KTM 400 LS-E/MIL Owner'S Manual Download Page 1

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KTM-Sportmotorcycle AG

A–5230 Mattighofen

www.ktm.at

KTM Group Partner

12/2003 FOTO: MITTERBAUER

400 LS-E/mil

ART.NR: 3.211.23-E

OWNER´S

MANUAL

2004

Summary of Contents for 400 LS-E/MIL

Page 1: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 12 2003 FOTO MITTERBAUER 400 LS E mil ART NR 3 211 23 E OWNER SMANUAL2004 ...

Page 2: ...E DANGEROUS TO LIFE AND LIMB CAUTION FAILING TO OBSERVE THESE INSTRUCTIONS MAY DAMAGE THE MOTORCYCLE OR IMPAIR ITS TRAFFIC SAFETY Please fill in the vehicle s serial numbers below Chassis number Engine number Dealer s stamp KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY OR CANCEL EQUIPMENT TECHNICAL INFORMATION COLORS MATERIAL SERVICE OFFERS SERVICES ETC WITHOUT NOTICE AND WITHOUT STATING REA...

Page 3: ...t technical skills and will be able to ser vice the motorcycle as described in this manual yourself If not please note that you should have the work marked with an asterisk in the chapter Maintenance of the chassis and engine performed by an authorized KTM workshop also in the interest of your own safety For your safety only use spare parts and accessories approved by KTM KTM shall not assume any ...

Page 4: ...ubricating the shock absorber linking 20 Checking the chain tension 21 Correcting the chain tension 21 Chain care 22 Chain wear 22 General information on KTM disk brakes 23 Changing the basic setting of the hand brake lever 23 Checking the front brake fluid level 24 Refilling the front brake fluid 24 Checking the front brake pads 24 Changing the basic setting the foot brake lever 24 Checking the r...

Page 5: ...ance Work Hand brake lever The hand brake lever 3 is located on the right side of the handlebar and actuates the front brake The basic setting of the hand brake lever can be changed with adjusting screw B see Maintenance Work Hand decompression lever The hand decompression lever 2 is only used in 2 exceptional cases a When the engine is flooded Sometimes the starter engine won t switch on again be...

Page 6: ...ture will light up when the cooling liquid reaches a temperature of 105 C Starter pushbutton emergency off switch light switch The emergency off switch 4 is designed for emergency situations and should not be used to switch off the engine The engine is ready for operation in the position ignition circuit and starter circuit are switched on The engine cannot be started in the position ignition circ...

Page 7: ... for the camouflage light The camouflage light parking light lamp in the headlight and taillight is turned on with the pull switch 5 Filler cap The filler cap 7 is lockable and equipped with a tank vent system To open insert the ignition key turn 90 in a counterclockwise direction and lift off the filler cap To lock mount the filler cap turn the ignition key 90 in a clockwise direction and pull of...

Page 8: ... twist grip is moved into the RES position Refuel as soon as possible and remember to turn the twist grip back into the ON position to ensure you will have reserve fuel next time Shift lever The shift lever is mounted on the left side of the engine The position of the gears is shown in the illustration The neutral or idle position is between 1st and 2nd gear Foot brake pedal The foot brake pedal i...

Page 9: ...wise direction Turn back the number of clicks corresponding to the fork type in a coun terclockwise direction WP 0518Y739 12 clicks Compression damping of the shock absorber The compression damping rate can be adjusted 7 fold with the adjusting control button 3 Turning in a counterclockwise direction will increase the damping turning in a clockwise direction will decrease the compression damping S...

Page 10: ...stment screw approx 3 turns in a clockwise direction for a maximum overall load 232 kg Headlight mask A rubber headlight mask is located in the tank bag for camouflage operation Attach the headlight mask to the two steel nipples 2 with the eye 3 on the adjustment screw for the headlight range Tank bag The tank bag can accommodate a first aid kit maps etc The tightening belts are fastened to the le...

Page 11: ...e insert the rear in the lock plate 3 attach the hook 2 and fold down the clip 1 After unlocking the retaining locks and unlatching pull the top case back from the frame When mounting make sure the front and bottom of the top case latch in position on the frame Maximum trunk load Left trunk 10 kg Right trunk 10 kg Top case 5 kg Make sure to distribute your luggage evenly among the trunks WARNING N...

