SX

Page 1: ...OWNER S MANUAL 2012 505 SX ATV Art no 3211728en ...

Page 2: ......

Page 3: ...specifications are non binding KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options de...

Page 4: ...According to the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by TÜV Management Service KTM Sportmotorcycle AG 5230 Mattighofen Austria ...

Page 5: ...Checks and maintenance measures when preparing for use 31 Starting 32 Starting off 33 Shifting 33 Braking 34 Riding 35 Riding in bends 36 Riding downhill 37 Riding uphill 38 Riding perpendicular to the slope 39 Turning on slopes 39 Riding through water 40 Switching off the engine 41 Stopping parking 42 Refueling 43 SERVICE SCHEDULE 44 Service schedule 44 Maintenance work as an additional order 46 ...

Page 6: ...x 86 Fork offset 88 Adjusting the fork offset x 89 Toe width of rear axle 89 Adjusting the toe width of rear axle x 90 Checking chain dirt 92 Cleaning the chain 92 Checking the chain tension 93 Checking the chain rear sprocket engine sprocket and chain guide 94 Adjusting chain tension 98 Checking the frame x 100 Checking the swingarm x 100 Greasing the rear wheel eccentric element 101 Checking the...

Page 7: ...y in the throttle cable 142 Adjusting play in throttle cable 143 Carburetor idle 144 Carburetor adjusting idle x 144 Draining the carburetor float chamber x 146 Ignition curve plug connection 147 Changing the ignition curve 148 Checking the basic setting of the shift lever 148 Adjusting the basic position of the shift lever x 149 MAINTENANCE WORK ON THE ENGINE 150 Checking the engine oil level 150...

Page 8: ... OF CONTENTS 6 TECHNICAL DATA FRONT SHOCK ABSORBER 176 TECHNICAL DATA REAR SHOCK ABSORBER 178 TECHNICAL DATA TIGHTENING TORQUES FOR CHASSIS 180 SUBSTANCES 182 AUXILIARY SUBSTANCES 186 STANDARDS 189 INDEX 190 ...

Page 9: ... understanding In the interest of your own safety have these jobs performed at an authorized KTM workshop There your vehicle 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 below Specific name Identifies a pro...

Page 10: ...ual are properly carried out Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components Using the vehicle in difficult conditions such as on sand or very muddy or wet terrain can lead to above average wear of components such as the drive train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the...

Page 11: ...ot included with the vehicle but can be ordered under the number in parentheses E g valve spring mounter 59029019000 During assembly non reusable parts e g self locking screws and nuts seals seal rings O rings pins lock washers must be replaced by new parts Where thread lockers are used on screw connections e g Loctite follow the instructions for use from the manufacturer Parts that are to be reus...

Page 12: ...10 p 24 Use straps or other suitable devices to secure the vehicle against accidents or falling over Pull the hand brake lever push the locking pawl 2 down and release the hand brake lever Figure 301776 10 p 20 Environment Off road riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest However it is a potential problem for the environment and can lead to...

Page 13: ...e measures are not taken Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this owner s manual carefully and completely before making your first trip It contains a lot of...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of the vehicle from the left front example 401377 10 ...

Page 15: ...ke p 20 2 Fuse box 3 Shock absorber compression adjustment 4 Front shock absorber 5 Shock absorber rebound adjustment 6 Heel protector 7 Shift lever p 25 8 Kill switch emergency OFF switch with rip cord p 21 9 Clutch lever p 19 10 Hot start lever p 19 ...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of the vehicle from the right rear example 401378 10 ...

Page 17: ...cap 2 Main silencer 3 Seat release 4 Shock absorber rebound adjustment 5 Rear sprocket with chain 6 Rear wheel eccentric element 7 Rear brake 8 Foot brake lever p 26 9 Handlebar bridge 10 Throttle lever p 142 11 Handlebar cushion ...

Page 18: ...number 301771 10 The chassis number 1 is stamped on the right side of the frame in the vicinity of the upper A arm 4 2 Type label 301858 10 The type label 1 is located on the frame tube on the right and left in front of the radiator ...

Page 19: ...mber 301772 10 The engine number 1 is stamped on the left side of the engine under the engine sprocket 4 4 Shock absorber part number front 301832 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber ...

Page 20: ...SERIAL NUMBERS 18 4 5 Shock absorber part number rear 301831 10 The shock absorber part number 1 is stamped on the upper part of the shock absorber ...

Page 21: ...t is closed The electric starter turns over when the electric starter button is pressed The clutch is hydraulically operated and self adjusting 5 2 Hot start lever 301775 10 Hot start lever 1 is fitted on the left side of the handlebar If you pull the hot start lever to the handlebar when starting the engine an opening is exposed in the carburetor through which the engine can draw additional air T...

Page 22: ...er is combined with the parking brake which blocks the front wheels to prevent the vehicle from rolling away To activate the parking brake pull the hand brake lever push the locking pawl 2 down and release the hand brake lever Possible states Hand brake lever in basic position Front wheels are not locked Hand brake lever pulled and locked in position Front wheels are locked ...

Page 23: ... carabiner 3 Possible states Clip is pulled off The ignition circuit is interrupted a running engine stops and a non running engine will not start Clip is mounted The ignition circuit is closed and the engine can be started Clip mounted and kill switch pressed The ignition circuit is interrupted a running engine stops and a non running engine will not start 5 5 Electric starter button 301793 10 El...

Page 24: ...id 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 doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the re...

Page 25: ...78 11 Replace the filler cap and turn clockwise until the release button 1 locks in place Check the fuel tank breather 2 to ensure it is properly seated If the fuel tank breather is at an angle or loose Correctly mount the fuel tank breather ...

Page 26: ...el tank With tap handle 1 on the fuel tap you can open or close the supply of fuel to the carbure tor Possible states Fuel supply closed OFF No fuel can flow from the tank to the carburetor Fuel supply open ON Fuel can flow from the tank to the carburetor The fuel tank empties completely ...

Page 27: ...fuel This gives a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed in to the stop 5 10 Shift lever 301783 10 The shift lever 1 is mounted on the left side of the engine ...

