KTM 450 SX ATV Page 92 Owner'S Manual Download

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MAINTENANCE ON CHASSIS AND ENGINE

301801-10

–

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.

(

p. 90)

9.38

Topping up the front brake fluid

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 irritation

Brake fluid can cause skin irritation on contact.

–

Avoid contact with skin and eyes, and keep out of the reach of children.

–

Wear suitable protective clothing and goggles.

–

If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.

Warning

Danger of accidents

Reduced braking due to old brake fluid.

–

Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be
glad to help.)

Summary of Contents for 450 SX ATV

Page 1: ...OWNER S MANUAL 2010 450 SX ATV 505 SX ATV Art no 3211488en ...

Page 2: ......

Page 3: ...ons 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 produ...

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: ...st use 27 Running in the engine 29 RIDING INSTRUCTIONS 31 Checks before putting into operation 31 Starting 32 Starting up 33 Shifting 34 Braking 34 Riding 35 Riding in bends 36 Riding downhill 37 Riding uphill 38 Riding perpendicular to the slope 39 Turning on slopes 39 Riding through water 41 Switching off the engine 41 Stopping parking 42 Refueling 43 SERVICE SCHEDULE 45 Important maintenance wo...

Page 6: ...hecking the chain tension 82 Checking rear sprocket engine sprocket for wear 83 Checking chain wear 84 Adjusting chain tension 85 Greasing the rear wheel eccentric element 87 Checking brake discs 87 Checking the free travel of the hand brake lever 88 Adjusting basic position of hand brake lever 89 Checking front brake fluid level 89 Topping up the front brake fluid x 90 Checking the front brake li...

Page 7: ...eeding the cooling system x 138 Carburetor idle 140 Carburetor adjusting idle x 140 Draining the carburetor float chamber x 142 Checking the engine oil level 143 Changing the engine oil and oil filter cleaning the oil screen x 145 Draining the engine oil x 145 Cleaning the oil screen x 146 Removing the oil filter x 147 Installing the oil filter x 149 Filling up with engine oil x 149 Adding engine ...

Page 8: ...TABLE OF CONTENTS 6 INDEX 183 ...

Page 9: ... understanding In the interest of your own safety have these jobs performed at an authorized KTM workshop There your vehicle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained below Specific name Identifies a pro...

Page 10: ...evention 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 difficult conditions such as on sand or very muddy or wet terrain can lead to above average wear of components such as the drive train or the b...

Page 11: ...ng brake Note Fire hazard Some vehicle components get very hot when the machine is driven Do not place the vehicle where there are flammable or explosive substances Do not place objects over the vehicle while it is still warm from being run Always let the vehicle cool first Switch off the engine Turn handle of the fuel tap to the OFF position Figure 301779 10 p 24 Use straps or other suitable devi...

Page 12: ...sibly you can ensure that such prob lems and conflicts do not have to occur To protect the future of off road 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 profes...

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

Page 14: ...VIEW OF VEHICLE 12 3 1 View of the vehicle from the left front example 301769 10 ...

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

Page 16: ...VIEW OF VEHICLE 14 3 2 View of the vehicle from the right rear example 301770 10 ...

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

Page 18: ...ssis number 301771 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 301858 10 The type label is located on the frame tube on the right and left in front of the radiator ...

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

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

Page 21: ...t is closed The electric starter turns over when the electric starter button is pressed The clutch is hydraulically operated and self adjusting 5 2 Hot start lever 301775 10 Hot start lever 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 Thi...

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

Page 23: ...r The throttle lever is used to control the engine speed 5 5 Electric starter button 301793 10 Electric starter button is fitted on the left side of the handlebar Possible states Electric starter button in basic position Electric starter button is pressed In this position the electric starter is actuated ...

Page 24: ...hed to clip It can be attached to the clothing of the rider by means of carabiner Possible states Clip is pulled off The ignition circuit is interrupted a running engine stops and a non running engine will not start Clip is mounted The ignition circuit is closed and the engine can be started Clip mounted and kill switch pressed The ignition circuit is interrupted a running engine stops and a non r...