Page 12: ...UNKS SPARE TANKS ETC CAN ALSO HAVE AN ADVERSE EFFECT ON DRIVING BEHAVIOR ALWAYS USE FRONT AND REAR TIRES WITH THE SAME TREAD PATTERN NEW TIRES HAVE A SMOOTH SURFACE AND WILL NOT HAVE FULL ADHESION THE ENTIRE TIRE TREAD NEEDS TO BE GROUND DURING THE FIRST 200 KILOMETERS OF CONSTANT DRIVING IN ALTERNATING BANKING POSITIONS FULL TIRE ADHESION WILL BE ACHIEVED WHEN THE BIKE IS BROKEN IN DRIVE THE FIRS...

Page 13: ...rect tire pressure will have an adverse effect on driving behavior 5 BRAKES Check the brakes for proper functioning and check the brake fluid level in the reservoir The reservoirs are designed not to require refilling even if the brake pads are worn If the brake fluid level drops below the mini mum amount this will indicate a leak in the brake system or completely worn brake pads Have the brake sy...

Page 14: ...scribed in the chapter Troubleshooting or visit an authorized KTM workshop IF THE ENGINE STARTS BUT DOES NOT SWITCH ON WHEN YOU PRESS THE STARTER PUSHBUTTON CHECK WHETHER the fuel tap is open you actuated the choke lever there is enough fuel in the tank If not refuel If so proceed as described in the chapter Troubleshooting or visit an authorized KTM workshop NOTE This motorcycle is equipped with ...

Page 15: ...p accelerating pull the clutch lever while engaging the next gear release the clutch lever and accelerate If the choke was actuated turn it off when the engine is warm After reaching the maximum speed by completely opening the throttle turn in back to 3 4 gas the speed will hardly be redu ced but fuel consumption will significantly decrease Always give as much gas as the engine can use a brusque o...

Page 16: ...e for 80 90 octane ROZ see activating the ignition curve for low octane fuel WARNING FUEL IS HIGHLY INFLAMMABLE AND TOXIC USE EXTREME CAUTION WHEN HANDLING FUEL DO NOT REFUEL YOUR MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARET TES ALWAYS SWITCH OFF THE ENGINE TO REFUEL BE CAREFUL NOT TO SPILL ANY FUEL ON THE ENGINE OR EXHAUST PIPE AS LONG AS THE BIKE IS HOT IMMEDIATELY WIPE UP ANY SPILLED FUEL IMM...

Page 17: ...t turn signal indicator lamps speedometer illumination horn emergency OFF switch grip heater socket Check screws and nuts for a tight fit Check the brake fluid level lining thickness and brake disks Check the brake lines for damage and tightness Check adjust the function smooth operation free travel of the hand foot brake lever Check the screws on the brake system for a tight fit Check the shock a...

Page 18: ...Check all control elements for smooth operation Check the brake performance Treat exposed metal components except brake and exhaust systems with wax based anti corrosion agents Treat ignition steering lock and light switch with contact spray Regularly check all screws nuts and clamps for a tight fit At least once a year After offroad use After cleaning Before each start LUBRICATION AND MAINTENANCE...

Page 19: ...LOOSE ALWAYS USE SELF LOCKING NUTS LET THE MOTORCYCLE COOL DOWN BEFORE SERVICING TO AVOID BEING BURNED PROPERLY DISPOSE OF OILS GREASE FILTERS FUEL CLEANSERS ETC OBSERVE THE REGULATIONS EFFECTIVE IN YOUR COUNTRY NEVER POUR USED OIL IN THE SEWER OR DISPOSE OF IT OUTDOORS 1 LITER OF USED OIL WILL POLLUTE 1 000 000 LITERS OF WATER REPLACE ANY SELF LOCKING NUTS YOU REMOVED IF YOU REMOVE ANY SCREWS OR ...

Page 20: ...rs of competitive driving unscrew the bleeder screws 3 several turns to allow any overpressure to escape from the forks To bleed jack up the motorcycle until the front wheel no longer touches the ground If the motorcycle is primarily used on the road this work can be performed during the periodical vehicle service CAUTION EXCESSIVE PRESSURE IN THE FORKS CAN ALSO CAUSE THE FORK TO LEAK IF YOUR FORK...

Page 21: ... Checking the rubber ring the WP shock absorber A vibration absorber is mounted on the shock absorber as a rubber ring This rubber ring is compressed with time and the damping action reduced accordingly Measure the gap width between the two disks at several points on the periphery The gap width must be at least 2 5 mm Have the rubber ring replaced at an authorized KTM workshop if it has reached th...