Page 28: ...sitions can be seen in the photograph The neutral or idle position is between the first and second gears 5 11 Foot brake lever 301781 10 The foot brake lever 1 is located in front of the right footrest and operates the rear wheel brake ...

Page 29: ...ainer will show you how to handle your ATV safely in various riding situations and on different terrain Your KTM dealer will be glad to advise you Warning Risk of injury Missing or poor protective clothing present an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing which must be undam...

Page 30: ...ding behavior Do not exceed the maximum permissible weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle unattended while the engine is running Secure the vehicle against use by unauthorized persons Always remove the ignition key Warning Danger of accidents Instable handling from loaded luggage The vehicle is not designed to carry luggage Do ...

Page 31: ...ng the vehicle on a suitable piece of land before making a longer trip Info Off road you should be accompanied by another person on another machine so that you can help each other Do not ride in terrain that demands skills beyond your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not exceed the overall maximum permitted weight a...

Page 32: ...PREPARING FOR USE 30 Guideline Maximum engine speed During the first operating hour 7 000 rpm Maximum engine performance During the first 3 operating hours 75 Avoid fully opening the throttle ...

Page 33: ...fluid level p 116 Check the front brake linings p 109 Check the rear brake linings p 119 Check that the brake system is functioning properly Check the coolant level p 138 Check the chain dirt accumulation p 92 Check the chain rear sprocket engine sprocket and chain guide p 94 Check the chain tension p 93 Check the tire condition p 127 Check the tire air pressure p 128 Check the air filter Check th...

Page 34: ...illing to start the cause can be old fuel in the float chamber The flammable elements of the fuel evaporate after standing for an extended period 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 before trying again Condition Vehicle has not been operated 1 week Drain the carburetor float chamber x p...

Page 35: ...se the clutch lever Condition The engine is hot and running Push the hot start lever all the way in with the engine running 7 3 Starting off Pull the hand brake lever and release it again Locking pawl moves into its basic position parking brake is deactivated Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttle carefully 7 4 Shifting Warning Da...

Page 36: ...er slowly and open the throttle or shift again 7 5 Braking Warning Danger of accidents If you brake too hard the wheels can lock When the front wheels lock the vehicle can no longer be steered Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do...

Page 37: ...d off by the rip cord attached to your clothing This short circuits the ignition circuit and the engine switches off During normal operation you sit erect on the vehicle with both hands on the handlebar and both feet on the footrests If the choke function was activated deactivate it after the engine has warmed up After reaching maximum speed by fully opening the throttle close the throttle so it i...

Page 38: ... before entering into bends Handling of the ATV is strongly influenced by shifts in the position of your body weight Always shift your body weight toward the inside of the bend and forward The faster you ride and the tighter the bend the more you need to shift your body weight Always exert pressure on the footrest on the inside of the bend Look in the direction of the bend while you are riding The...

Page 39: ... slope with a slippery surface The vehicle can easily go out of control and roll over Note Material damage Damage to vehicle after fall or rollover Perform a vehicle check as is done every time before you start to ride Always ride straight up or down a slope and never at a slant Engage a gear with which you can ride all the way down the slope without shifting Shift your body weight to the rear and...

Page 40: ... vehicle can easily go out of control and roll over Always ride straight up or down a slope and never at a slant Engage a gear with which you can ride all the way up the slope without shifting Shift ing on the slope can cause the vehicle to roll over Shift your body weight to the front and ride cautiously Keep your vehicle speed and engine speed as constant as possible Always be prepared to jump s...

Page 41: ...d immediately dis mount on the uphill side 7 11 Turning on slopes Warning Danger of accidents Danger of accidents from turning the vehicle on a slope Never ride down a slope backward The vehicle can roll over easily Always position yourself next to the vehicle in a location where you cannot be caught by a wheel When turning on a slope always stand on the uphill side of the vehicle to avoid injury ...

Page 42: ...essure to the footrest on the uphill side When the vehicle is standing perpendicular to the slope or slightly downhill apply the parking brake Mount the vehicle start the engine pull the clutch lever and engage 1st gear Cau tiously release the parking brake and ride down the hill in 1st gear Ride downhill p 37 If you lose control over the vehicle you should get away from the vehicle as fast as pos...

Page 43: ...r dry the brakes by lightly activating both brakes until normal braking power is available again If the vehicle became submerged an authorized KTM workshop must perform a thor ough check and comprehensive service Do not start the engine 7 13 Switching off the engine Info There are two ways to switch off the engine Alternative 1 Switch off the engine using the kill switch Press kill switch 4 at eng...

Page 44: ...is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first 400296 01 Stop the vehicle and park it on a surface that is as horizontal as possible Shift gear to neutral Switch off the engine p 41 Pull the clip off of the emergency OFF switch Pull the hand brake lever push the l...

Page 45: ...d 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 doc tor immediately Change clothing that has come into contact with fuel Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the grou...

Page 46: ...nd leakage Check the rear brake fluid level p 116 Check the free travel of the foot brake lever p 114 Check the frame and swingarm x Check the swingarm bearing x Check the heim joints on the upper and lower shock absorbers x Check the tire condition p 127 Check the tire air pressure p 128 Check the wheel bearing for play x Check the wheel hubs x Check for rim run out x Check the front wheel suspen...

Page 47: ...nt level p 137 Check cables for damage and routing without sharp bends x Check the cables for damage routing without sharp bends and correct adjustment Clean the air filter and air filter box x Change glass fiber yarn filling of main silencer x Check the screws and nuts for tightness x Check the idle x Check that the radiator fan is functioning properly x Final inspection check the vehicle for ope...

Page 48: ...front shock absorber x Service the front shock absorber x Change the oil in the rear shock absorber x Service the rear shock absorber x Change the spark plug and spark plug connector x Change the piston x Change the piston in difficult operating conditions x Check measure the cylinder x Check the cylinder head x Change the valves valve springs and valve spring seats x Check the camshaft and rocker...

Page 49: ...d lubrication system x Check the timing assembly x Change all engine bearings x S20A Every 20 operating hours corresponds to about 140 liters of fuel 37 US gal S40A Every 40 operating hours corresponds to about 280 liters of fuel 74 US gal S80A Every 80 operating hours corresponds to about 560 liters of fuel 148 US gal J1A Annually ...

