KTM 450 XC Page 98 Owner'S Manual Download | Manualshive

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MAINTENANCE ON CHASSIS AND ENGINE

96

9.24

Checking the play in the Bowden cable using the reverse gear release lever

600141-10

–

Move the handlebar to the straight-ahead position. Move the reverse gear release lever
back and forth slightly to ascertain the play in the Bowden cable



.

Guideline

Play in the Bowden cable on the reverse
gear release lever

10 mm (0.39 in)

» If the Bowden cable play on the reverse gear release lever does not agree with the

specifications:

–

Adjust the play in the Bowden cable using the reverse gear release lever.

9.25

Adjusting the play in the Bowden cable using the reverse gear release lever

–

Check that the Bowden cable is correctly laid from the reverse gear release lever.

600141-11

–

Move the handlebar to the straight-ahead position.

–

Release the nut



and using the screw



, adjust the play of the Bowden cable



on

the reverse gear release lever.
Guideline

Play in the Bowden cable on the reverse
gear release lever

10 mm (0.39 in)

–

Tighten nut



.

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Summary of Contents for 450 XC

Page 1: ...OWNER S MANUAL 2009 450 XC ATV 525 XC ATV ART NO 3211377en...

Page 2: ......

Page 3: ...tions 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 de...

Page 4: ...with the express written permission of the copyright owner ISO 9001 12 100 6061 Within the meaning of the international quality management standard ISO 9001 KTM uses quality assurance processes that...

Page 5: ...button 33 Electric starter button 34 Ignition switch 34 Indicator lamp overview 35 Emergency OFF switch with rip cord 35 Opening filler cap 36 Closing filler cap 36 Fuel tap 37 Choke 38 Hot start butt...

Page 6: ...dlebar position 91 Adjusting handlebar position x 92 Checking play in gas Bowden cable 94 Adjusting play in gas Bowden cable 95 Checking the play in the Bowden cable using the reverse gear release lev...

Page 7: ...r x 147 Adjusting basic position of clutch lever 148 Checking fluid level of hydraulic clutch 149 Cooling system 150 Radiator fan 150 Checking antifreeze and coolant level 151 Checking the coolant lev...

Page 8: ...es 189 Capacity fuel 189 TECHNICAL DATA FRONT SHOCK ABSORBER 190 TECHNICAL DATA REAR SHOCK ABSORBER 191 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 192 SUBSTANCES 194 AUXILIARY SUBSTANCES 197 STANDARDS...

Page 9: ...d technical 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 spe...

Page 10: ...and prevention 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...

Page 11: ...facturer Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear Replace damaged or worn parts After finishing the repair and maintenance work ensure tha...

Page 12: ...nd 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...

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

Page 14: ...IMPORTANT NOTES 12 2 1 Overview of labels 700376 01...

Page 15: ...Hangtag 2 Information on use 3 Emission control 450 XC ATV 3 Emission control 525 XC ATV 4 Warning label 5 Information on not riding as a passenger 6 Information on putting into operation 7 Informati...

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

Page 17: ...IMPORTANT NOTES 15 700372 01 Information on use 700373 01 Emission control 450 XC ATV...

Page 18: ...IMPORTANT NOTES 16 700374 01 Emission control 525 XC 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: ...ings 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...

Page 22: ...mportant 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 y...

Page 23: ...21...

Page 24: ...VIEW OF VEHICLE 22 3 VIEW OF VEHICLE 3 1 View of the vehicle from the left front symbol display 600148 10...

Page 25: ...4 Front shock absorber 5 Right hand brake caliper 6 Steering damper holder steering damper is optional 7 Front left shock absorber 8 Outside brake disk guard 9 Shift lever 10 Left footrest 11 Heel pro...

Page 26: ...VIEW OF VEHICLE 24 3 2 View of the vehicle from the right rear symbol display 600149 10...

Page 27: ...P 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 Compensating tank for coolant 10 Manifold 11 Top...

Page 28: ...AL NUMBERS 4 1 Chassis number 100002 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 100034 10 The type label is located on the...

Page 29: ...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 100001 10 The engine number is stamped on...

Page 30: ...4 5 Setting number front shock absorber 100033 10 The setting number is stamped into the top of the shock absorber 4 6 Setting number rear shock absorber 100032 10 The setting number is stamped into...

