KTM 450 SX 2009 Owner'S Manual Download

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MAINTENANCE ON CHASSIS AND ENGINE

118

9.48

Removing rear brake linings

Warning

Danger of accidents

Improper brake maintenance and repair.

–

Always have your brake system maintained and repaired in an authorized KTM workshop.

100063-10

–

Press the brake caliper by hand on to the brake disc in order to press back the brake
piston.

100064-10

–

Loosen the screw



while holding the hexagonal head



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.

Summary of Contents for 450 SX 2009

Page 1: ...OWNER S MANUAL 2009 450 SX ATV 505 SX ATV ART NO 3211378en ...

Page 2: ......

Page 3: ...ations resulting from continuing devel opment and design can however not be completely excluded All 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 pr...

Page 4: ...d only with the express written permission of the copyright owner ISO 9001 12 100 6061 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: ...tor lamp overview 35 Emergency OFF switch with rip cord 35 Opening filler cap 36 Closing filler cap 36 Fuel tap 37 Choke 38 Shift lever 38 Foot brake pedal 39 TIPS ON PUTTING INTO OPERATION 40 Advice on first use 40 Running in the engine 43 RIDING INSTRUCTIONS 44 Checks before putting into operation 44 Starting 45 Starting up 47 Shifting 47 Braking 48 Riding 49 Riding in bends 49 Riding downhill 5...

Page 6: ...dth of rear axle 88 Adjusting the toe width of the rear axle x 89 Handlebar position 91 Adjusting the handlebar position x 92 Checking play in gas Bowden cable 94 Adjusting play in gas Bowden cable 95 Checking chain dirt 96 Cleaning the chain 96 Checking the chain tension 97 Checking rear sprocket engine sprocket for wear 98 Checking chain wear 98 Adjusting chain tension 100 Greasing the rear whee...

Page 7: ...Checking the fluid level of the hydraulic clutch 148 Cooling system 148 Radiator fan 149 Checking the antifreeze and coolant level 149 Checking the coolant level 150 Draining coolant x 151 Filling coolant bleeding the cooling system x 153 Carburetor idle 155 Carburetor adjusting the idle speed x 155 Emptying the carburetor float chamber x 157 Checking engine oil level 158 Changing the engine oil a...

Page 8: ... 6 Capacity fuel 183 TECHNICAL DATA FRONT SHOCK ABSORBER 184 TECHNICAL DATA REAR SHOCK ABSORBER 186 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 188 SUBSTANCES 190 AUXILIARY SUBSTANCES 194 STANDARDS 197 INDEX 198 ...

Page 9: ...understanding In the interest of your own safety have these jobs done in 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 in the following Specific name Identifies ...

Page 10: ...vention of wear is that the engine and chassis maintenance and adjustment work described in the owner s manual are properly carried out Poor adjustment and tuning of the engine and chassis can lead to damage and breakage of components Using the vehicle in extreme conditions such as very muddy or wet terrain can lead to above average wear of components such as the transmission train or the brakes F...

Page 11: ...s running Do not place the vehicle where there are flammable or explosive substances Switch off the engine Turn handle of the fuel tap to the OFF position Figure 800052 10 p 37 Use straps or other suitable devices to secure the vehicle against accidents or falling over Pull handbrake lever push the locking pawl downwards and release the handbrake lever Figure 100006 10 p 30 Work rules When assembl...

Page 12: ...and conflicts do not have to occur To protect the future of offroad sport make sure that you use your ATV legally display environ mental consciousness and respect the rights of others Rider training If you have never ridden an ATV before it is important that you participate in a driver training course before you ride the vehicle for the first time A professional trainer will show you how to handle...

Page 13: ...IMPORTANT NOTES 11 ...

Page 14: ...IMPORTANT NOTES 12 2 1 Overview of labels 800043 10 ...

Page 15: ...1 Hangtag 2 Information on use 3 Emission control 450 SX ATV 3 Emission control 505 SX ATV 4 Warning label 5 Information on not riding as a passenger 6 Information on putting into operation 7 Information on chain tension ...

Page 16: ...IMPORTANT NOTES 14 700367 01 Hangtag ...

Page 17: ...IMPORTANT NOTES 15 700372 01 Information on use 800045 10 Emission control 450 SX ATV ...

Page 18: ...IMPORTANT NOTES 16 800044 10 Emission control 505 SX ATV ...

Page 19: ...IMPORTANT NOTES 17 700368 01 Warning label ...

Page 20: ...IMPORTANT NOTES 18 700370 01 Information on not riding as a passenger 700371 01 Information on putting into operation ...

Page 21: ...nings Be sure to pay attention to the notes and warnings given here Info Various notes and warning stickers are attached to the vehicle Do not remove any notes and warning stickers If they are missing you or others may not recognize dangers and may therefore be injured ...

Page 22: ...important that you read this owner s manual carefully and completely before making your first trip It contains a lot of information and tips to help you operate and handle your vehicle Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the vehicle The owne...

Page 23: ...21 ...

Page 24: ...VIEW OF VEHICLE 22 3 1 View of the vehicle from the left front example 800062 10 ...

Page 25: ...shock absorber 5 Steering damper holder steering damper is optional 6 Right hand brake caliper 7 Front left shock absorber 8 Outside brake disk guard 9 Shift lever 10 Left footrest 11 Heel protector 12 Emergency OFF switch with rip cord 13 Clutch lever 14 Hot start lever ...

Page 26: ...VIEW OF VEHICLE 24 3 2 View of the vehicle from the right rear example 800046 10 ...

Page 27: ...er button ENG STOP switch 2 Filler cap 3 Main silencer 4 Rear shock absorber 5 Rear sprocket with chain 6 Rear wheel eccentric element 7 Rear brake 8 Foot brake pedal 9 Manifold 10 Top A arm 11 Front right fender 12 Throttle lever 13 Ignition switch ...