Page 50: ...s start with the standard setting Between test rides always change only one setting This will enable you to better assess the effect of the setting on vehicle han dling Do not make radical changes to the settings proceed in small steps instead Even small changes can have a large impact on vehi cle handling 9 2 Compression damping of the shock absorber The compression damping of the shock absorber ...

Page 51: ... After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The low speed setting has an impact on the slow to normal compression of the shock abs...

Page 52: ...ifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with ...

Page 53: ... increase damping turn counterclockwise to reduce damping 9 5 Rear shock absorber adjusting the rebound damping Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make ad...

Page 54: ...be glad to help Info The rebound damping setting has an impact on the rebound of the shock absorber 301792 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn back to the left by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Info Turning to the right increases damping while turning ...

Page 55: ...ments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info Increasing the spring preload raises the center of gravity of the vehicle This can have a large impact on ...

Page 56: ...pring preload A is the difference in length between the spring pack when it is unloaded and when it is installed Tighten the spring packet by turning the adjusting ring to the specified measurement Guideline Spring preload Comfort 3 mm 0 12 in Standard 5 mm 0 2 in Sport 3 mm 0 12 in Tighten the retaining ring and adjusting ring Info If you increase the spring preload you should also slightly incre...

Page 57: ...lowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Info The low speed setting has an impact on the slow to normal compression of the shock absorber The left and right shock a...

Page 58: ...the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to ...

Page 59: ... increase damping turn counterclockwise to reduce damping 9 9 Front shock absorber adjusting the rebound damping Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make a...

Page 60: ...d damping setting has an impact on the rebound of the shock absorber The left and right shock absorbers should have the same settings 301788 10 Turn adjusting screw 1 clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Comfort 20 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwise...

Page 61: ...suspension travel of the short soft spring Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower The suspension travel and the progressive part of the long hard spring is not fully utilized Less cross over makes the spring action at the front harder and the front of the vehicle lies higher Adjust the spring preload for the front shock absorbers p 60...

Page 62: ...vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury...

Page 63: ...by measuring the length of the spring Raise the vehicle with the lifting gear p 67 Clean the shock absorber thoroughly 301790 11 Release counter ring 1 Hook wrench 83019001000 Turn adjusting ring 2 until the spring pack is no longer under tension Measure the overall spring pack when not under tension ...

Page 64: ...n it is unloaded and when it is installed The spring pack should never be installed loosely without preload The stan dard setting is the lowest permissible spring preload Therefore you can only increase the spring preload If you increase the spring preload you should also slightly increase the rebound damping The left and right shock absorbers should have the same settings Tighten the retaining ri...

Page 65: ...y turning the handlebar support 1 and the handlebar support 2 The holes on the handlebar support are placed at a distance of A from the center Distance A between holes 3 5 mm 0 138 in The holes on the handlebar bridge are placed at a distance of B from the center Distance B between holes 7 5 mm 0 295 in ...

Page 66: ...UNING THE CHASSIS 64 9 13 Adjusting handlebar position x 301846 10 Remove the handlebar cushion Info Protect the vehicle and its attachments from damage by covering them Do not bend the cables and lines ...

Page 67: ...n the desired position Mount and tighten screw 6 Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount and tighten screw 5 Guideline Screw steering column top M20x1 5 25 Nm 18 4 lbf ft Mount and tighten screws 7 Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount the handlebar support 4 in the desired position using the screws Mount new self locking nuts 3 and tighten Guideline Nut han...

Page 68: ...TUNING THE CHASSIS 66 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure cables and wiring are positioned correctly Mount the handlebar cushion ...

Page 69: ...Raise the vehicle on the frame underneath the engine The wheels must no longer touch the ground Secure the vehicle 10 2 Removing the vehicle from the lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Lower the vehicle Remove the lifting gear 10 3 Removing the rear shock absorber x Raise the vehicle with the lifting ...

Page 70: ...th a tension belt to prevent it from swinging down further Attach the swingarm to the subframe with a tension belt 1 to relieve the shock absorber Remove the bottom screw of the shock absorber Tip Press the screw out of the swingarm with a screw driver while moving the tension belt Remove the top screw 2 of the shock absorber and carefully remove the shock absorber out of the vehicle toward the re...

Page 71: ... Screw rear top shock absorber M12 60 Nm 44 3 lbf ft Position the shock absorber in the swingarm Mount and tighten the bottom screw Guideline Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Remove the tension belt Install the rear fender p 74 Remove the vehicle from the lifting gear p 67 10 5 Removing the radiator spoiler Info The operations are the same on the left and right Remove the sea...

Page 72: ...S 70 301817 10 Remove the screws 1 on the fuel tank 301816 10 Remove the screws 2 on the radiator Detach the radiator spoiler and remove it 10 6 Installing the radiator spoiler Info The operations are the same on the left and right ...

Page 73: ... into holder 2 of the fuel tank and position it on the radiator 301818 10 Mount and tighten screws 3 on the radiator Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws 4 on the fuel tank Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Mount the seat p 78 ...

Page 74: ...72 10 7 Removing the front cover 301811 10 Remove screw 1 Slide the front cover up and remove it 10 8 Installing the front cover 301812 10 Position the front cover in slots 1 on both sides of the front trim Mount and tighten the screw ...

Page 75: ...MAINTENANCE WORK ON THE CHASSIS 73 10 9 Removing the rear fender Remove the seat p 78 301822 10 Remove screws 1 ...

Page 76: ...der 3 at the rear and remove it 10 10 Installing the rear fender 301821 11 Raise the rear of the air filter box lid 1 At the same time use your other hand to press on the carburetor connection boot to kink it at that location Info This prevents the carburetor connection boot from disconnecting from the carbu retor Position front fender 2 Fix the air filter box lid in the fender Info If the air fil...

Page 77: ...AINTENANCE WORK ON THE CHASSIS 75 301822 11 Mount and tighten screws 3 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 78 10 11 Removing the front trim Remove the front cover p 72 ...