Page 25: ...1778 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 26: ...uel 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 27: ...fuel This gives a richer fuel air mixture which is needed for a cold start Info If the engine is warm the choke function must be deactivated Possible states Choke function activated The choke lever is pulled out to the stop Choke function deactivated The choke lever is pushed in to the stop 5 11 Shift lever 301783 10 The shift lever is mounted on the left side of the engine ...

Page 28: ...ositions can be seen in the photograph The neutral or idle position is between the first and second gears 5 12 Foot brake pedal 301781 10 The foot brake pedal is located in front of the right footrest and operates the rear wheel brake ...

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

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

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

Page 32: ...TTING INTO OPERATION 30 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 33: ... p 82 Check the chain dirt accumulation p 81 Check the tire condition p 110 Check the tire air pressure p 110 Check the front brake fluid level p 89 Check the rear brake fluid level p 99 Check the front brake linings p 92 Check the rear brake linings p 102 Check brake system function Check that the rear hubs are tight Check that the footrests are tight Check the handlebar bridge bearing for excess...

Page 34: ...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 Drain the carburetor ...

Page 35: ...n the electric starter button is pressed Do not open the throttle Release the clutch lever Condition The engine is hot and running Push the hot start lever all the way in with the engine running 7 3 Starting up Info Switch your lights on before leaving You will then be seen earlier by other motorists Pull the hand brake lever and release it again Locking pawl moves into its basic position parking ...

Page 36: ...an be seen in the illustration First gear is used for starting off or for steep inclines To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again 7 5 Braking Warning Danger of accidents If you brake too hard the wheels can lock When the front wheels lock the vehicl...

Page 37: ...6 Riding Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop If the vehicle goes out of control and you fall off the vehicle the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing This short circuits the ignition circuit and the engine switches off During normal operation you sit erect on t...

Page 38: ...er of accidents Excessive speed and turning at sharp angles can cause the vehicle to roll over Decrease your speed before entering into bends Handling of the ATV is strongly influenced by shifts in the position of your body weight Always shift your body weight toward the inside of the bend and forward The faster you ride and the tighter the bend the more you need to shift your body weight Always e...

Page 39: ...er ride 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 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 cautio...

Page 40: ...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 41: ...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 42: ...arefully 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 cl...

Page 43: ...ter can 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 I...

Page 44: ...e Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these components to cool down before starting work on them Note Danger of damage Danger of damage from accidental rolling of vehicle Park the vehicle on a surface that is as horizontal as possible and activate the parking brake Note Fire hazard Some vehicle components get very hot when the machine ...

Page 45: ...ing see illustration 7 15 Refueling Danger Fire hazard Fuel is highly flammable Never refuel the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning...

Page 46: ...el to get into the ground water the ground or the sewage system 400287 10 Switch off the engine Open the filler cap p 22 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx 10 3 l 2 72 US gal Super unleaded ROZ 95 RON 95 PON 91 p 178 Close the filler cap p 23 ...

Page 47: ...k 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 135 Check the exhaust system for leakage and faulty attachment Check control cables for damage smooth operation and routing without sharp bends Check the fluid level of the hydraulic clutch p 133 Clean the air filter x p 132 Check cables for dam...

Page 48: ...peration 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 play Grease the rear wheel eccentric element p 87 Check all screws to make sure they are tight Wheels Check rim...

Page 49: ...rber x Service the front shock absorber x Change the oil in the rear shock absorber x Service the rear shock absorber x Treat electric contacts with contact spray Change hydraulic clutch fluid Change brake fluid 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 the cylinder x Replace piston x Check the ...

Page 50: ...r components x S10A Every 10 service hours corresponds to about 70 liters of fuel 18 5 US gal after every race S20A Every 20 service hours corresponds to about 140 liters of fuel 37 US gal S40A Every 40 service hours corresponds to about 280 liters of fuel 74 US gal S80A Every 80 service hours corresponds to about 560 liters of fuel 148 US gal J1A annually J2A every 2 years 8 3 Important checks an...