Page 28: ...ssis number 800047 10 The chassis number is stamped on the right side of the frame in the vicinity of the upper control arm 4 2 Type label 800048 10 The type label is located on the frame tube on the right and left in front of the radiator ...

Page 29: ...0 The key number is indicated on the KEYCODECARD Info You need the key number to order a replacement key Keep the KEYCODECARD in a safe place 4 4 Engine number 800049 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 30: ...sorber part number front 800067 10 The shock absorber part number is stamped on the upper part of the shock absorber 4 6 Shock absorber part number rear 800068 10 The shock absorber part number is stamped on the upper part of the shock absorber ...

Page 31: ...rcuit 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 100005 10 Hot start lever 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...

Page 32: ...rking brake is combined with the handbrake lever so that the front wheels can be blocked to prevent the vehicle from rolling To actuate the parking brake pull the handbrake lever push the locking pawl down wards and release the handbrake lever Possible states Handbrake lever in basic position Front wheels not blocked Handbrake lever pulled and latched Front wheels blocked ...

Page 33: ...The light switch is fitted on the left side of the handlebar Possible states High beam on HI Light switch is turned upwards In this position the high beam and the tail light are switched on Low beam on LO Light switch is at the middle setting In this position the low beam and tail lights are switched on Lights off OFF Light switch is turned downwards In this position all lights are switched off ...

Page 34: ... In this position the low beam and tail lights are switched on Lights off Light switch has been turned down In this position all lights are switched off 5 7 ENG STOP switch 100030 10 The ENG STOP switch is fitted on the left side of the handlebar Possible states Ignition off OFF In this position the ignition circuit is interrupted a running engine stops and the engine cannot be started Ignition on...

Page 35: ...g engine stops and the engine cannot be started ENG STOP switch on The switch must be in this position to operate the vehicle the ignition circuit is closed 5 9 Electric starter button 100029 10 The START electric starter button is fitted on the left side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed In this position the electric starter...

Page 36: ...starter button is pressed In this position the electric starter is actuated 5 11 Ignition switch 800050 10 The ignition switch is located in the instrument support Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a standing engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started ...

Page 37: ...mergency OFF switch is mounted on the left in front of the fuel tank A rip cord is attached to clip It can be attached to the clothing of the rider by means of carabiner The emergency OFF switch shuts the engine off if the rider falls off the vehicle 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...

Page 38: ...nterclockwise and lift it free 5 15 Closing filler cap 100012 11 Replace the filler cap and turn clockwise until the release button locks in place Check the fuel tank breather to ensure it is properly seated If the fuel tank breather is at an angle or loose Correctly mount the fuel tank breather ...

Page 39: ...he fuel tank With tap handle 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 40: ...tra fuel This gives a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed in to the stop 5 18 Shift lever 800054 10 The shift lever is mounted on the left side of the engine ...

Page 41: ...ar positions can be seen in the photograph The neutral or idle position is between the first and second gears 5 19 Foot brake pedal 800055 10 The foot brake pedal is located in front of the right footrest and operates the rear wheel brake ...

Page 42: ...w 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 insufficient protective clothing increases the risk of injury Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing which must be in perfect cond...

Page 43: ...able riding behavior Do not exceed the maximum permitted 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 luggag...

Page 44: ...ion of the footbrake lever x p 113 Become accustomed to handling the vehicle on a suitable piece of land before making a longer trip Info When traveling offroad you should be accompanied by another person on another machine so that you can help each other Do not make any offroad trips that over stress your ability and experience Hold the handlebar firmly with both hands and keep your feet on the f...

Page 45: ... in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first 3 service hours 7 000 rpm maximum engine performance During the first 3 service hours 50 During the next 12 service hours 75 Avoid fully opening the throttle ...

Page 46: ...n tension p 97 Check the chain dirt accumulation p 96 Check the tire condition p 125 Check the tire air pressure p 125 Check the front brake fluid level p 105 Check the rear brake fluid level p 114 Check the front brake linings p 107 Check the rear brake linings p 117 Check brake system function Check that the rear hubs are tight Check that the footrests are tight Check the handlebar bridge bearin...

Page 47: ...e speeds Info If the engine is unwilling 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 Empt...

Page 48: ...nction and blocks the ignition current When the electric starter but ton is activated the electric starter turns over the engine but the engine does not start because there is no ignition spark Shift gear to neutral Condition The engine is cold Pull choke lever out as far as possible Condition The engine is hot Pull the hot start lever all the way out Pull the clutch lever Press the electric start...

Page 49: ...lock Do not change into a low gear at high engine speed The engine races and the rear wheels can block 800054 11 Condition When conditions allow incline road situation etc you can shift into a higher gear Release the throttle while simultaneously pulling the clutch lever shift into the next gear release the clutch and open the throttle Info The position of the 5 forward gears can be seen in the il...

Page 50: ... accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently Info Use the hand brake lever to activate the front brakes and the foot brake pedal to activate the rear brakes When braking release the throttle and apply the front and rear brakes at the same time Shift the transmission to lower gears according to the vehicle s speed Braking should...

Page 51: ...by fully opening the throttle close the throttle so it is 3 4 open This barely reduces vehicle speed but lowers fuel consumption considerably Always open the throttle only as much as the engine can handle abrupt pressure on the throttle increases fuel consumption Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent and longer slipping of the clutch This...

Page 52: ... 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 farther back you are sitting the more the vehicle has the tendency to move straight ahead The farther forward you shift your weight t...

Page 53: ...ide on a 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 everytime 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 Shift your body weight to the rear and ride caut...

Page 54: ...rface The 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 Shifting 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 sideways o...

Page 55: ...ount immediately to 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 should ...

Page 56: ...refully until you reach a location where you can turn it Control its speed using the front brake To turn the vehicle steer it to the side When doing so you should always stand on the uphill side and apply pressure to the footrest on the uphill side When the vehicle is standing perpendicular to the slope or slightly downhill activate the parking brake Mount the vehicle start the engine pull the clu...