Page 78: ...MAINTENANCE WORK ON THE CHASSIS 76 301820 10 Remove screws 1 Raise the front trim and disconnect the plug in connector from the emergency OFF switch with the rip cord Remove the front trim ...

Page 79: ...e plug in connector of the emergency OFF switch with the rip cord and posi tion the front trim Mount all screws Fully tighten screws 1 Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Fully tighten screws 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the front cover p 72 ...

Page 80: ...1809 10 Pull the release hook 1 back Lift up the seat at the rear pull it back and then remove from above 10 14 Mounting the seat 301810 10 Hook slot 1 on the seat into collar sleeve A of the fuel tank lower the rear of the seat and slide tab 2 under fuel tank B ...

Page 81: ... Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Remove the seat...

Page 82: ...nfo This prevents the carburetor connection boot from disconnecting from the carbu retor Unhook the air filter holder 3 and swing it to the side Remove the air filter 4 with the air filter support Remove the air filter from the air filter support 10 16 Installing the air filter x 301262 10 Mount the clean air filter onto the air filter support Grease the air filter in area A Long life grease p 186...

Page 83: ... can penetrate into the engine and cause damage Mount the seat p 78 10 17 Cleaning the air filter and air filter box x Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Do not clean the air filter with fuel or petroleum since these substances attack the foa...

Page 84: ...and tightness Install the air filter x p 80 10 18 Checking the toe x Park the vehicle on a horizontal surface Check the tire condition p 127 Check the tire air pressure p 128 Check the chassis parts for damage play and wear 300272 10 Load the vehicle with the specified weight Guideline Average rider weight 75 85 kg 165 187 lb Move the handlebar into the straight ahead position and fix it Handlebar...

Page 85: ...MAINTENANCE WORK ON THE CHASSIS 83 400333 10 Measure distances A and B If distances A and B are not equal Adjust the toe x p 84 Measure distances C and D Guideline Toe Front 0 mm 0 in ...

Page 86: ...oes not meet specifications Adjust the toe x p 84 10 19 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 127 Check the tire air pressure p 128 Check the chassis parts for damage play and wear Replace damaged or worn parts 300272 10 Load the vehicle with the specified weight Guideline Average rider weight 75 85 kg 165 187 lb Move the handlebar into the straigh...

Page 87: ...ASSIS 85 400333 11 Loosen nuts 2 and 3 Adjust the distances A and B to the same value by rotating the tie rods 1 Adjust the distances C and D to the specified value by evenly rotating the tie rods 1 Guideline Toe Front 0 mm 0 in ...

Page 88: ... the wheel center from rim flange to rim flange Tighten nuts 2 and 3 Guideline Lock nut tie rod outside M12x1 25 20 Nm 14 8 lbf ft Lock nut tie rod inside M12LHx1 25 20 Nm 14 8 lbf ft Info The tie rods 1 must still be freely movable 10 20 Checking adjusting the camber x Info The left and right camber should have the same settings The operations are the same on the left and right Raise the vehicle ...

Page 89: ...277 10 Insert tool 4 in the heim joint and clip onto the A arm Camber gauge 83019014000 Check the camber on both heim joints If marking 5 is not aligned with the top edge of the A arm Turn tool 4 with the heim joint in steps of 180 until the marking is in line with the top edge of the A arm Remove tool 4 ...

Page 90: ...rk offset The fork offset has an impact on the handling of the vehicle The fork offset can optionally be adjusted Fork offset is defined as the slanted position of the swivel axis in the direction of the longitudinal axis of the vehicle in relation to a verti cal line to the driving surface When both sleeves are installed in front of the A arms the fork offset increases This enhances driving stabi...

Page 91: ...th the lifting gear p 67 300274 11 Remove screws 1 with bushings 2 Place the A arm with bushings 2 in the desired position Mount and tighten screws 1 Guideline Screw A arm top M10x52 45 Nm 33 2 lbf ft Remove the vehicle from the lifting gear p 67 10 23 Toe width of rear axle 301794 10 The toe width A can be adjusted by installing the spacer in various ways Difference between narrow wide toe 76 mm ...

Page 92: ...he feel of the new ride behavior Engage 1st gear B00883 10 Loosen nuts 4 of the wheel hubs on both sides Raise the vehicle with the lifting gear p 67 Remove the nuts 4 on both sides and take all parts off of the rear axle 0 0 3 3 0 0 1 1 0 0 2 2 100103 10 Setting a narrow toe width Mount the wheel hub 1 Mount the conical ring 2 with the cone facing outward Mount the spacer 3 with the cone facing i...

Page 93: ... with the cone facing inward Mount the conical ring 2 with the cone facing outward Mount the wheel hub 1 Mount the washer and the new self locking nut B00883 10 Remove the vehicle from the lifting gear p 67 Tighten nuts 4 on both sides Guideline Nut rear wheel hub M18x1 5 130 Nm 95 9 lbf ft Shift gear to neutral ...

Page 94: ... is very dirty Clean the chain p 92 10 26 Cleaning the chain Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance ...

Page 95: ... secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain may snap Conversely if the chain is too loose it may jump off the engine and rear sprockets causing the rear wheel to lock up or even leading to engine damage Check for correc...

Page 96: ...r ent chain positions Chain tension 140 145 mm 5 51 5 71 in If the chain tension does not meet specifications Adjust the chain tension p 98 10 28 Checking the chain rear sprocket engine sprocket and chain guide 400227 01 Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the rear sprocket or engine sprocket x Info The...

Page 97: ...he upper chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance B at the longest chain section 272 mm 10 71 in If the distance B is greater than the specified measurement Replace the chain x Info When you replace the chain you should also change the rear sprocket and engine sprocket New chains wear out faster on old wor...

Page 98: ...ENANCE WORK ON THE CHASSIS 96 B00465 01 Check the chain sliding guard at the top for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard x ...

Page 99: ...or wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard x Check the chain sliding guard for tightness If the chain sliding guard is loose Tighten the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 100: ...sting chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain may snap Conversely if the chain...