Page 31: ...ectric starter button is pressed Clutch lever pulled In this position the force lock between the engine and the gear is broken and the starting circuit is closed The electric starter turns over when t...

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...

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 o...

Page 34: ...n this position the low beam and tail lights are switched on Lights off Light switch has been swiveled down In this position all lights are switched off 5 7 ENG STOP switch 100030 10 The ENG STOP swit...

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 S...

Page 36: ...starter button is pressed In this position the electric starter is actuated 5 11 Ignition switch 100031 10 The ignition switch is located in the instrument support Possible states Ignition off In this...

Page 37: ...switched to idle 5 13 Emergency OFF switch with rip cord 100010 10 The emergency 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 cl...

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...

Page 39: ...close the supply of fuel to the car buretor Possible states Fuel supply off OFF No fuel can flow from the tank to the carburetor Fuel supply on ON Fuel can flow from the tank to the carburetor The fu...

Page 40: ...stop Choke function deactivated The choke lever is pushed in to the stop 5 18 Hot start button 100015 10 The hot start button red is fitted on the left side of the carburetor Activating the hot start...

Page 41: ...ever is mounted on the left side of the engine 100017 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears Reverse gear can only be en...

Page 42: ...OPERATING ELEMENTS 40 5 20 Foot brake pedal 100016 10 The foot brake pedal is located in front of the right footrest and operates the rear wheel brake...

Page 43: ...sional trainer will show you how to handle your ATV safely in various riding situations and on different terrain Your KTM dealer will be glad to advise you Warning Risk of injury Risk of injury by mis...

Page 44: ...ble 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 runn...

Page 45: ...tion of the footbrake lever x p 114 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 p...

Page 46: ...t 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 running in period During the...

Page 47: ...the chain tension p 98 Check the chain dirt accumulation p 97 Check the tire condition p 125 Checking the tire air pressure p 126 Check the front brake fluid level p 106 Check the rear brake fluid le...

Page 48: ...ngine 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 cha...

Page 49: ...rrent 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 The green idling...

Page 50: ...ock Do not change into a low gear at high engine speed The engine races and the rear wheels can block 100017 10 Condition When conditions allow incline road situation etc you can shift into a higher g...

Page 51: ...ehicle and run the engine at idling speed Activate the clutch and engage 1st gear Apply light pressure to the shift lever and activate the reverse gear release lever Press the shift lever all the way...

Page 52: ...nd let the engine run at idling speed Press the shift lever up until 1st gear engages Info The reverse gear release lever no longer needs to be activated Slowly release the clutch lever while carefull...

Page 53: ...f 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...

Page 54: ...he 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...

Page 55: ...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...

Page 56: ...face 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...

Page 57: ...unt immediately to the uphill side 7 13 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...

Page 58: ...efully 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 ap...

Page 59: ...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 dept...

Page 60: ...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 consumi...

Page 61: ...vehicle and park it on a surface that is as horizontal as possible Shift gear to neutral The green idling speed indicator lamp N lights up Switch off the engine p 57 Remove the ignition key and the cl...

Page 62: ...in 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 swallow...

Page 63: ...ck vent hoses for damage and routing without sharp bends Check idle Attachments Check the cooling system for leakage Check the antifreeze and coolant level p 151 Check the exhaust system for leakage a...

Page 64: ...mn bearing for wear and smooth operation Clean and grease bearing and sealing elements of steering column Check steering for smooth operation and play Check the bearing of the handlebar bridge of exce...

Page 65: ...to be carried out by an authorized KTM workshop as additional order Competition use Hobby use J1A J2A S15A S30A S45A S30A S60A S90A Carry out a complete shock absorber service Clean and adjust carbur...

Page 66: ...ng Check wear of all transmission components including shafts and bearings Check long bypass valve spring Change glass fiber yarn filling of main silencer Replace foot brake cylinder seals Check carbu...

Page 67: ...adjust Bowden cables Clean the chain p 97 Check the chain tension p 98 Check the chain wear p 99 Check rear sprocket engine sprocket for wear p 99 Clean the air filter x p 147 Checking the tire air pr...

Page 68: ...Always place the 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...

Page 69: ...to the settings proceed in small steps instead Even small changes can have a large impact on vehi cle handling 9 4 Front shock absorber adjusting the compression damping Danger Danger of accidents The...