Page 57: ...n enter into the engine through the air filter and cause engine damage Only ride through water if it reaches no higher than the upper edge of the footrest Before riding through water determine the depth and current of the water Ride slowly and negotiate around obstacles After riding through water dry the brakes by lightly activating both brakes until normal braking power is available again If the ...

Page 58: ... OFF switch with a rip cord Pull off clip Figure 100010 10 p 35 Info When the engine is switched off using the emergency OFF switch the power consuming components are not switched off All power consuming components that are switched on head lights tail light CDI etc continue consuming electricity This uses battery power and causes it to discharge 7 14 Stopping parking Warning Danger of burns Some ...

Page 59: ... switch Pull handbrake lever push the locking pawl downwards and release the handbrake lever Figure 100006 10 p 30 The front wheels are blocked Turn handle of the fuel tap to the OFF position Figure 800052 10 p 37 Fuel no longer flows from the tank to the carburetor If the vehicle must be parked on an incline additionally secure the rear wheels against rolling see illustration 7 15 Refueling Dange...

Page 60: ...wallowed 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 ground water the ground or the sewage system 400287 10 Switch off the engine Open the filler cap p 36 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in ...

Page 61: ...kage Check vent hoses for damage and routing without sharp bends Check idle Attachments Check the cooling system for leaks Check the antifreeze and coolant level p 149 Check the exhaust system for leakage and looseness Check Bowden cables for damage smooth operation and routing without sharp bends Check the fluid level of the hydraulic clutch p 148 Clean the air filter x p 146 Check cables for dam...

Page 62: ...h operation Clean and grease bearing and sealing elements of steering column Check the handlebar for smooth operation and play Check the handlebar bridge bearing for excessive play Check tie rods and tie rod ends for damage and play Check front wheel suspension for wear and tightness Check that front and rear wheel hubs are tight Check the swingarm bearing Check the bearing of the rear axle for pl...

Page 63: ...nce work to be carried out by an authorized KTM workshop as additional job S10A S20A S40A J1A J2A Carry out a complete shock absorber service Treat electric contacts with contact spray Change hydraulic clutch fluid Change brake fluid Clean spark arrestor Check wear of clutch discs x Check long clutch springs x Check clutch slave cylinder for dents x Check outer clutch hub for dents x Check measure...

Page 64: ...e transmission x Check the shift mechanism x Check the spring length of the oil pressure regulator valve x Change glass fiber yarn filling of main silencer x Replace foot brake cylinder seals x Check set the carburetor components x S10A Every 10 service hours corresponds to about 70 liters of fuel after every race S20A Every 20 service hours corresponds to about 140 liters of fuel S40A Every 40 se...

Page 65: ...d adjust Bowden cables Clean the chain p 96 Check the chain tension p 97 Check the chain wear p 98 Check rear sprocket engine sprocket for wear p 98 Clean the air filter x p 146 Check the tire air pressure p 125 Check the tire condition p 125 Check the coolant level p 150 Check that all operating elements for smooth operation Check braking force incl parking brake Check all screws nuts and hose cl...

Page 66: ... vehicle on a firm and even surface Lower the vehicle Remove the work stand 9 3 Basic information on changing the chassis settings The standard setting of the chassis is the result of many fine tuning tests It is laid out for the weight of the average rider with a full set of protective clothing and for a sporty driving style Standard rider weight 70 80 kg 154 176 lb By making a variety of adjustm...

Page 67: ...ck absorber is able to regulate the compression damping separately in the low speed and high speed ranges Dual Compression Control The terms low speed and high speed refer to the motion of the shock absorber during compression and not to the road speed of the vehicle Modifications to the low speed setting also affects the high speed setting and vice versa 9 5 Front shock absorber adjusting the hig...

Page 68: ...onding to the shock absorber type Guideline Compression damping high speed Comfort 2 turns Standard 2 turns Sport 1 5 turns Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 6 Front shock absorber adjusting the low speed compression damping Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compre...

Page 69: ...to normal compression of the shock absorber 800057 10 Turn adjusting screw clockwise to the last perceptible click using a screwdriver Info Do not loosen screw connection Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 24 clicks Standard 22 clicks Sport 24 clicks Info Turn clockwise to increase damping turn...

Page 70: ...essed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers Only make adjustments within the recommended range Info The rebound damping setting has an impact on the compression of the shock absorber 800059 10 Turn adjusting screw clockwise to the last perceptib...

Page 71: ...andling When changing the chassis settings always start with the standard setting Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping The left and right shock absorbers should have the same settings 9 8 Front shock absorber adjusting the cross over Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly co...

Page 72: ...ing is not fully utilized Less cross over makes the spring action at the front harder and the front of the vehicle lies higher Jack up the vehicle p 64 Clean the shock absorber thoroughly 800063 10 Loosen adjusting rings and Suitable tools are available from an authorized KTM workshop Hook wrench 83019001000 800063 11 Cross over setting is measured between sliding bushing and the collar of adjusti...

Page 73: ...rber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers Make adjustments in small steps only Info Increasing the spring preload raises the center of gravity of the vehicle This can have a large impact on vehicle handling Tip ...

Page 74: ...ing preload is the difference in length between the spring pack when 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 sho...

Page 75: ...n so never dismantle the shock absorber or carry out any mainte nance on it yourself Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers Only make adjustments within the recommended range Info The high speed setting takes effect during the fast compression of the shock absorber 800060 10 Turn adjusting screw clockwise all the way using a ring wrench...

Page 76: ...hock absorber adjusting the low speed compression damping Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers Only make adjustments within...

Page 77: ...cks Sport 18 clicks Info Turn clockwise to increase damping turn counterclockwise to reduce suspension damping 9 12 Rear shock absorber adjusting the rebound damping Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any mainte nance on it yourself Warning Danger of acc...