Page 101: ...rear wheel or using the spe cial tool to rotate the rear wheel eccentric element forward or backward Guideline Chain tension 140 145 mm 5 51 5 71 in Info Rotating the rear wheel eccentric element forward increases chain tension Rotating the rear wheel eccentric element backward reduces chain tension The rear wheel eccentric element should always be positioned such that the grease nipple B is visib...

Page 102: ...e x Info A frame that has been damaged due to a mechanical impact must always be changed Repair of the frame is not authorized by KTM 10 31 Checking the swingarm x 401386 01 Check the swingarm for damage cracking and deformation If the swingarm shows signs of damage cracking or deformation Change the swingarm x Info A damaged swingarm must always be changed Repair of the swingarm is not authorized...

Page 103: ...se nipple 1 until grease emerges from the left shaft seal ring A Long life grease p 184 Remove excess grease 10 33 Checking the rubber grip 401197 01 Check the rubber grips on the handlebar for damage and wear and to ensure they are firmly seated If a rubber grip is damaged worn or loose Change and secure the rubber grip Rubber grip adhesive 00062030051 p 188 ...

Page 104: ...rd the rubber grip 10 35 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 301814 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws 1 Remove cover 2 with membrane 3 Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the coolant level d...

Page 105: ... Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw clockwise 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 10 37 Removing the engine guard 301823 1...

Page 106: ...IS 104 10 38 Installing the engine guard 301823 10 Position the engine guard on the frame bearer Mount and tighten screws 1 and 2 Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 107: ...vel on hand brake lever according to specifications 301799 10 Push the hand brake lever forward and check free travel A Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specifications Adjust the basic position of hand brake lever p 105 11 2 Adjusting basic position of hand brake lever 301800 10 Check the free travel of the hand brake lever p 105 Adjust the basic settin...

Page 108: ...ce Do not make any adjustments while riding 11 3 Checking brake discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 400362 10 Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement A Info Wear reduces the th...

Page 109: ...rn out brake lin ings Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 301801 10 Move the brake fluid reservoir mounted on the handlebar to...

Page 110: ... with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking efficiency due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fue...

Page 111: ...ge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 182 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 11 6 Checking the front brake linings Warning Danger of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help...

Page 112: ...ing is visible Change the front brake linings x p 112 Install the wheel wheels p 126 11 7 Removing front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Info The operations are the same on the left and right Remove the wheel wheels p 125 Pull the hand brake lever and re...

Page 113: ...anger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals ...

Page 114: ...ntil the brake linings are in contact with the brake disc and there is a pressure point Install the wheel wheels p 126 11 9 Changing the front brake linings x Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flu...

Page 115: ...nmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only c...

Page 116: ...e fluid level to level A Guideline Dimension A brake fluid level below top edge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 182 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 11 10 Checking free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the fo...

Page 117: ... in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 115 Reconnect spring 1 11 11 Adjusting basic position of foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust free travel on foot br...

Page 118: ...rake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold screw 5 and tighten nut 4 Guideline Remaining nuts chassis M8 30 Nm 22 1 lbf ft Hold push rod 3 and tighten nut 2 Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft Reconnect spring 1 11 12 Checking rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom o...

Page 119: ...7 11 13 Topping up brake fluid of rear brake x Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom of the viewer this indicates a leakage in the brake system or worn out brake lin ings Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on contact ...

Page 120: ...s substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a...

Page 121: ...f accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 100038 10 Check the brake linings for minimum thickness A Minimum thickness A 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 123 Check the brake linings for damage and cracking If damage or cracki...

Page 122: ...ly Your authorized KTM workshop will be glad to help 301830 10 Press the brake caliper onto the brake disc by hand in order to push back the brake pis ton 100064 10 Loosen the screw 1 while holding the hexagonal head 2 of the bearing bolt Unscrew the screw by approx 10 turns and use the screw to press the bearing bolt out of the brake caliper Remove screw ...

Page 123: ...e discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from ...

Page 124: ...e brake lining 100068 10 Grease the bearing bolt 2 and insert the brake caliper with the bearing bolt into the brake caliper support 3 Lubricant T625 p 187 100069 10 Swing the brake caliper downward Mount and tighten the screw Guideline Screw rear brake caliper M6 10 Nm 7 4 lbf ft Loctite 243 Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a press...

Page 125: ... due to old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based...

Page 126: ... back to its basic position and make sure that no brake fluid over flows from the brake fluid reservoir Mount the rear brake linings x p 121 Add brake fluid to level A Brake fluid DOT 4 DOT 5 1 p 182 Mount the screw cap with the membrane and tighten Info Clean up overflowed or spilt brake fluid immediately with water ...

Page 127: ...and brake lever push the locking pawl 2 down and release the hand brake lever Figure 301776 10 p 20 B00884 10 Loosen the wheel nuts 1 Raise the vehicle with the lifting gear p 67 Remove the wheel nuts Remove the wheel Info Carefully remove the wheel making sure it does not become jammed with the threads of the screws ...

Page 128: ...ial damage Damage and destruction of components from incorrect positioning and mounting Do not swap the wheels the tire valves must always be on the outside when the wheels are positioned and mounted Info Proceed in the same way on the other wheels if necessary ...

Page 129: ...and brake lever Figure 301776 10 p 20 Tighten the wheel nuts crosswise Guideline Wheel nut M10x1 25 45 Nm 33 2 lbf ft 12 3 Checking the tire condition Info Only mount tires that have been approved and or recommended by KTM Other tires could have a negative effect on vehicle handling The type condition and air pressure of the tires all have an important impact on the handling characteristics of the...

Page 130: ... regard less of the actual state of wear If the tire is older than five years Change the tire 12 4 Checking the 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 Check the tire pressure on all wheels and correct it if necessary 400695 01 Remove the dust cap Check the...

Page 131: ... sparks or open flames Charge only in well ventilated areas 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 physician Switch off all power consumers and switch off the engine Remove the rear fender p 73 300279 10 Disconnect the negative minus cable 1 of the battery Pull back the plus pole cover a...

Page 132: ... Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open flames Charge only in well ventilated areas 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 physician Warning Environmental hazard The battery contains elemen...