Page 51: ...ine sprocket for wear p 83 Clean the air filter x p 132 Check the tire air pressure p 110 Check the tire condition p 110 Check the coolant level p 136 Check that all controls for smooth operation Check braking force incl parking brake Check all screws nuts and hose clamps regularly for tightness NB1A Depending on conditions of use according to requirements ...

Page 52: ... 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 Average rider weight 70 80 kg 154 176 lb By making a variety of adjustments to t...

Page 53: ...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 high s...

Page 54: ...umber of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 1 5 turns Standard 1 turn Sport 1 turn 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 Disassembly of pressurized parts can lead to injury The shock absorbe...

Page 55: ...e shock absorber The left and right shock absorbers should have the same settings 301787 10 Turn adjusting screw clockwise with a screwdriver up to the last perceptible click Info Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks Info Turn clockwi...

Page 56: ...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 The left and right shock absorbers should have the same settings 301788 10 Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorb...

Page 57: ...sed to adjust the suspension travel of the short soft spring Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower The suspension travel and the progressive part of the long hard spring is not fully utilized Less cross over makes the spring action at the front harder and the front of the vehicle lies higher Jack up the vehicle p 50 Clean the shock a...

Page 58: ...orbers should have the same settings Tighten the adjusting ring Remove the vehicle from the work stand p 50 9 9 Front shock absorber adjusting the spring preload Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Warning Danger of ...

Page 59: ...icle handling Tip Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Jack up the vehicle p 50 Clean the shock absorber thoroughly 301790 11 Loosen lock ring Hook wrench 83019001000 Turn adjusting ring until the spring pack is fully unloaded Measure the entire spring pack when it is unloaded ...

Page 60: ...rmissible spring preload Therefore you can only increase the spring preload If you increase the spring preload you should also slightly increase the rebound damping The left and right shock absorbers should have the same settings Tighten the lock ring and the adjusting ring Remove the vehicle from the work stand p 50 9 10 Rear shock absorber adjusting the high speed compression damping Danger Dang...

Page 61: ...t during the fast compression of the shock absorber 301791 10 Turn adjusting screw clockwise all the way using a ring wrench Info Do not loosen screw connection Turn back counterclockwise by the number of turns corresponding to the shock absorber type Guideline Compression damping high speed Comfort 1 5 turns Standard 1 turn Sport 1 turn Info Turn clockwise to increase damping turn counterclockwis...

Page 62: ...accidents Do not make any radical changes to the adjustment of the shock absorbers Only make adjustments within the recommended range Info The low speed setting takes effect during the slow to normal compression of the shock absorber 301791 11 Turn adjusting screw clockwise to the last perceptible click using a screwdriver Info Do not loosen screw connection Turn back counterclockwise by the numbe...

Page 63: ...y of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help 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...

Page 64: ...ns damp ing 9 13 Rear shock absorber adjusting the spring preload x Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the description provided Your authorized KTM workshop will be glad to help Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers Make adjust...

Page 65: ... the length of the spring Remove the rear shock absorber x p 64 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 Turn the adjusting ring until the spring pack is fully unloaded ...

Page 66: ...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 66 9 14 Removing the rear shock absorber x Jack up the vehicle p 50 Remove the re...

Page 67: ... 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 68: ...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 127 Remove the vehicle from the work stand p 50 9 16 Checking the toe x Park the vehicle on a horizontal surface Check the tire condition p 110 Check the tire air pressure p 110 Check th...

Page 69: ...INE 67 300272 10 Load the vehicle with the specified weight Guideline Average 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 70: ...MAINTENANCE ON CHASSIS AND ENGINE 68 400333 10 Measure distances and If distances and are not equal Adjust the toe x p 69 Measure distances and Guideline Toe Front 0 mm 0 in ...