Page 78: ...s Sport 14 clicks Tip Experience has shown that settings outside of this range are detrimental to vehi cle handling When changing the chassis settings always start with the standard setting Info Turning to the right increases damping while turning to the left lessens damp ing 9 13 Rear shock absorber adjusting the spring preload x Danger Danger of accidents The shock absorber is under high pressur...

Page 79: ...an have a large impact on vehicle handling Tip Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove the rear shock absorber x p 78 After removing the shock absorber clean it thoroughly 200601 01 Loosen lock ring Hold adjusting ring while doing so Suitable tools are available from an authorized KTM workshop Hook wrench 83019002000 Tu...

Page 80: ...d Tighten the spring pack by turning the adjusting ring to the specified setting Guideline Spring preload Comfort 3 mm Standard 5 mm Sport 5 mm Tighten the lock ring and the adjusting ring Info If you increase the spring preload you should also slightly increase the rebound damping Install the rear shock absorber x p 80 9 14 Removing the rear shock absorber x Jack up the vehicle p 64 Remove the re...

Page 81: ... with a tension belt to prevent it from swinging down further Attach the swingarm to the subframe with a tension belt 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 of the shock absorber and carefully remove the shock absorber out of the vehicle toward the rea...

Page 82: ...2 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 142 Remove the vehicle from the work stand p 64 9 16 Checking the toe x Park the vehicle on a horizontal surface Check the tire condition p 125 Check the tire air pressure p 125 Check th...

Page 83: ...NE 81 300272 10 Load the vehicle with the specified weight Guideline Standard rider weight 70 80 kg 154 176 lb Move the handlebar into the straight ahead position and fix it Handlebar fixation for straight ahead position 83019015100 ...

Page 84: ...MAINTENANCE ON CHASSIS AND ENGINE 82 400333 10 Measure distances and If distances and are not equal Adjust the toe x p 83 ...

Page 85: ...o rim flange If the toe does not meet specifications Adjust the toe x p 83 9 17 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 125 Check the tire air pressure p 125 Check the chassis parts for damage play and wear Replace damaged or worn parts 300272 10 Load the vehicle with the specified weight Guideline Standard rider weight 70 80 kg 154 176 lb Move the h...

Page 86: ...MAINTENANCE ON CHASSIS AND ENGINE 84 400333 11 Loosen nuts and Adjust the distances and to the same value by rotating the tie rods ...

Page 87: ...n driv ing straight ahead The distance is measured at the height of the wheel center from rim flange to rim flange Tighten nuts and 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 must still be freely movable 9 18 Checking adjusting the camber x Info The left and right camber should have the same settings The oper...

Page 88: ...00277 10 Insert tool in the heim joint and clip onto the A arm Camber gauge 83019014000 Check the camber on both heim joints If marking is not aligned with the top edge of the A arm Turn tool with the heim joint in steps of 180 until the marking is in line with the top edge of the A arm Remove tool ...

Page 89: ...ffset 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 stability...

Page 90: ... the vehicle p 64 300274 11 Remove screws with bushings Place the A arm with bushings in the desired position Mount and tighten screws Guideline Screw A arm top M10x52 45 Nm 33 2 lbf ft Remove the vehicle from the work stand p 64 9 21 Toe width of rear axle 300276 10 The toe width can be adjusted by installed the spacing sleeve in various ways Difference between narrow wide toe 76 mm 2 99 in ...

Page 91: ...ifications ride slowly at first to get the feel of the new handling characteristics Engage 1st gear 100102 10 Loosen nuts of the wheel hubs on both sides Jack up the vehicle p 64 Remove nuts on both sides and take all parts off of the rear axle 100103 10 Setting a narrow toe width Mount wheel hub Mount conical ring with the cone facing outward Mount spacing sleeve with the cone facing inward Mount...

Page 92: ...ing sleeve with the cone facing inward Mount conical ring with the cone facing outward Mount wheel hub Mount the washer and the new self locking nut 100102 10 Remove the vehicle from the work stand p 64 Tighten nuts on both sides Guideline Nut rear wheel hub M18x1 5 130 Nm 95 9 lbf ft Shift gear to neutral ...

Page 93: ...usted 4 fold by turning the handlebar support and the handlebar support The holes on the handlebar support are placed at a distance of from the center Distance between holes 3 5 mm 0 138 in The holes on the handlebar bridge are placed at a distance of from the center Distance between holes 7 5 mm 0 295 in ...

Page 94: ...NE 92 9 24 Adjusting the handlebar position x 100100 10 Pull the instrument support off the handlebar and swing it to the side Info Protect the vehicle and its attachments from damage by covering them Do not bend the cables and lines ...

Page 95: ...dlebar bridge onto the steering column in the desired position Mount and tighten screw Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount and tighten screw Guideline Screw steering column top M20x1 5 25 Nm 18 4 lbf ft Mount and tighten screws Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount handlebar support in the desired position using the screws Mount new self locking nuts and...

Page 96: ...ioned correctly Position the instrument support on the handlebar 9 25 Checking play in gas Bowden cable 600142 10 Move the handlebar to the straight ahead position Move the throttle lever back and forth slightly to ascertain the play in the gas Bowden cable Guideline Play in gas Bowden cable 3 5 mm 0 12 0 2 in If the gas Bowden cable play does not meet specifications Adjust the play in the gas Bow...

Page 97: ...art the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idle speed must not change If the idle speed changes Adjust the play in the gas Bowden cable p 95 9 26 Adjusting play in gas Bowden cable Check gas Bowden cable route 600142 11 Move the handlebar to the straight ahead position Loosen the nut and use the screw to adjust the play in the gas Bowden ca...

Page 98: ...ing the chain Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info The service life of the chain depends largely on its maintenance Clean the chain regularly and then treat with chain spray Chain cleaner p 194 Offroad chain spray p 195 ...