Page 70: ...range are detrimental to vehi cle handling When changing the chassis settings always start with the standard setting Info Turn clockwise to increase damping turn counterclockwise to reduce suspension...

Page 71: ...il it stops Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Rebound damping Standard 20 clicks Maximum deviation from standard value 5 5 clicks Ti...

Page 72: ...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 p...

Page 73: ...rs should have the same settings Remove the vehicle from the work stand p 66 9 7 Front shock absorber adjusting the spring preload Danger Danger of accidents The shock absorber is under high pressure...

Page 74: ...ays start from the standard setting Jack up the vehicle p 66 Clean the shock absorber thoroughly 100083 10 Press the spring pack and the spring retainer down to make the securing clip accessible Using...

Page 75: ...of the spring retainer 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 prel...

Page 76: ...he adjusting wheel clockwise until it stops Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compression damping Standard 17 clicks Maximum deviati...

Page 77: ...mpressed 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 absorber...

Page 78: ...settings always start with the standard setting Info Turning to the right increases damping while turning to the left lessens damp ing 9 10 Rear shock absorber adjusting the spring preload x Danger Da...

Page 79: ...resent 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 100082 10 Loosen the lock nut Hold adjusting ring w...

Page 80: ...ring to measurement Guideline Spring preload Standard 3 mm 0 12 in Tighten the lock nut and the adjusting ring Info The adjusting ring is made of plastic Therefore do not lock the adjusting ring too...

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 Pre...

Page 82: ...w rear top shock absorber M12 60 Nm 44 3 lbf ft Position the shock absorber in the swingarm Mount and tighten the bottom screw Guideline Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Remove t...

Page 83: ...E 81 500228 01 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 stra...

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: ...im flange If the toe does not meet specifications Adjust the toe x p 83 9 14 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 125 Checking the tire air pressure...

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: ...en 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...

Page 88: ...amaged or worn parts 600127 10 Insert the tool in the heim joint and clip onto the A arm Camber gauge 83019014000 Check the camber on both heim joints If the marking is not aligned with the top edge o...

Page 89: ...ork offset The fork offset has an impact on the handling of the vehicle The fork offset can optionally be adjusted Fork offset is defined as the slanted position of the swivel axis in the direction of...

Page 90: ...screws with bushings Check parts for damage and wear Replace damaged or worn parts Place the A arm with the bushings in the desired position Mount and tighten screws Guideline Screw A arm top M10x52...

Page 91: ...teristics Engage 1st gear 100102 10 Loosen nuts of the wheel hubs on both sides Jack up the vehicle p 66 Remove the nuts on both sides and take all parts off of the rear axle Check parts for damage an...

Page 92: ...sleeve 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 100102 10 Remove the vehicle from the work sta...

Page 93: ...sted 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 o...

Page 94: ...INE 92 9 21 Adjusting 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...

Page 95: ...ce damaged or worn parts Place the handlebar 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 scre...

Page 96: ...tioned correctly Position the instrument support on the handlebar 9 22 Checking play in gas Bowden cable 600142 10 Move the handlebar to the straight ahead position Move the throttle lever back and fo...

Page 97: ...rt 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...

Page 98: ...play on the reverse gear release lever does not agree with the specifications Adjust the play in the Bowden cable using the reverse gear release lever p 96 9 25 Adjusting the play in the Bowden cable...

Page 99: ...ng 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 Th...

Page 100: ...ak 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 necessa...

Page 101: ...et 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 sproc...

Page 102: ...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 distanc...

Page 103: ...an 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 en...

Page 104: ...ear 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...

Page 105: ...n to fill the rear wheel eccentric element via the grease nipple until grease emerges from the left shaft seal ring Long life grease p 196 9 33 Checking brake discs Warning Danger of accidents Reduced...

Page 106: ...imit of brake discs Front 3 5 mm 0 138 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the brake disc 9 34 Checking the free play of the hand brake lever Wa...

Page 107: ...e 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 ha...

Page 108: ...ke 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...

Page 109: ...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...

Page 110: ...e fluid DOT 4 DOT 5 1 p 194 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid im...

Page 111: ...linings x p 111 Mount the wheel wheels p 124 9 39 Removing front brake linings x Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired...

Page 112: ...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 con...

Page 113: ...e way 100073 10 Mount the locking split pins Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot Mount the wheel wheels p 124 9 41 Changing...