Page 71: ...es not meet specifications Adjust the toe x p 69 9 17 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 110 Check the tire air pressure p 110 Check the chassis parts for damage play and wear Replace damaged or worn parts 300272 10 Load the vehicle with the specified weight Guideline Average rider weight 70 80 kg 154 176 lb Move the handlebar into the straight ...

Page 72: ...SIS AND ENGINE 70 400333 11 Loosen nuts and Adjust the distances and to the same value by rotating the tie rods Adjust the distances and to the specified value by evenly rotating the tie rods Guideline Toe Front 0 mm 0 in ...

Page 73: ...he 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 operations are the same on the left and right Jack up the v...

Page 74: ...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 75: ...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 76: ...k up the vehicle p 50 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 50 9 21 Toe width of rear axle 301794 10 The toe width can be adjusted by installed the spacer in various ways Difference between narrow wide toe 76 mm 2 99 in ...

Page 77: ...t first to get the feel of the new ride behavior Engage 1st gear 301538 10 Loosen nuts of the wheel hubs on both sides Jack up the vehicle p 50 Remove the nuts on both sides and take all parts off of the rear axle 0 0 3 3 0 0 1 1 0 0 2 2 100103 10 Setting a narrow toe width Mount the wheel hub Mount the conical ring with the cone facing outward Mount the spacer with the cone facing inward Mount th...

Page 78: ...acer with the cone facing inward Mount the conical ring with the cone facing outward Mount the wheel hub Mount the washer and the new self locking nut 301538 10 Remove the vehicle from the work stand p 50 Tighten nuts on both sides Guideline Nut rear wheel hub M18x1 5 130 Nm 95 9 lbf ft Shift gear to neutral ...

Page 79: ...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 80: ...NCE ON CHASSIS AND ENGINE 78 9 24 Adjusting handlebar position x 301846 10 Remove the handlebar cushion Info Protect the vehicle and its attachments from damage by covering them Do not bend the cables and lines ...

Page 81: ...lumn 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 the handlebar support in the desired position using the screws Mount new self locking nuts and tighten Guideline Nut handleb...

Page 82: ... the throttle cable Guideline Play in throttle cable 3 5 mm 0 12 0 2 in If the throttle cable play does not meet specifications Adjust the play in the throttle cable p 81 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 S...

Page 83: ...tle cable route 301795 10 Move the handlebar to the straight ahead position Loosen the nut and use the screw to adjust the play in the throttle cable Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 9 27 Checking chain dirt 400678 01 Check the chain for heavy soiling If the chain is very dirty Clean the chain p 82 ...

Page 84: ...ad chain spray p 180 9 29 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain...

Page 85: ...ositions Chain tension 140 145 mm 5 51 5 71 in If the chain tension does not meet specifications Adjust the chain tension p 85 9 30 Checking rear sprocket engine sprocket for wear 400227 01 Check rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Replace the rear sprocket engine sprocket Info When fitting the chain joint always make sure that the closed side of th...

Page 86: ...3 lb Measure the distance of 18 chain links in the 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 spr...

Page 87: ...ssion output shaft or the drive chain may snap Conversely if the chain is too loose it may jump off the engine and rear sprockets causing the rear wheel to lock up or even leading to engine damage Check for 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 componen...

Page 88: ... special tool to rotate the rear wheel eccentric element forward or backward Guideline Chain tension 140 145 mm 5 51 5 71 in Info Rotating the rear wheel eccentric element forward increases chain tension Rotating the rear wheel eccentric element backward reduces chain tension The rear wheel eccentric element should always be positioned such that the grease nipple is visible This ensures that the v...

Page 89: ... discs Warning Danger of accidents Reduced braking efficiency due to worn brake disc s Change the worn brake disc s without delay Your authorized KTM workshop will be glad to help 400362 10 Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement Info Wear reduces the thickness of the brake disc around the area used by the brake linin...

Page 90: ...l 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 front brake in the brake system The front brake can fail due to overheating Adjust free travel on hand brake lever according to specifications 301799 10 Push the hand brake lever forward and check free travel Free play of hand brake lever 3 mm 0 12...