Page 99: ...eak On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheels or damage the engine Check for correct chain tension and adjust if necessary Park the vehicle on a horizontal surface and shift gears to neutral 100093 10 Push the upper chain section at the end of the chain sliding component upwards to measure the chain tension Info The l...

Page 100: ...ket are worn Replace the rear sprocket engine sprocket Info When fitting the chain joint always make sure that the closed side of the joint faces forward riding direction The engine sprocket rear sprocket and chain should always be replaced together Check that the chain guides are tight 9 31 Checking chain wear Park the vehicle on a horizontal surface and shift gears to neutral ...

Page 101: ... upper chain section Info Chain wear is not always even so you should repeat this measurement at differ ent chain positions Maximum distance at the longest chain section 272 mm 10 71 in If the distance is greater than the specified measurement Replace the chain Info When you replace the chain you should also replace the rear sprocket and engine sprocket New chains wear out faster on old worn sproc...

Page 102: ...can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheels or damage the engine Check for correct chain tension and adjust if necessary Park the vehicle on a horizontal surface and shift gears to neutral 100093 10 Push the upper chain section at the end of the chain sliding...

Page 103: ...rear wheel 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 is visible This ensures that the vehi...

Page 104: ... to fill the rear wheel eccentric element via the grease nipple until grease emerges from the left shaft seal ring Long life grease p 192 9 34 Checking the brake discs Warning Danger of accidents Reduced braking due to worn brake discs Worn brake discs should be replaced immediately in an authorized KTM workshop ...

Page 105: ...isc thickness is less than the specified value Change the brake disc Check the front and rear brake discs for damage cracking and deformation If the brake disc exhibits damage cracking or deformation Change the brake disc 9 35 Checking the free play of the hand brake lever Warning Danger of accidents Brake system failure If there is no free travel on the hand brake lever pressure builds up on the ...

Page 106: ... handbrake lever to your hand size by turning adjusting screw Info Pull the brake lever forward and turn the adjusting screw Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the handbrake lever and the handlebar The range of adjustment is limited Turn the adjusting s...

Page 107: ...nt and rear brake fluid replaced according to the service plan in an authorized KTM workshop 100035 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the viewer When the brake fluid level has dropped below the bottom of the viewer Add front brake fluid x p 105 9 38 Adding front brake fluid x Warning Danger of accidents Brake system f...

Page 108: ... front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not des...

Page 109: ...asurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 190 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 39 Checking the front brake linings Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Remove the wheel whe...

Page 110: ...linings x p 110 Install the wheel wheels p 123 9 40 Removing front brake linings x Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop Info The operations are the same on the left and right Remove the wheel wheels p 122 Pull and release the handbrake lever Locking pawl moves into its basic position pa...

Page 111: ...sary Warning Danger of accidents Reduced braking 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 origina...

Page 112: ... split pins Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Install the wheel wheels p 123 9 42 Changing the front brake linings x Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with wat...

Page 113: ...zard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean ...

Page 114: ...ke linings x p 109 Add brake fluid to level Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 190 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 43 Checking free play of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot brake pedal pressure...

Page 115: ...12 0 2 in If the free travel does not meet specifications Adjust the basic position of the footbrake lever x p 113 Reconnect spring 9 44 Adjusting basic position of footbrake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free trave...

Page 116: ...n of the footbrake lever Guideline Free play at foot brake lever 3 5 mm 0 12 0 2 in Hold screw and tighten nut Guideline Remaining nuts chassis M8 30 Nm 22 1 lbf ft Hold push rod and tighten nut Guideline Remaining nuts chassis M6 15 Nm 11 1 lbf ft Reconnect spring 9 45 Checking rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom ...

Page 117: ...Add rear brake fluid x p 115 9 46 Adding rear brake fluid 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 Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Skin irritations Brake fluid can cause skin irritation on con...

Page 118: ...ials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a...

Page 119: ...immediately with water 9 47 Checking rear brake linings Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop 100038 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 121 ...

Page 120: ... system maintained and repaired in an authorized KTM workshop 100063 10 Press the brake caliper by hand on to the brake disc in order to press back the brake piston 100064 10 Loosen the screw while holding the hexagonal head 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 121: ... keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking 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 fr...

Page 122: ...piston side of the brake pad 100068 10 Grease bearing bolt and insert the brake caliper with the bearing bolt into brake caliper support Lubricant T625 p 195 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 tig...

Page 123: ...rake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brak...

Page 124: ... the brake fluid reservoir Install the rear brake linings x p 119 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 190 Mount screw with membrane Info Clean up overflowed or spilt brake fluid immediately with water 9 51 Removing wheel wheels Info Proceed in the same way on the other wheels if necessary Pull handbrake lever push the locking pawl downwards and release the handbrake lever Figure 1...

Page 125: ... Carefully remove the wheel making sure it does not become jammed with the threads of the screws 9 52 Installing the wheel wheels Note Material 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 ...

Page 126: ... the front wheels Carefully position the wheel on the hub being careful not to damage the threads of the screws Mount wheel nuts but do not tighten Remove the vehicle from the work stand p 64 Pull handbrake lever push the locking pawl downwards and release the handbrake lever Figure 100006 10 p 30 Tighten the wheel nuts crosswise Guideline Wheel nut M10x1 25 45 Nm 33 2 lbf ft ...

Page 127: ... effect on riding behavior especially on wet surfaces Examine the tires for cuts foreign bodies and other damage 9 54 Checking 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 100044 10 Remove dust ca...

Page 128: ...y from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician Switch off all power consuming components and switch off the engine Remove the rear fender p 140 300279 10 Disconnect the negative minus cable of the battery Pull back the plu...

Page 129: ...hemical burns Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a physician W...

Page 130: ... s service life If the charge current the charge voltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery is discharged from starting it must be recharged immediately If it stands for a long time in a discharged state the battery becomes over discharged and sulfated and then it is destroyed The battery is maintenan...