Page 114: ...ard 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 bas...

Page 115: ...luid to level Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 194 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten...

Page 116: ...2 0 2 in If the free travel does not meet specifications Adjust the basic position of the footbrake lever x p 114 Reconnect spring 9 43 Adjusting basic position of footbrake lever x Warning Danger of...

Page 117: ...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 Guidel...

Page 118: ...luid of the rear brake x p 116 9 45 Topping up brake fluid of front brake x Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom of the viewer this indicate...

Page 119: ...als 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...

Page 120: ...p overflowed or spilt brake fluid immediately with water 9 46 Checking rear brake linings Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced im...

Page 121: ...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 hol...

Page 122: ...eep 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...

Page 123: ...pling plate is mounted on the piston side of the brake pad 100068 10 Grease the bearing bolt and insert the brake caliper with the bearing bolt into the brake caliper support Lubricant T625 p 198 1000...

Page 124: ...e 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 oi...

Page 125: ...he rear brake linings x p 120 Top up the brake fluid to level Brake fluid DOT 4 DOT 5 1 p 194 Check parts for damage and wear Replace damaged or worn parts Refit screw with membrane Info Clean up over...

Page 126: ...aking sure it does not become jammed with the threads of the screws 9 51 Mounting wheel wheels Note Material damage Damage and destruction of components from incorrect positioning and mounting Do not...

Page 127: ...Wheel nut M10x1 25 45 Nm 33 2 lbf ft 9 52 Tire condition checking Info Fit only tires approved by KTM Other tires could have a negative effect on riding behavior The type condition and air pressure of...

Page 128: ...pressure off road 0 3 bar 4 psi If the tire pressure does not meet specifications Correct tire pressure Mount dust cap 9 54 Removing the battery Warning Risk of injury Battery acid and battery gases c...

Page 129: ...er and disconnect the positive plus cable of the battery Loosen the rubber band Remove the battery 9 55 Installing the battery 200150 11 Check parts for damage and wear Replace damaged or worn parts P...

Page 130: ...atteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc acco...

Page 131: ...ger 58429074000 You can also use the battery charger to test rest potential and start potential of the bat tery and to test the generator With this device you cannot overcharge the battery Info Never...

Page 132: ...fuse 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 Ne...

Page 133: ...es is located on the inside cover of the fuse box Remove the faulty fuse Guideline Fuse 110A ignition CDI controller indicator lamps ON N R Fuse 215A high beam low beam parking light tail light brake...

Page 134: ...scribed 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...

Page 135: ...sconnected for better performance 9 60 Changing ignition curve Remove the front trim p 138 Changing the ignition curve from Performance to Soft Connect the plug in connector Figure 100105 10 p 133 Sof...

Page 136: ...k Lift up the seat at the rear pull it back and then remove from above 9 62 Mounting the seat 100046 10 Check parts for damage and wear Replace damaged or worn parts Hook the slot on the seat into the...

Page 137: ...the rear of the seat until the release hook engages Make sure that the seat is correctly locked in 9 63 Removing the radiator spoiler Info The operations are the same on the left and right Remove the...

Page 138: ...radiator spoiler and the fuel tank 9 64 Installing the radiator spoiler Info The operations are the same on the left and right 100058 10 Check parts for damage and wear Replace damaged or worn parts...

Page 139: ...on the radiator Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Fit 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 65 Removing the fr...

Page 140: ...alling the front cover 100055 10 Check parts for damage and wear Replace damaged or worn parts Position the front cover in the slots on both sides of the front trim Mount and tighten screw 9 67 Removi...

Page 141: ...ENANCE ON CHASSIS AND ENGINE 139 100075 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...

Page 142: ...lug in connectors of the head 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 Ful...

Page 143: ...200148 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 carbure tor connection...

Page 144: ...amaged or worn parts 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...

Page 145: ...MAINTENANCE ON CHASSIS AND ENGINE 143 200149 11 Fit and tighten screws with collar sleeves Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 134...

Page 146: ...ve the engine guard 9 72 Installing the engine guard 600133 10 Check parts for damage and wear Replace damaged or worn parts Position the engine guard on the frame bearer Mount and tighten screws and...

Page 147: ...vice life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Problem materials cause envir...

Page 148: ...er 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 air filter holder and swi...