Page 91: ...he hand brake lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 9 37 Checking front brake fluid level 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 ...

Page 92: ...s 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 irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rinse thoroughly with water ...

Page 93: ...c should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive and may damage painted surfaces Use only clean brake fluid from a sealed container ...

Page 94: ...w top edge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 175 Position the cover with the membrane Mount and tighten 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 efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad...

Page 95: ...ge or cracking is visible Change the front brake linings x p 95 Install the wheel wheels p 108 9 40 Removing front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Info The operations are the same on the left and right Remove the wheel wheels p 107 Pull the hand brake le...

Page 96: ...sary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from ...

Page 97: ... hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Install the wheel wheels p 108 9 42 Changing the front brake linings x Warning Skin irritation Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid gets into your eyes rin...

Page 98: ... Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable 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 is corrosive and may dama...

Page 99: ...ect brake fluid level to Guideline Dimension brake fluid level below top edge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 175 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 9 43 Checking free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the foot ...

Page 100: ...2 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 98 Reconnect spring 9 44 Adjusting basic position of foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free trave...

Page 101: ...n of the foot brake 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 102: ...r brake fluid x p 100 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 irritation Brake fluid can cause skin irritation on contact Avo...

Page 103: ...ces cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable 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 is corrosive and may damage painted surface...

Page 104: ... of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 100038 10 Check the brake linings for minimum thickness Minimum thickness 1 mm 0 04 in If the minimum thickness is less than specified Change the rear brake linings x p 106 Check the brake linings for damage and cracking If damage or cracking...

Page 105: ...ut professionally Your authorized KTM workshop will be glad to help 301830 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 106: ...s keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking efficiency due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ con...

Page 107: ...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 180 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 108: ...nge the brake fluid of the front and rear brakes according to the service schedule Your authorized KTM workshop will be glad to help Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Never user DOT 5 brake fluid This is based on silicone oil and is colored ...

Page 109: ... the brake fluid reservoir Install the rear brake linings x p 104 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 175 Refit 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 the hand brake lever push the locking pawl down and release the hand brake lever Figure ...

Page 110: ... 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 111: ...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 50 Pull the hand brake lever push the locking pawl down and release the hand brake lever Figure 301776 10 p 20 Tighten the wheel nuts crosswise Guideline Wheel nut M10x1 25 45 Nm 33 2 lbf ft ...

Page 112: ... bodies and other damage Check the tire age Info The tire s date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits indicate the week of manufacture and the last two digits the year of manufacture KTM recommends that the tires be changed after 5 years at the latest regardless of the actual state of wear If the tires ...

Page 113: ...njury Battery acid and battery gases cause serious cauterization 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 wate...

Page 114: ...he positive plus cable of the battery Loosen the rubber band Remove the battery 9 56 Installing the battery 300279 11 Place the battery in the battery holder 4Ah battery YTX5L BS p 168 Reconnect rubber band Attach the positive plus cable and replace the plus pole cover Connect the negative minus cable of the battery Install the rear fender p 127 ...

Page 115: ...nse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and acid are harmful to the environment Do not discard batteries with the household trash Dispose of a defective battery in an environmentally compatible manner Give the battery to your KTM dealer or to a recycling center that acc...

Page 116: ...yte escapes via the safety valves This reduces the battery capacity If the vehicle is started repeatedly until the battery is depleted the battery must be charged immediately If the battery is left in a discharged state for an extended period it will drain completely and sulfate destroying the battery The battery is maintenance free which means that the acid level does not need to be checked Switc...

Page 117: ...s device you cannot overcharge the battery Info Never remove the lid Charge the battery to a maximum of 10 of the capacity specified on the bat tery housing 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 127 9 ...

Page 118: ... electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Insert the new fuse Fuse 58011109120 Tip Replacement fuse should always be present in the starter relay to make sure it is available when needed Replace the protection covers 9 59 Changing the fuses of individual power consumers Remove the front cover p 122 S...