Page 22: ...AR SPROCKET CARRIER IN ADDITION TO PREMATURE WEAR IT COULD CAUSE THE CHAIN TO TEAR IF THE CHAIN IS TOO LOOSE IT CAN FALL OFF THE REAR SPROCKETS AND BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE IN BOTH CASES THE MOTORCYCLE CAN EASILY GO OUT OF CONTROL Correcting the chain tension Loosen the collar nut 1 loosen the counternuts 2 and turn the left and right adjustment screws 3 the same distance Tighten ...

Page 23: ...N MOUNTING THE CHAIN JOINT MAKE SURE THE LOCKING MEMBER ALWAYS RUNS IN THE DIRECTION OF TRAVEL Rear sprockets and chain guides should also be checked for wear at this time and replaced if necessary Chain wear To check for chain wear proceed as follows Switch the transmission to idle and pull the upper part of the chain up with a load of 10 15 km see illustration Now measure the distance between 18...

Page 24: ...mmediately BRAKE FLUID KTM fills DOT 5 1 one of the highest grade commercial brake fluids availa ble into the brake system We recommend that you continue to use this brake fluid DOT 5 1 brake fluid is based on glyco ether and has an amber color If DOT 5 1 is not available you can also use DOT 4 brake fluid Never use DOT 5 brake fluid It is based on silicone oil and has a purple color The gaskets a...

Page 25: ...ness should not be less than 1 mm WARNING THE LINING ON THE BRAKE PADS MAY NOT BE LESS THAN 1 MM THICK AT THE WEAKEST POINT 1 OTHERWISE THE BRAKES MAY FAIL FOR YOUR OWN SAFETY HAVE THE BRAKE PADS REPLACED IN TIME CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE WHEN THE LINING IS PARTLY OR COMPLE TELY WORN OFF THE STEEL PARTS ON THE BRAKE PADS WILL GRIND AGAINST THE BRAKE DISKS THIS SIGNIFICANTLY D...

Page 26: ...ER USE DOT 5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND HAS A PURPLE COLOR THE GASKETS AND BRAKE HOSES ARE NOT DESIGNED FOR THIS TYPE OF BRAKE FLUID KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATIONS AVOID COMING INTO CONTACT WITH THE SKIN OR EYES IF BRAKE FLUID SPLASHES INTO YOUR EYES RINSE THOROUGHLY WITH WATER AND CONSULT A DOCTOR CAUTION MAKE SURE NO BRAKE FL...

Page 27: ...e the driving tabs 7 engage in the slots in the drive Position the front wheel and speedometer drive and mount the wheel spindle The speedometer cable must run along the outside of the fork protector and in front of the triple clamp to the speedometer Mount the collar nut 1 leading the speedometer cable upwards parallel to the fork leg see below Tighten the clamp screws 2 on the right fork leg to ...

Page 28: ...ORQUES COR RECTED BY AN AUTHORIZED KTM WORKSHOP AS SOON AS POSSIBLE A LOOSE WHEEL SPINDLE CAN CAUSE THE MOTORCYCLE S HANDLING PERFORMANCE TO BECOME INSTABLE AFTER MOUNTING THE REAR WHEEL ALWAYS APPLY THE FOOT BRAKE UNTIL YOU FEEL THE PRESSURE POINT KEEP THE BRAKE DISK FREE OF OIL AND GREASE OTHERWISE THE BRAKING EFFECT WILL BE SIGNIFICANTLY IMPAIRED To check for wear place the rear wheel on the wo...

Page 29: ...ES CAN HAVE A NEGATIVE INFLUENCE ON THE MOTORCYCLE S HANDLING PERFORMANCE ALWAYS USE THE SAME TYPE AND BRAND OF TIRE FOR THE FRONT AND REAR WHEEL FOR YOUR OWN SAFETY IMMEDIATELY REPLACE ANY DAMAGED TIRES BALD TIRES ARE ESPECIALLY DANGEROUS ON WET ROADS UNDERINFLATED TIRES WILL RESULT IN EXCESSIVE WEAR AND CAUSE THE TIRE TO OVERHEAT NEW TIRES HAVE A SMOOTH SURFACE AND WILL NOT HAVE FULL ADHESION TH...

Page 30: ... microprocessor Connect the device to the socket next to the speedometer see chapter Socket and to the power supply system 230V The device will perform a self test as soon as it is connected to the power supply system It is ready to operate when all of the LEDs light up for approx 2 seconds Connecting an accumulator with at least 3 5V residual voltage will start the charging procedure A test is pe...