Page 131: ... this device you cannot overcharge the battery Info Never remove the lid Charge the battery according to the instructions on the battery casing 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 142 9 58 Changing m...

Page 132: ... the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Insert a new fuse Fuse 58011109120 Info If the new fuse burns out contact an authorized KTM workshop Tip The spare fuse should always be present in the starter relay so that it is avail able if needed Replace the protection covers 9 59 Changing the fuses of individual power consuming components Re...

Page 133: ...ver of the fuse box Remove the faulty fuse Guideline Fuse 1 10A ignition CDI contoller indicator lamps ON Fuse 2 15A high beam low beam parking light tail light brake light high beam indicator lamp Fuse 3 10A radiator fan Fuse 4 empty Fuse 5 empty Fuse res 10A 15A replacement fuses Info You can recognize a blown fuse by its broken filament ...

Page 134: ...rescribed amperage Never by pass or repair fuses Insert a new fuse of the appropriate strength Fuse 58011109110 Fuse 58011109115 Info If the new fuse burns out contact an authorized KTM workshop Tip The spare fuse should always be present in the starter relay so that it is available if needed Close the cover of the fuse box Install the front cover p 138 ...

Page 135: ...nnected for better driveability 9 61 Changing the ignition curve Remove the front trim p 138 Changing the ignition curve from Performance to Soft Disconnect plug in connector Figure 100105 10 p 133 Soft The plug in connector is disconnected for better driveability p 133 Changing the ignition curve from Soft to Performance Connect the plug in connector Figure 100105 10 p 133 Performance The plug in...

Page 136: ...seat 100041 10 Pull the release hook back Lift up the seat at the rear pull it back and then remove from above 9 63 Mounting the seat 100046 10 Hook slot on the seat into collar sleeve of the fuel tank lower the rear of the seat and slide tab under fuel tank ...

Page 137: ...own the rear of the seat until release hook engages Make sure that the seat is correctly locked in 9 64 Removing the radiator spoiler Info The operations are the same on the left and right Remove the seat p 134 300249 10 Remove the screws on the fuel tank ...

Page 138: ... the radiator Unhinge and remove the radiator spoiler and the fuel tank 9 65 Installing the radiator spoiler Info The operations are the same on the left and right 100058 10 Hook catch of the radiator spoiler into holder of the fuel tank and position it on the radiator ...

Page 139: ... on the radiator Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount and tighten screws on the fuel tank Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Mount the seat p 134 9 66 Removing the front cover 300252 10 Remove screw Slide the front cover up and remove it ...

Page 140: ...CHASSIS AND ENGINE 138 9 67 Installing the front cover 300253 10 Position the front cover in slots on both sides of the front trim Mount and tighten the screw 9 68 Removing the front trim Remove the front cover p 137 ...

Page 141: ...TENANCE ON CHASSIS AND ENGINE 139 300256 10 Remove screws Raise the front trim and disconnect the plug in connectors from the head light and the emergency OFF switch with the rip cord Remove the front trim ...

Page 142: ...light and the emergency OFF switch with the rip cord and position the front trim Mount all screws Fully tighten screws Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Fully tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the front cover p 138 9 70 Removing the rear fender Remove the seat p 134 ...

Page 143: ... Raise the rear of the air filter box lid At the same time use your other hand to press on the carburetor connection boot to kink it at that location This prevents the carbure tor connection boot from disconnecting from the carburetor Raise fender at the rear and remove it ...

Page 144: ...other hand to press on the carburetor connection boot to kink it at that location This prevents the carburetor connection boot from disconnecting from the carburetor Position front fender Fix the air filter box lid in the fender Info If the air filter box lid is not correctly mounted dust and dirt can penetrate into the engine and cause damage ...

Page 145: ...MAINTENANCE ON CHASSIS AND ENGINE 143 300254 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 134 ...

Page 146: ...600133 10 Remove screws and Remove the engine guard 9 73 Installing the engine guard 600133 10 Position the engine guard on the frame bearer Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 147: ...ironmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Remove the seat p 134 300258 10 Raise the rear of the air filter box lid At the same time use your other hand to press on the carburetor connection boot to kink it at that location This prevents the carbu retor connection boot from disconnecting from the carburetor Unhook the...

Page 148: ...can cause damage Mount the air filter box lid Info If the air filter box lid is not correctly mounted dust and dirt can penetrate into the engine and cause damage Mount the seat p 134 9 76 Cleaning air filter x Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Do n...

Page 149: ... damage and tightness Install the air filter x p 146 9 77 Adjusting basic position of clutch lever 300232 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw 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 a...

Page 150: ... not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 p 192 Position the cover with the membrane Mount and tighten the screws 9 79 Cooling system 300259 10 The water pump in the engine forces the coolant to flow The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap The specified coolant temperature is therefo...

Page 151: ...iator radiator hoses or other cooling system components when the engine is hot Allow the engine and cool ing system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and con tac...

Page 152: ...oolant level does not meet specifications Correct the coolant level Alternative 1 Coolant p 190 Alternative 2 Coolant mixed ready to use p 190 Mount the radiator cap 9 82 Checking the coolant level Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is driven Do not open the radiator radiator hoses or other cooling system components when the engine is h...

Page 153: ...rim p 138 400243 10 Remove the radiator cap Check the coolant level in the radiator Coolant level above the radiator fins 10 mm 0 39 in If the level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant p 190 Alternative 2 Coolant mixed ready to use p 190 Mount the radiator cap 9 83 Draining coolant x Warning Danger of scalding The coolant gets very hot...

Page 154: ...ant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Remove the front trim p 138 300266 10 Place a suitable container under the vehicle Remove screw Remove screw 300267 10 Remove the radiator cap Completely drain the coolant Mount screw with a new seal and tighten it Guideline Screw water pump cover M6 10 ...