Page 119: ... used Fuse 5 power supply for auxiliary equipment Fuse res 10A spare fuses Info You can recognize a blown fuse by its broken filament Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Insert a new fuse of the appropriate strength Fuse 58011109110 Tip The replacement fuses should always...

Page 120: ... The plug in connector is disconnected for better driveability 9 61 Changing the ignition curve Remove the front trim p 123 Changing the ignition curve from Performance to Soft Disconnect plug in connector Figure 301829 10 p 118 Soft The plug in connector is disconnected for better driveability p 118 Changing the ignition curve from Soft to Performance Connect the plug in connector Figure 301829 1...

Page 121: ...seat 301809 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 301810 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 122: ...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 119 301817 10 Remove the screws on the fuel tank ...

Page 123: ...crews on the radiator Detach the radiator spoiler and remove it 9 65 Installing the radiator spoiler Info The operations are the same on the left and right 301819 10 Hook catch of the radiator spoiler into holder of the fuel tank and position it on the radiator ...

Page 124: ... 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 119 9 66 Removing the front cover 301811 10 Remove screw Slide the front cover up and remove it ...

Page 125: ...CHASSIS AND ENGINE 123 9 67 Installing the front cover 301812 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 122 ...

Page 126: ...MAINTENANCE ON CHASSIS AND ENGINE 124 301820 10 Remove screws Raise the front trim and disconnect the plug in connector from the emergency OFF switch with the rip cord Remove the front trim ...

Page 127: ...he emergency OFF switch with the rip cord and posi tion 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 123 9 70 Removing the rear fender Remove the seat p 119 ...

Page 128: ... 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 129: ...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 130: ...MAINTENANCE ON CHASSIS AND ENGINE 128 301822 11 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 119 ...

Page 131: ...301823 10 Remove screws and Remove the engine guard 9 73 Installing the engine guard 301823 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 132: ...ronmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Remove the seat p 119 301824 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...

Page 133: ...ase p 180 301825 10 Put in both parts together position them and fix them with the air filter support Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and 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 119 ...

Page 134: ...e air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 130 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 179 Info Only press the air filter to dry it never wring it out Oil the dry air filter with a high quality filter oil Oil for foam air filter p 181 Clean the air filter box Check carburet...

Page 135: ...nge of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 9 78 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 301814 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover wit...

Page 136: ...d coolant temperature is therefore permissible without danger of function problems 120 C 248 F Cooling is effected by the air stream The radiator fan provides extra cooling The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 9 80 Radiator fan 301827 10 The radiator fan is located on the radiator under the fuel tank Working range within which radiator f...

Page 137: ...etween coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately 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 123 400243 10 Remove the radiator cap Check ...

Page 138: ...diately 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 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...

Page 139: ... If you scald yourself hold the affected area under lukewarm 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 tact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Cha...

Page 140: ...ant bleeding the cooling system x 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 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 ...

Page 141: ...d ready to use p 175 301840 10 Open screw to bleed the radiator Tighten the screw when coolant emerges from the opening Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 301839 10 Add coolant to level above the radiator fins Guideline 10 mm 0 39 in Mount the radiator cap Install the front trim p 125 Make a short test ride Check the coolant level p 136 ...

Page 142: ...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 idle x 301826 10 Screw in the idle adjusting screw ...

Page 143: ...hest idle speed Info If there is a large increase in the engine speed reduce the idle speed to a nor mal level and repeat the above steps The extremely sporty rider will set the mixture about 1 4 of a turn back from this ideal value leaner clockwise since the engine has a higher operating tempera ture in sporting use If the procedure described here does not lead to satisfactory results the cause m...

Page 144: ...uel tank expands when warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed con...

Page 145: ...rburetor 301826 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 the 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 146: ...it one minute before checking the level The engine oil reaches the middle of the viewer When the engine oil does not reach the middle of the viewer Add engine oil p 150 800061 11 Condition The 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 Add engine oil p 150 ...