Page 133: ... life If the charging current charging voltage and charging time are exceeded electrolyte escapes via the safety valves This reduces the battery capacity If the vehicle is started repeatedly until the battery is depleted the battery must be charged immediately If the battery is left in a discharged state for an extended period it will drain completely and sulfate destroying the battery The battery...

Page 134: ... device you cannot overcharge the battery Info Never remove the lid 1 Charge the battery to a maximum of 10 of the capacity specified on the bat tery housing 2 Switch off the charger after charging Disconnect the battery Guideline The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the vehicle is not in use 3 months Install the rear fender p 74 ...

Page 135: ...ctrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Insert the new fuse Fuse 58011109120 Tip Replacement fuse 4 should always be present in the starter relay to make sure it is available when needed Replace the protection covers 13 5 Changing the fuses of individual power consumers Remove the front cover p 72 Switch...

Page 136: ... Fuse 5 power supply for auxiliary equipment Fuse res 10A spare fuses Info You can recognize a blown fuse by its broken filament A Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used Use only fuses with the prescribed amperage Never by pass or repair fuses Insert a new fuse of the appropriate strength Fuse 58011109110 Tip The replacement fuses should always be p...

Page 137: ...ELECTRICAL SYSTEM 135 Close the cover of the fuse box Install the front cover p 72 ...

Page 138: ... temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream The radiator fan provides extra cooling The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 14 2 Radiator fan 301827 10 The radiator fan 1 is located on the radiator under the fuel tank Working range within which radiator fan is switched on and off ...

Page 139: ...olant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Remove the front trim p 75 400243 10 Remove the radiator cap Check antifreeze of c...

Page 140: ...y Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach...

Page 141: ...scald yourself hold the affected area under lukewarm water immediately Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes th...

Page 142: ...eding the cooling system x Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep...

Page 143: ... use p 182 301840 10 Open screw 2 to bleed the radiator Tighten the screw when coolant emerges from the opening Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 301839 10 Add coolant to level A above the radiator fins Guideline 10 mm 0 39 in Mount the radiator cap Install the front trim p 77 Make a short test ride Check the coolant level p 138 ...

Page 144: ...he throttle lever back and forth slightly to ascertain the play in the throttle cable A Guideline Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 143 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure the...

Page 145: ...nge If the idle speed changes Adjust the play in the throttle cable p 143 15 3 Adjusting play in throttle cable Check the throttle cable routing 301795 10 Move the handlebar to the straight ahead position Loosen the nut 1 and use the screw 2 to adjust the play in the throttle cable A Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 1 ...

Page 146: ...y higher the engine does not start When the elec tric starter button is activated the electric starter turns over the engine but the engine does not start because there is no ignition spark The idle speed is adjusted with the adjustment screw 2 The idle mixture is adjusted with the idle mixture adjustment screw 1 15 5 Carburetor adjusting idle x 301826 10 Screw in the idle adjusting screw 1 until ...

Page 147: ...e speed Info If there is a large increase in the engine speed reduce the idle speed to a nor mal level and repeat the above steps The extremely sporty rider will set the mixture about 1 4 of a turn back from this ideal value leaner clockwise since the engine has a higher operating tempera ture in sporting use If the procedure described here does not lead to satisfactory results the cause may be a ...

Page 148: ... expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a d...

Page 149: ...container Info Water in the float chamber results in malfunctioning Undo the screw 1 turn it counterclockwise a few turns and drain the fuel from the float chamber Tighten screw 1 15 7 Ignition curve plug connection 301829 10 Plug in connector 1 is located under the trim at the front on the frame tube Possible states Performance The plug in connector is connected to achieve better performance Soft...

Page 150: ...he plug in connector 1 Figure 301829 10 p 147 Performance The plug in connector is connected to achieve better performance p 147 Install the front trim p 77 15 9 Checking the basic setting of the shift lever 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and determine the distance A between the upper edge of your boot and the shift lever Distance between shift lever and upper edge o...

Page 151: ...teeth A of the shift lever and shift shaft Position the shift lever in the desired position on the shift shaft and engage the gearing Info The range of adjustment is limited The shift lever should not come into contact with other vehicle components dur ing shifting Mount and tighten the screw Guideline Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 152: ...Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil reaches the middle of the viewer A When the engine oil does not reach the middle of the viewer A Add engine oil p 156 800061 11 Condition The engine is cold Check the engine oil level The engine oil reaches the bottom of the viewer B When the engine oil does not reach the bottom ...

Page 153: ...gine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the engine oil o...

Page 154: ... magnet M12x1 5 20 Nm 14 8 lbf ft Clean the oil screen x p 153 16 4 Removing the oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filt...

Page 155: ...lter case Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area 16 5 Cleaning the oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately ...

Page 156: ...ne 301842 10 Loosen screw plug 1 by striking it lightly with a hammer a few times Remove plug 1 with oil screen 2 and the O rings Drain the remaining engine oil Thoroughly clean the parts and sealing area Mount and tighten screw plug 1 with oil screen 2 and the O rings Guideline Plug oil screen M32x1 5 30 Nm 22 1 lbf ft Lubricated with engine oil 16 6 Installing the oil filter x 301844 10 Fill oil...

Page 157: ... Nm 4 4 lbf ft 16 7 Filling up with engine oil x Info A lack of engine oil or poor quality engine oil results in premature wear to the engine 301845 10 Remove the filler cap 1 on the clutch cover and fill up with engine oil Engine oil 2 00 l 2 11 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 183 External temperature 0 C 32 F Engine oil SAE 5W 40 p 183 Mount and tighten filler cap 1 ...

Page 158: ...out an effective exhaust extraction system Start the engine and check that it is oil tight Check the engine oil level p 150 16 8 Adding engine oil Info A lack of engine oil or poor quality engine oil results in premature wear to the engine 301845 10 Check the engine for leakage Remove the filler cap 1 on the clutch cover and fill up with engine oil Condition External temperature 0 C 32 F Engine oi...

Page 159: ...NTENANCE WORK ON THE ENGINE 157 Info To ensure optimal engine oil performance it is advisable to not use different engine oils We recommend making an oil change in this case Mount and tighten filler cap 1 ...