Page 155: ...mmediately with water and con tact 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 coolants out of the reach of children Remove the front trim p 138 Remove the radiator spoiler p 135 300267 11 Remove the radiator cap Fill the coolant into the radiator Coolant 1 50 l ...

Page 156: ...n the screw when coolant emerges from the opening Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 300269 10 Add coolant to level above the radiator fins Guideline 10 mm 0 39 in Mount the radiator cap Install the front trim p 140 Make a short test ride Check the coolant level p 150 ...

Page 157: ...he idle speed is set significantly 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 The idle mixture is adjusted with the idle mixture adjustment screw 9 86 Carburetor adjusting the idle speed x 300280 10 Scr...

Page 158: ...e point between these two positions with the highest idle speed Info If there is a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extremely sporty rider will set the mixture about 1 4 of a turn back from this ideal value leaner in a clockwise direction since the engine becomes hotter in sporting use If the procedure described here does not lead to sati...

Page 159: ...y Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of 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...

Page 160: ... carburetor 300280 11 Guide the hose coming down behind the engine into a suitable container Info Water in the float chamber results in malfunctioning Undo the screw turn it counterclockwise a few turns and drain the fuel from the float chamber Tighten screw 9 88 Checking engine oil level Info The engine oil level can be checked on a cold or hot engine Park the vehicle on a horizontal surface ...

Page 161: ...ne oil does not reach the middle of the viewer Top up the engine oil p 164 800061 11 Condition Engine is cold Check the engine oil level The engine oil reaches the bottom of the viewer When the engine oil does not reach the bottom of the viewer Top up the engine oil p 164 9 89 Changing the engine oil and oil filter cleaning the oil screen x Drain the engine oil x p 160 Remove the oil filter x p 16...

Page 162: ...ease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Drain the engine oil only when the engine is warm Park the vehicle on a horizontal surface Remove the engine guard p 144 300270 10 Place a suitable container under the engine Remove oil drain plug with the seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with the magnet Clean ...

Page 163: ...ies etc according to regulations Place a suitable container under the engine 300271 10 Loosen screw plug by striking it lightly with a hammer a few times Remove screw plug with oil screen and the O rings Drain the remaining engine oil Thoroughly clean 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 9 92 Removin...

Page 164: ...eaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine 300262 10 Remove screws Take off the oil filter cover with the O ring 300263 10 Pull oil filter element out of the oil filter case Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area ...

Page 165: ... it in the oil filter housing 300262 11 Oil the O ring of the oil filter cover and install it with the oil filter cover Mount and tighten screws Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft 9 94 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 166: ...ount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in a closed space Start the engine and check that it is oil tight Check the engine oil level p 158 9 95 Topping up engine oil Info Too little engine oil or poor qu...

Page 167: ...ll up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 191 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 191 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 screw cap ...

Page 168: ... fuel in the float cham ber Empty the carburetor float chamber x p 157 Fuel feed interrupted Check the tank breather Clean fuel tap Clean carburetor Engine flooded Clean and dry spark plug or replace if necessary Spark plug oily or wet Clean and dry spark plug or replace if necessary Electrode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 0 7 mm 0 ...

Page 169: ... metal area on engine and try to start the engine Guideline You should see a strong spark on the spark plug If there is no spark change the spark plug If there is still no spark remove the spark plug cap from the ignition cable hold it at the speci fied distance from the ground contact and try to start the engine Guideline 5 mm 0 2 in If you now have a spark replace the spark plug connector If the...

Page 170: ...nsor TPS incorrectly set or faulty Have the throttle valve sensor TPS checked or adjusted The engine cannot be cranked electric starter Operating error Follow the instructions on starting the engine p 45 Battery discharged Recharge the battery x p 127 Check the cause of discharging Main fuse burned out Change the main fuse p 129 Check electrical system Low external temperature Recharge the battery...

Page 171: ...d connector Check electrical system Clean socket connector and treat it with contact spray Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level p 150 Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 151 Fill coolant bleed the cooling system x p 153 Bent radiator hose Replace the radiato...

Page 172: ...ive Have ignition system checked 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 158 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x p 159 Parts of the electrical system are not functional Fault in the electrical system Change the fuses of ind...

Page 173: ...etc according to regulations Info If you clean the vehicle regularly its value and appearance are 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 since it could fall over Never raise the vehicle on your own even if a gear is engaged Fuel can leak out of the fuel tank Before you clean the vehicl...

Page 174: ...ed causes water at inaccessible positions in the engine and the brakes to evaporate Push back the protection covers on the handlebar instruments to allow water to evaporate After the vehicle has cooled off oil or grease all moving parts and bearings Clean the chain p 96 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and polishing materials f...

Page 175: ...it out of the reach of children Info If you want to store the vehicle for a longer period take the following actions Info Before storing the vehicle check all parts for function and wear If service repairs or replacements are necessary you should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the start of the new season Clean the v...

Page 176: ...porous materials since they prevent humidity from escaping thus causing corrosion Info Avoid running the engine of a vehicle in storage for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust 12 2 Putting the vehicle into operation after storage Install the battery p 127 Fill up with fuel p 57 ...

Page 177: ...e diameter intake 40 4 mm 1 591 in Valve diameter exhaust 31 7 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 Press...

Page 178: ...GK CR 9 EKB Spark plug electrode gap 0 7 mm 0 028 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 13 1 Capacity engine oil Engine oil 2 00 l 2 11 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 191 External temperature 0 C 32 F Engine oil SAE 5W 40 p 191 13 2 Capacity coolant Coolant 1 50 l 1 59 qt Coolant p 190 Coolant mixed ready to ...

Page 179: ... 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 Loctite 243 Oil jet clutch oil supply M5x1 6 Nm 4 4 lbf ft Loctite 243 Nut cylin...