Page 31: ...The following power consumers are protected by fuse 1 10 amperes Headlight lamp Parking light lamp License plate illumination The following power consumers are protected by fuse 2 10 amperes Parking light Turn signal Brake light Horn Headlight flasher The following power consumers are protected by fuse 3 10 amperes Ignition Electric starter system Fan The following power consumers are protected by...

Page 32: ...ETTLE ON THE REFLECTOR Attach the retaining clip mount the rubber cap and attach the plug to the light bulb Mount the headlight mask Position the headlight mask so that the headlight lamp is under the cockpit Press down the fender in the front pull up the headlight mask and insert the retaining pins 5 in the recess of the fender Mount the screws 1 Replacing the parking lamp Remove the headlight ma...

Page 33: ...TROL Make a mark on a light colored wall behind a horizontal surface 5 cm below the center distance between the headlights Position your motorcycle 5 meters from the wall in a fully loaded condition baggage driver passen ger and switch on the night lights The light dark boundary should be at the mark STANDARD SETTING Driver with baggage approx 105 kg Turn the adjustment screw in a coun terclockwis...

Page 34: ...C OIL WITH MINERAL OIL NEVER ADD MINERAL HYDRAULIC OIL OR BRAKE FLUID Checking the setting of the hand decompression cable Set the piston to compression to close the valves by slowly actuating the kickstarter until you hear the automatic decompression click disengage You should be able to actuate the decompression lever 10 mm until you feel resistance the exhaust valves will start to open To adjus...

Page 35: ...l increase the idle speed turning in a counterclockwise direction will reduce the idle speed The idle speed should be between 1400 1500 rpm Draining the float chamber in the carburetor The float chamber in the carburetor should be drained after every wet wash to remove any penetrating water Water in the float chamber will cause the engine to malfunction This work should be performed when the engin...

Page 36: ...TEM CONTACT AN AUTHORI ZED KTM WORKSHOP AS SOON AS POSSIBLE TO HAVE THE ERROR ELIMINATED YOU WILL DAMAGE THE ENGINE IF YOU CONTINUE TO DRIVE WHEN THE COOLING LIQUID TEMPERATURE WARNING LAMP IS ON THE FAN IN THE LEFT RADIATOR IS NOT RUNNING THE FAN SHOULD RUN FROM A COOLING LIQUID TEMPERATURE OF 105 C WHENE VER THE ENGINE IS RUNNING IF THE FAN IS NOT RUNNING AND YOU HAVE ENOUGH COOLING LIQUID YOU C...

Page 37: ...g sure it is centered and fix with the wing screw Mount the filter box cover and tighten the screw on the side cover Checking the engine oil level You can check the engine oil level when the engine is cold or warm Place the motorcycle on a level surface on the main stand You should be able to see the engine oil at the lower edge of the inspection glass A when the engine is cold The engine oil shou...

Page 38: ... bearing positi ons in the engine will not be adequately lubricated and can lead to engine damage We therefore recommend having the oil changed at an authorized KTM workshop The oil change must be performed by an authorized KTM workshop during the warranty period otherwise the warranty will become null and void Change the engine oil when the engine is at an operating temperature WARNING THE ENGINE...

Page 39: ... oil if necessary CAUTION NOT ENOUGH ENGINE OIL OR LOW GRADE ENGINE OIL WILL CAUSES PREMATURE ENGINE WEAR CHECKING THE OIL WHEN THE ENGINE IS COLD WILL NOT SHOW THE CORRECT OIL LEVEL ON THE DIP STICK DO NOT EXCEED THE MAXIMUM LEVEL DO NOT ALLOW TO DROP BELOW THE MINIMUM LEVEL When you are finished check the entire oil system and engine for leaks Mount the fine filter cover on the frame breast pipe...

Page 40: ... 16 18 1 21 510 12 022 100 FORK WRENCH A F 13 17 1 ITEM PART NO DESCRIPTION PCS 22 510 12 023 100 FORK WRENCH A F 10 13 1 23 510 12 023 000 FORK WRENCH A F 8 10 1 24 530 12 024 100 SCREWDRIVER L 105MM 1 28 530 12 028 000 UNIVERSAL PLIERS 1 66 503 10 266 000 CHAIN JOINT 5 8X1 4 X RING 1 70 503 29 070 000 T WRENCH A F 6 8 10 1 71 503 29 071 000 WRENCH A F 13 1 80 503 29 080 000 UNIVERSAL WRENCH A F ...