Page 147: ...Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the engine oil...

Page 148: ...gnet M12x1 5 20 Nm 14 8 lbf ft Clean the oil screen x p 146 9 91 Cleaning the oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters...

Page 149: ...oil screen M32x1 5 30 Nm 22 1 lbf ft 9 92 Removing the oil filter x Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under lukewarm water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fl...

Page 150: ... 301843 10 Remove screws Take off the oil filter cover with the O ring 301844 11 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 151: ... it in the oil filter housing 301843 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 A lack of engine oil or poor quality engine oil results in premature wear to the engine ...

Page 152: ...176 Mount and tighten filler 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 143 9 95 Adding engine oil Info A lack of engine oil or poor q...

Page 153: ...ll up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 176 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 176 Info To ensure optimal engine oil performance it is advisable to not use different engine oils We recommend making an oil change in this case Mount and tighten filler cap ...

Page 154: ...trode distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 0 7 mm 0 028 in Fault in ignition system Check the ignition system x Socket connector of CDI control device pulse generator or ignition coil oxidized Clean the plug in connector and treat it with con tact spray Water in carburetor or jets blocked Check adjust the carburetor components x Idle speed...

Page 155: ...he instructions on starting the engine p 32 Battery discharged Recharge the battery x p 113 Check the charging voltage x Check the quiescent current x Check the alternator x Blown fuse Change the main fuse p 115 Engine does not speed up Carburetor running over because float needle dirty or worn Check adjust the carburetor components x Loose carburetor jets Check adjust the carburetor components x ...

Page 156: ... oxidized connector Check the electrical system Clean the plug in connector and treat it with con tact spray Engine overheats Coolant level low Check the cooling system for leakage Check the coolant level p 136 Radiator fins excessively dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 137 Fill coolant bleed the cooling system x p 138 Bent radiator hose Change the ra...

Page 157: ...tle Adjust the valve clearance x High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level p 143 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screen x p 145 Piston or cylinder worn Measure the piston cylinder mounting clear ance x Battery discharged Battery is ...

Page 158: ...sposed of as stipulated in applicable 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 Close ...

Page 159: ...nd the brakes to evaporate Push back the protective covers from the handlebar armatures to allow any water that may have entered there to evaporate After the vehicle has cooled off oil or grease all moving parts and bearings Clean the chain p 82 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and polishing materials for metal rubber and plast...

Page 160: ...each 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 vehicle p 156 Ch...

Page 161: ...e non porous materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine for a short time only Because the engine will not warm up sufficiently the water vapor produced dur ing combustion will condense causing engine parts and the exhaust system to rust 12 2 Putting the vehicle into operation after storage Install the battery p 112 Fill up with fuel p 43 Che...

Page 162: ...lve 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 Pre...

Page 163: ...NGK 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 176 External temperature 0 C 32 F Engine oil SAE 5W 40 p 176 13 2 Capacity coolant Coolant 1 50 l 1 59 qt Coolant p 175 Coolant mixed ready to...

Page 164: ...apter M5 6 Nm 4 4 lbf ft Loctite 243 Screw locking lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw oil filter cover M5 6 Nm 4 4 lbf ft Screw oil pump cover M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator bracket M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator cable holder M5 6 Nm 4 4 lbf ft Loctite 243 Screw timing train axle retaining bracket M5 6 Nm 4 4 lbf ft Loctite 243 Oil jet clutch oil supply M5x1 6 Nm ...

Page 165: ... ft Stud cylinder head M6 10 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...

Page 166: ...g 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 167: ...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 168: ...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 169: ...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 170: ...ance free 16 1 Tires Front tire Rear tire 20 x 6 00 10 MAXXIS Razr MX 931 18 x 10 00 8 MAXXIS Razr MX 932 Additional information is available in the Service section under http www ktm com 16 2 Capacity fuel Total fuel tank capacity approx 10 3 l 2 72 US gal Super unleaded ROZ 95 RON 95 PON 91 p 178 ...