Page 180: ...0 Nm 7 4 lbf ft Oil jet timing chain tensioner M6x0 6 6 Nm 4 4 lbf ft Loctite 243 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 housing 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 243 Spark plug M10 10 12 Nm 7 4 8 9 lbf ft Plug cam le...

Page 181: ...r M12x1 5 20 Nm 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 tensio...

Page 182: ...cation 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 Bore diameter 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 183: ...el 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 1 265 mm 49 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 165 kg 364 lb Fuel tank full 173...

Page 184: ...1 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 38 Chain 5 8 x 1...

Page 185: ...ing light W2 1x9 5d 12 V 5 W Indicator lights W2 1x4 6d 12 V 1 2 W Brake tail light LED 16 2 Tires Front tire Rear tire 20 x 6 00 10 MAXXIS Razr MX 931 18 x 10 00 8 MAXXIS Razr MX 932 For further information see the Service section under http www ktm com 16 3 Capacity fuel Total fuel tank capacity approx 10 3 l 2 72 US gal Super unleaded ROZ 95 RON 95 PON 91 p 193 ...

Page 186: ...t 24 clicks Standard 22 clicks Sport 24 clicks Rebound damping Comfort 23 clicks Standard 21 clicks Sport 19 clicks Cross over 19 1 5 mm 0 75 0 059 in Info Measured with no preload on the main spring Spring preload 5 mm 0 2 in Spring rate main spring 24 29 N mm 137 166 lb in Spring rate auxiliary spring 40 N mm 228 lb in Spring length main spring 275 mm 10 83 in Spring length auxiliary spring 60 m...

Page 187: ...TECHNICAL DATA FRONT SHOCK ABSORBER 185 Gas pressure 10 bar 145 psi Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 192 ...

Page 188: ...ort 1 5 turns Compression damping low speed Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping Comfort 18 clicks Standard 16 clicks Sport 14 clicks Cross over 19 1 5 mm 0 75 0 059 in Info Measured with no preload on the main spring Spring preload Comfort 3 mm Standard 5 mm Sport 5 mm Spring rate main spring 82 N mm 468 lb in Spring rate auxiliary spring 100 N mm 571 lb in ...

Page 189: ...CK ABSORBER 187 Spring length main spring 200 mm 7 87 in 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 192 ...

Page 190: ... 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 bracket screw M10 60 Nm 44 3 lbf ft Engine ca...

Page 191: ...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 lbf ft Screw steerin...

Page 192: ...nd Motorex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze 25 45 C 13 49 F 50 Anti corrosion antifreeze 50 distilled water Coolant mixed ready to use Antifre...

Page 193: ...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 197 SAE p 197 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 194: ...lic 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 197 SAE 2 5 Guideline Use only oils that comply with the specified standards see sp...

Page 195: ...SUBSTANCES 193 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 196: ...over Chain cleaner Specification KTM recommends Motorex products Supplier Motorex Chain Clean 611 Cleaning and polishing materials for metal rubber and plastic Specification KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex products Supplier Motorex Accu Contact ...

Page 197: ...er Motorex Moto Polish Lubricant T625 Specification KTM recommends Molykote products Supplier Molykote 33 Medium Motorcycle cleaner Specification KTM recommends Motorex products Supplier Motorex Moto Clean 900 Offroad chain spray Specification KTM recommends Motorex products Supplier Motorex Chain Lube 622 ...

Page 198: ...AUXILIARY SUBSTANCES 196 Oil for foam air filter Specification KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power ...

Page 199: ...vals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle and ATV engines With most motorcycles and ATVs the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifyi...

Page 200: ...ake fluid of front brake adding 105 Brake fluid of rear brake adding 115 checking 114 Brake linings of front brake changing 110 checking 107 installing 109 removing 108 Brake linings of rear brake changing 121 checking 117 installing 119 removing 118 Brakes 48 C Camber adjusting 85 checking 85 Carburetor adjusting idle 155 emptying the float chamber 157 idle 155 Chain cleaning 96 Chain tension adj...

Page 201: ...g 144 removing 144 Engine number 27 Engine oil changing 159 draining 160 filling 163 topping up 164 Engine oil level checking 158 Environment 10 F Fender rear installing 142 removing 140 Filler cap closing 36 opening 36 Filling up fuel 57 Foot brake pedal 39 adjusting basic position 113 checking free play 112 Fork offset 87 adjusting 88 Front cover installing 138 removing 137 Front shock absorber ...

Page 202: ...1 adjusting 92 Hot start lever 29 I Ignition curve changing 133 plug connection 133 Ignition switch 34 Indicator lamp overview 35 K Key number 27 L Light switch 31 32 M Main fuse changing 129 Maintenance 8 O Oil filter changing 159 installing 163 removing 161 Oil screen cleaning 159 161 Owner s manual 20 P Parking 56 Parking brake 30 Play in gas Bowden cable adjusting 95 checking 94 Putting into o...

Page 203: ...ng bends 49 downhill 51 general information 49 perpendicular to the slope 53 riding through water 55 starting up 47 uphill 52 S Seat mounting 134 removing 134 Service schedule 59 63 Shifting forward gears 47 Shock absorber shock absorber part number front 28 shock absorber part number rear 28 Spare parts 9 Starting 45 Stopping 56 Storage 173 T Technical data carburetor 180 chassis 181 183 chassis ...

Page 204: ...0 rear toe width adjusting 89 Toe width of rear axle 88 Transport 9 Troubleshooting 166 170 Turning on slopes 53 Type label 26 U Use definition 8 V Vehicle cleaning 171 jacking up 64 removing from work stand 64 W Wheel wheels installing 123 removing 122 Work rules 9 ...

Page 205: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 06 2008 Photo Mitterbauer 3211378en 3211378en ...

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Summary of Contents for 450 SX 2009

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KTM 450 SX 2009, Owner'S Manual

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Summary of Contents for 450 SX 2009

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