Page 160: ...onmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info If you clean the vehicle regularly its value and appearance will be maintained over a long period Avoid direct sunshine on the vehicle during cleaning Info Do not place the vehicle onto the rear frame bracket to clean it...

Page 161: ... Reduced braking efficiency due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning take a short ride until the engine reaches operating temperature Info The heat produced causes water at inaccessible locations in the engine and the brakes to evaporate Push back the protection caps from the handlebar controls to allow any water that may have entered ...

Page 162: ...CLEANING CARE 160 Treat all plastic parts and powder coated parts with a mild cleaning and care product Paint cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces p 188 ...

Page 163: ...the vehicle for a longer period take the following actions Before storing the vehicle check all parts for function and wear If service repairs or replacements are necessary these should be done during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season 401387 01 Clean the vehicle p 158 Change the engine oil and oil filter c...

Page 164: ...sing corrosion Avoid running the engine of a vehicle in storage for a short time only Because the engine will not warm up sufficiently the water vapor produced during com bustion will condense causing engine parts and the exhaust system to rust 18 2 Preparing the vehicle for use after storage 401388 01 Recharge the battery x p 130 Install the battery p 130 Fill up with fuel p 43 Perform checks and...

Page 165: ...ctrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 0 7 mm 0 028 in Fault in ignition system Check the ignition system x Socket connector of CDI control device pulse generator or ignition coil oxidized Clean the plug in connector and treat it with con tact spray Water in carburetor or jets blocked Check adjust the carburetor components x Idle spee...

Page 166: ...133 The engine cannot be cranked electric starter Operating error Follow the instructions on starting the engine p 32 Battery discharged Recharge the battery x p 130 Check the charging voltage x Check the quiescent current x Check the alternator x Blown fuse Change the main fuse p 132 Engine does not speed up Carburetor running over because float needle dirty or worn Check adjust the carburetor co...

Page 167: ...nnector Check the electrical system Clean the plug in connector and treat it with con tact spray Engine overheats Coolant level low Check the cooling system for leakage Check the coolant level p 138 Radiator fins excessively dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 139 Fill coolant bleed the cooling system x p 140 Bent radiator hose Change the radiator hose ...

Page 168: ... too little Adjust the valve clearance x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 150 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x p 151 Piston or cylinder worn Piston cylinder determine the mounting clear ance x Battery discharged B...

Page 169: ... mm 1 248 in Valve clearance cold intake 0 07 0 13 mm 0 0028 0 0051 in Valve clearance cold exhaust 0 12 0 18 mm 0 0047 0 0071 in Crankshaft bearing 2 cylinder roller bearing Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmi...

Page 170: ...ark plug electrode gap 0 7 mm 0 028 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 20 1 Capacity engine oil Engine oil 2 00 l 2 11 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 183 External temperature 0 C 32 F Engine oil SAE 5W 40 p 183 20 2 Capacity coolant Coolant 1 50 l 1 59 qt Coolant p 182 Coolant mixed ready to use p 182 ...

Page 171: ... Loctite 243 Screw ignition pulse generator adapter M5 6 Nm 4 4 lbf ft Loctite 243 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator bracket M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator cable holder M5 6 Nm 4 4 lbf ft Loctite 243 Screw timing train axle retaining bracket M5 6 Nm 4 4 lbf ft Lo...

Page 172: ...m 5 9 lbf ft Screw water pump cover M6 10 Nm 7 4 lbf ft Stud cylinder head M6 10 Nm 7 4 lbf ft Screw camshaft bearing bridge M7x1 14 Nm 10 3 lbf ft Lubricated with engine oil Screw clutch cover M7x1 14 Nm 10 3 lbf ft Screw engine case M7x1 14 Nm 10 3 lbf ft Plug crankshaft location M8 20 Nm 14 8 lbf ft Screw engine sprocket M10 60 Nm 44 3 lbf ft Loctite 2701 Spark plug M10 10 12 Nm 7 4 8 9 lbf ft ...

Page 173: ... 14 8 lbf ft Axle guide rail for timing chain M14x1 15 Nm 11 1 lbf ft Axle tension rail for timing chain M14x1 15 Nm 11 1 lbf ft Nut compensating sprocket M14x1 20 Nm 14 8 lbf ft Loctite 243 Oil suction pipe M14x1 15 Nm 11 1 lbf ft Loctite 243 Oil pressure regulator valve plug M14x1 5 18 Nm 13 3 lbf ft Nut inner clutch hub M18x1 5 80 Nm 59 lbf ft Loctite 243 Plug timing chain tensioner M24x1 5 25 ...

Page 174: ...tion number 4125L Needle position 3 th position from top Idle mixture adjusting screw Open 1 5 turns Pump membrane stop 2 15 mm 0 0846 in Hot start button Diameter of bore in carburetor body 2 5 mm 0 098 in Main jet 175 Jet needle OBEKR Idling jet 42 Idle air jet 100 Cold start jet 85 ...

Page 175: ... Front 244 mm 9 61 in Rear 258 mm 10 16 in Fork offset Front 50 mm 1 97 in Toe Front 0 mm 0 in Camber Front 0 Toe width Front 1 265 mm 49 8 in Rear narrow 1 265 mm 49 8 in Rear wide 1 341 mm 52 8 in Wheelbase 1 280 10 mm 50 39 0 39 in Turning radius 5 685 mm 223 82 in Fording depth 305 mm 12 01 in Seat height unloaded 795 mm 31 3 in Ground clearance unloaded 265 mm 10 43 in Weight Fuel tank empty ...

Page 176: ...t 1 100 mm 43 31 in Brake system Front Disc brakes brake calipers fixed 4 brake pistons per brake caliper Rear Disc brake brake caliper floating 1 brake piston Brake discs diameter Front 180 mm 7 09 in Rear 200 mm 7 87 in Brake discs wear limit Front 3 5 mm 0 138 in Rear 3 5 mm 0 138 in Tire air pressure off road 0 3 bar 4 psi Rim Front 5x10 DWT Al 6061 Rear 8x8 DWT Al 6061 Rear wheel gearing 14 3...