Page 41: ...ergency off tip switch visit a workshop Replace the fuse 3 Remove the seat and replace the main fuse If the fuse blows again visit a workshop Visit a workshop Visit a workshop Open the fuel tap refuel do not actuate the choke follow the starting instructions see Driving Instructions Inflammable constituents in modern fuels volatilize if left stan ding over longer periods of time If the motorcycle ...

Page 42: ...retor and clean the jets Have the carburetor adjusted Replace the spark plug Have the ignition system checked Disassemble the carburetor clean and check for wear Replace the float needle valve Replace the float Adjust the choke cable Replace the diaphragm Check the vacuum hoses and vent hoses on the carburetor for a tight fit and kink free installation Tighten the jets Have the ignition system che...

Page 43: ...rator Battery charge maintainer is not working because the fuse is blown REMEDY Run the vent hose without kinks or replace Check the oil level with the engine at operating temperature and correct if necessary Use thicker engine oil See the Engine Oil chapter Remove the seat and replace the main fuse If it blows again visit an authorized workshop Charge the battery and determine the cause for disch...

Page 44: ...orcycle is to be immobilized for a longer period of time proceed as follows Clean the motorcycle thoroughly see the chapter CLEANING Change the engine oil the oil filter and the fine filter old engine oil contains aggressive impurities Check the quantity of antifreeze and cooling liquid Allow the engine to warm up close the fuel tap and wait until the engine stalls Open the drain plug on the float...

Page 45: ...60 55 W Sockel P43t Parking light 12V 5W base W2 1x9 5d Instrument lights 12V 1 2W base W2x4 6d Indicator lamps 12V 1 2W base W2x4 6d Rear brake light 12V 21 5W base BaY15d Turn signal 12V 10W base Ba15s License plate illumination 12V 5W base W2 1x9 5d Grip heater connected 2 phase Battery maintenance free 12V 11Ah Steering head angle 62 5 Wheel base 1480 10 mm Seat height unloaded 890 mm Ground c...

Page 46: ...h Gear ratio 1st gear 14 35 2nd gear 15 24 3rd gear 18 21 4th gear 20 19 5th gear 22 18 Ignition system breakerless transistorized DC CDI ignition system with digital ignition advance type KOKUSAN Ignition point adjustment to max 37 from TDC at 6000 rpm Generator 12V 200W Spark plug NGK DPR 8 EA9 Electrode distance 0 9 mm Cooling system liquid cooled permanent circulation of cooling liquid through...

Page 47: ...octite 243 20 Nm HH screw for handlebar mount dampened M10 Loctite 243 20 Nm Rim lock M8 5 Nm Steering stem clamping M8 20 Nm Subframe M8 Loctite 243 35 Nm Spoke nipple 4 Nm Screw to adjust the spring preload on the shock absorber M6 8 Nm Other chassis screws M6 10 Nm M8 25 Nm M10 45 Nm Other collar nuts on chassis M6 15 Nm M8 30 Nm M10 50 Nm TIGHTENING TORQUES CHASSIS COMPARISON OF AUTOMOTIVE FLU...

Page 48: ...C E bu wh ye r b u p l b l b n g u p r e h s a l f t n o r f t h g i r bl wh h c t i w s e r u t a r e p m e t G h c t i w s m a e b w o l h g i h h c t i w s n r o h h c t i w s r e h s a l f r o t i c a p a c t e k c o s r b r b h c t i w s l a r t u e n br headlight t h g i l g n i k r a p M o t a l u g e r r e i f i t c e r r M n a f g n i l o o c bu bl gn re gn br 400 LS E mil 2004 gn bl wh y...

Page 49: ...ng and mounting the front wheel 26 Dismounting and mounting the rear wheel 27 Draining the float chamber in the carburetor 34 Driving instructions 12 Driving off 14 Engine number engine type 4 Engine oil 36 Filler cap 6 Foot brake pedal 7 Fuel tap 7 Fuel refueling 15 Fuses for individual power consumers 30 General information on KTM disk brakes 23 Grab handle 10 Hand break lever 4 Hxand decompress...

Page 50: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner 12 2003 FOTO MITTERBAUER 400 LS E mil ART NR 3 211 23 E OWNER SMANUAL2004 ...

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