Page 171: ...t 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 12 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 8 mm Spring rate main spring 24 29 N mm 137 166 lb in Spring rate auxiliary spring 40 N mm 228 lb in ...

Page 172: ...OCK ABSORBER 170 Spring length main spring 275 mm 10 83 in Spring length auxiliary spring 60 mm 2 36 in Fitted length 463 mm 18 23 in Gas pressure 10 bar 145 psi Shock absorber oil Shock absorber oil SAE 2 5 50180342S1 p 177 ...

Page 173: ...n Sport 1 turn Compression damping low speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks Rebound damping Comfort 20 clicks Standard 15 clicks Sport 15 clicks Cross over 19 1 5 mm 0 75 0 059 in Info Measured at the tension free 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 174: ...CK ABSORBER 172 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 177 ...

Page 175: ...ont 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...

Page 176: ...r 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 steer...

Page 177: ...otorex products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready ...

Page 178: ... the 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 182 SAE p 182 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 Suppl...

Page 179: ...ydraulic 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 182 SAE 2 5 Guideline Use only oils that comply with the specified standards s...

Page 180: ...OPERATING SUBSTANCES 178 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 181: ... Remover Chain cleaner Guideline KTM recommends Motorex products Supplier Motorex Chain Clean 611 Cleaning and polishing materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 Contact spray Guideline KTM recommends Motorex products Supplier Motorex Accu Contact ...

Page 182: ...r Motorex Fett 2000 Lubricant T625 Guideline KTM recommends Molykote products Supplier Molykote 33 Medium Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Off road chain spray Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 ...

Page 183: ...AUXILIARY SUBSTANCES 181 Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power ...

Page 184: ...ce intervals are demanded for automobile engines high performance at high engine speeds are in the foreground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Stan dard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils ...

Page 185: ...rake fluid of front brake topping up 90 Brake fluid of rear brake checking 99 topping up 100 Brake linings of front brake changing 95 checking 92 installing 94 removing 93 Brake linings of rear brake changing 106 checking 102 installing 104 removing 103 Brakes 34 C Camber adjusting 71 checking 71 Carburetor adjusting idle 140 float chamber emptying 142 idle 140 Chain cleaning 82 Chain tension adju...

Page 186: ...umber 17 Engine oil adding 150 changing 145 draining 145 refilling 149 Engine oil level checking 143 Environment 10 F Fender rear installing 127 removing 125 Filler cap closing 23 opening 22 Filling up fuel 43 Foot brake pedal 26 basic position adjusting 98 free travel checking 97 Fork offset 73 adjusting 74 Front cover installing 123 removing 122 Front shock absorber compression damping high spee...

Page 187: ...onnection 118 K Kill switch 22 M Main fuse changing 115 Maintenance 8 O Oil filter changing 145 installing 149 removing 147 Oil screen cleaning 145 146 Owner s manual 11 P Parking 42 Parking brake 20 Play in throttle cable adjusting 81 checking 80 Putting into operation advice on first use 27 after storage 159 checks before putting into operation 31 R Radiator fan 134 Radiator spoiler installing 1...

Page 188: ...5 49 Shifting forward gears 34 Shock absorber shock absorber part number front 17 shock absorber part number rear 18 Spare parts 9 Starting 32 Stopping 42 Storage 158 T Technical data carburetor 165 chassis 166 168 chassis tightening torques 173 174 engine 160 161 engine tightening torques 162 164 front shock absorber 169 170 rear shock absorber 171 172 Throttle lever 21 Tire air pressure checking...

Page 189: ...INDEX 187 U Use definition 8 V Vehicle cleaning 156 jacking up 50 removing from work stand 50 W Wheel wheels installing 108 removing 107 Work rules 9 ...

Page 190: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 05 2009 Photo Mitterbauer 3211488en 3211488en ...

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KTM 450 SX ATV, Owner'S Manual

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