Page 149: ...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 Mount the seat p 134 9 75 Cleaning air filter x Warning Environme...

Page 150: ...damage and tightness Install the air filter x p 147 9 76 Adjusting basic position of clutch lever 300232 10 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw In...

Page 151: ...unted on the handlebar to a horizontal position Remove screws Remove cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in If the level of the cooling liquid...

Page 152: ...re 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 cooli...

Page 153: ...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 immediat...

Page 154: ...ions Correct the coolant level Alternative 1 Coolant p 194 Alternative 2 Coolant mixed ready to use p 194 Mount the compensating tank cover Install the front trim p 140 9 81 Checking the coolant level...

Page 155: ...n The radiator must be completely full The coolant level must be between MIN and MAX If the level of the cooling liquid does not meet specifications Open the compensating tank cover and correct the co...

Page 156: ...ur 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 i...

Page 157: ...e the screws and empty the compensating tank Check parts for damage and wear Replace damaged or worn parts Position the compensating tank Mount and tighten screws Guideline Remaining screws chassis M6...

Page 158: ...ge clothes that have come into contact with coolants Keep coolants out of the reach of children 400360 10 Position the vehicle as shown and secure it against rolling away The height difference must be...

Page 159: ...ws chassis M6 10 Nm 7 4 lbf ft Info Ensure that the radiator is always filled with a sufficient amount of coolant 600122 10 Open the screw to bleed the radiator Tighten the screw when coolant emerges...

Page 160: ...gine with a correctly set idle speed is easier to start than if the idle is set wrongly Info The carburetor and its components are subject to increased wear caused by engine vibration Wear can result...

Page 161: ...speed with the adjusting screw Guideline Choke function deactivated The choke lever is pushed in to the stop p 38 Idle speed 1 500 1 600 rpm Info If the idle speed is set significantly higher the eng...

Page 162: ...factory results the cause may be a wrongly dimensioned idling jet If you can turn the idle adjusting screw to the end without any change of engine speed you have to fit a smaller idling jet The idle a...

Page 163: ...ontact 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 an...

Page 164: ...t chamber Tighten screw 9 87 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 600131 10 Condition The engine is at op...

Page 165: ...p 163 Remove the oil filter x p 166 Mount the oil filter x p 168 Fill up with engine oil x p 168 9 89 Draining engine oil cleaning oil screens x Warning Danger of scalding Engine oil and gear oil get...

Page 166: ...ne oil only when the engine is warm Park the vehicle on a horizontal surface Remove the engine guard p 144 600134 10 Place a suitable container under the engine Remove the oil drain plug 600135 10 Rem...

Page 167: ...parts for damage and wear Replace damaged or worn parts Thoroughly clean parts and sealing area Oil the O rings mount them on the oil screen and using a long hexagon key insert them until the O ring i...

Page 168: ...gine oil 600134 11 Fit oil drain plug with seal ring and tighten it Guideline Oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Install the engine guard p 144 9 90 Removing the oil filter x Warning...

Page 169: ...luid batteries etc according to regulations Place a suitable container under the engine 600137 10 Disconnect the ground cable from the engine Remove screws and Take off the oil filter cover with the O...

Page 170: ...er 600137 10 Oil the O rings of the oil filter covers and mount them with the oil filter covers Mount and tighten screws and Guideline Screw oil filter cover M5 6 Nm 4 4 lbf ft Connect the ground cabl...

Page 171: ...r 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 en...

Page 172: ...l up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 195 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 195 Info To ensure optimal engine oil performanc...

Page 173: ...here is old fuel in the float chamber Empty the carburetor float chamber x p 161 Fuel feed interrupted Check the tank breather Clean fuel tap Clean carburetor Engine flooded Clean and dry spark plug o...

Page 174: ...TROUBLESHOOTING 172...

Page 175: ...ove spark plug connect ignition cable hold spark plug to ground bare 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 cha...

Page 176: ...for throttle lever faulty Check wiring harness visual check Check electrical system Throttle valve sensor TPS incorrectly set or faulty Have the throttle valve sensor TPS checked or adjusted The engi...

Page 177: ...or Engine takes in bad air Check rubber sleeves and carburetor for tightness Loose contact or oxidized connector Check electrical system Clean socket connector and treat it with contact spray Engine o...