Page 177: ...enance free 23 1 Tires Front tire Rear tire 20 x 6 00 10 DWT MXF V2 202 18 x 10 00 8 DWT MXR V1 202 Additional information is available in the Service section under http www ktm com 23 2 Capacity fuel Total fuel tank capacity approx 10 3 l 2 72 US gal Super unleaded ROZ 95 RON 95 PON 91 p 185 ...

Page 178: ...icks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 12 clicks Cross over 19 1 5 mm 0 75 0 059 in Spring preload Comfort 3 mm 0 12 in Standard 5 mm 0 2 in Sport 8 mm 0 31 in Spring rate main spring Weight of rider 64 75 kg 141 165 lb 21 26 N mm 120 148 lb in Weight of rider 75 85 kg 165 187 lb 24 29 N mm 137 166 lb in Weight of rider 85 95 kg 187 209 lb 27 32 N mm 154 183 lb in Spring r...

Page 179: ...CHNICAL DATA FRONT SHOCK ABSORBER 177 Spring length auxiliary spring 60 mm 2 36 in Fitted length 463 mm 18 23 in Gas pressure 10 bar 145 psi Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 184 ...

Page 180: ...icks Sport 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Cross over 19 1 5 mm 0 75 0 059 in Spring preload Comfort 3 mm 0 12 in Standard 5 mm 0 2 in Sport 3 mm 0 12 in Spring rate main spring Rider weight 65 75 kg 143 165 lb 70 N mm 400 lb in Rider weight 75 85 kg 165 187 lb 74 N mm 423 lb in Rider weight 85 95 kg 187 209 lb 78 N mm 445 lb in Spring rate auxiliary ...

Page 181: ...HNICAL DATA REAR SHOCK ABSORBER 179 Spring length auxiliary spring 55 mm 2 17 in Fitted length 440 5 mm 17 342 in Gas pressure 10 bar 145 psi Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 184 ...

Page 182: ...M8 20 Nm 14 8 lbf ft Loctite 243 Screw front brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw rear brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw rear wheel eccentric element M8 20 Nm 14 8 lbf ft Screw steering bridge M8 20 Nm 14 8 lbf ft Screw subframe M8 35 Nm 25 8 lbf ft Loctite 243 Engine b...

Page 183: ...6 lbf ft Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Screw rear top shock absorber M12 60 Nm 44 3 lbf ft Lock nut tie rod inside M12LHx1 25 20 Nm 14 8 lbf ft Lock nut tie rod outside M12x1 25 20 Nm 14 8 lbf ft Nut A arm top M12x1 25 30 Nm 22 1 lbf ft Nut ball head A arm bottom M12x1 5 40 Nm 29 5 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel hub M18x1 5 130 Nm 95 9 ...

Page 184: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 185: ...corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 5W 40 According to JASO T903 MA p 189 SAE p 189 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier M...

Page 186: ...ic Fluid 75 Long life grease According to NLGI Guideline Use only grease that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Fett 2000 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 189 SAE 2 5 Guideline Use only oils that comply with the specified standards see spe...

Page 187: ...95 RON 95 PON 91 Guideline Only use unleaded super fuel that matches or is equivalent to the specified fuel grade Fuel with an ethanol content of up to 10 E10 fuel is safe to use Info Do not use fuel containing methanol e g M15 M85 M100 or more than 10 ethanol e g E15 E25 E85 E100 ...

Page 188: ... Remover Chain cleaner Guideline KTM recommends Motorex products Supplier Motorex Chain Clean Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine Long life grease Guideline KTM recommends Motorex products Supplier Motorex Bike Grease 2000 ...

Page 189: ...Medium Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chainlube Offroad Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power ...

Page 190: ... cleaner and polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Rubber grip adhesive 00062030051 Supplier KTM Sportmotorcycle AG GRIP GLUE ...

Page 191: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 192: ...nt brake checking 107 Brake fluid of front brake topping up 108 Brake fluid of rear brake checking 116 topping up 117 Brake linings of front brake changing 112 checking 109 installing 111 removing 110 Brake linings of rear brake changing 123 checking 119 installing 121 removing 120 Brakes 105 124 C Camber adjusting 86 checking 86 Carburetor adjusting idle 144 float chamber emptying 146 idle 144 Ch...

Page 193: ...29 135 Emergency OFF switch with rip cord 21 Engine running in 29 switching off 41 Engine guard installing 104 removing 103 Engine number 17 Engine oil adding 156 changing 151 draining 151 refilling 155 Engine oil level checking 150 Engine sprocket checking 94 Environment 10 F Fender rear installing 74 removing 73 Filler cap closing 23 opening 22 Filling up fuel 43 Foot brake lever 26 basic positi...

Page 194: ...hanging fuses of individual power consumers 133 main fuse changing 132 H Hand brake lever 20 basic position adjusting 105 free travel checking 105 Handlebar position 63 adjusting 64 Hot start lever 19 I Ignition curve changing 148 plug connection 147 K Kill switch 21 M Main fuse changing 132 Maintenance work on the engine 150 157 O Oil filter changing 151 installing 154 removing 152 Oil screen cle...

Page 195: ...ocket checking 94 Rear wheel eccentric element greasing 101 Rider training 9 Riding bends 36 brakes 34 downhill 37 engine switching off 41 general information 35 perpendicular to the slope 39 riding through water 40 starting off 33 stopping parking 42 turning on slopes 39 uphill 38 Rubber grip checking 101 securing 102 S Seat mounting 78 removing 78 Service 8 Shift lever basic position adjusting 1...

Page 196: ... 178 179 Throttle lever 142 Tire air pressure checking 128 Tire condition checking 127 Toe adjusting 84 checking 82 rear toe width adjusting 90 Toe width of rear axle 89 Transport 10 Troubleshooting 163 166 Tuning the engine 142 149 Type label 16 U Use definition 8 V Vehicle cleaning 158 lifting gear raising with 67 lifting gear removing from 67 W Warranty 8 Wheel wheels installing 126 removing 12...

Page 197: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 08 2011 Photo Mitterbauer 3211728en 3211728en ...

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KTM 2012 505 SX, Owner'S Manual

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