Page 178: ...Electronic ignition adjustment defective 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...

Page 179: ...ries 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 pl...

Page 180: ...d 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...

Page 181: ...p 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...

Page 182: ...orous 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 th...

Page 183: ...diameter intake 35 mm 1 38 in Valve diameter exhaust 30 mm 1 18 in Valve clearance cold intake 0 10 0 15 mm 0 0039 0 0059 in Valve clearance cold exhaust 0 10 0 15 mm 0 0039 0 0059 in Crankshaft beari...

Page 184: ...6 mm 0 024 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 Engin...

Page 185: ...haft lever M5 6 Nm 4 4 lbf ft Loctite 243 Screw stator bracket M5 6 Nm 4 4 lbf ft Loctite 243 Nut adjusting screw valve clearance M6x0 75 11 Nm 8 1 lbf ft Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft...

Page 186: ...p section M6x45 10 Nm 7 4 lbf ft Screw on cylinder head top section M6x50 10 Nm 7 4 lbf ft Screw on cylinder head top section M6x55 10 9 10 Nm 7 4 lbf ft Screw on cylinder head top section M6x75 10 Nm...

Page 187: ...20 Nm 14 8 lbf ft Plug oil pressure regulator valve M12x1 5 20 Nm 14 8 lbf ft Locking screw oil sieve short M16x1 5 10 Nm 7 4 lbf ft lubricated with engine oil Nut inner clutch hub M18x1 5 120 Nm 88 5...

Page 188: ...H Needle position 450 XC ATV 2nd position from top Needle position 525 XC ATV 3rd position from top Idle mixture adjusting screw Open 1 0 turn Pump membrane stop 2 15 mm 0 0846 in Main jet 170 Jet nee...

Page 189: ...ension travel Front 275 mm 10 83 in Rear 272 mm 10 71 in Fork offset Front 46 mm 1 81 in Toe Front 0 mm 0 in Camber Front 0 Toe width Front 1 115 mm 43 9 in Rear 1 148 mm 45 2 in Wheelbase 1 280 10 mm...

Page 190: ...Brake system Front Disc brakes brake calipers fixed 4 brake pistons per brake caliper Rear Disc brake brake caliper floating 1 brake piston Diameter of brake discs Front 180 mm 7 09 in Rear 200 mm 7 8...

Page 191: ...x9 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 21 x 7 00 10 MAXXIS Razr M 931 20 x 11 00 9 MAXXIS Razr M 932 For further information see the...

Page 192: ...0 clicks Maximum deviation from standard value 5 5 clicks Cross over 14 1 5 mm 0 55 0 059 in Clip position spring preload Standard 8th position from top Corresponds to a spring preload of 9 mm 0 35 in...

Page 193: ...number KT 8710 Compression damping Standard 17 clicks Maximum deviation from standard value 5 5 clicks Rebound damping Standard 15 clicks Maximum deviation from standard value 5 5 clicks Spring preloa...

Page 194: ...ar brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw front brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw rear brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw bearing support steering M8 25...

Page 195: ...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 Nut ball head A arm bottom M12x1 5 40 Nm 29 5 lbf ft Nut front wheel hub M12 70 Nm 51 6 lbf ft Screw...

Page 196: ...trol and 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 infer...

Page 197: ...orresponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Cross Power 4T Engine oil SAE 5W 40 According to JASO T903 MA p 200 SAE p 200 SAE 5W 40 Guideline Use only...

Page 198: ...properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Long life grease According to NLGI Guideline Use only grease that complies with the specified standards see specificatio...

Page 199: ...irt Bio Remover Chain cleaner Specification KTM recommends Motorex products Supplier Motorex Chain Clean 611 Cleaning and polishing materials for metal rubber and plastic Specification KTM recommends...

Page 200: ...r Motorex Moto Polish Lubricant T625 Specification KTM recommends Molykote products Supplier Molykote 33 Medium Motorcycle cleaner Specification KTM recommends Motorex products Supplier Motorex Moto C...

Page 201: ...AUXILIARY SUBSTANCES 199 Oil for foam air filter Specification KTM recommends Motorex products Supplier Motorex Twin Air Liquid Power...

Page 202: ...intervals 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...

Page 203: ...luid of front brake topping up 106 Brake fluid of rear brake checking 115 topping up 116 Brake linings of front brake changing 111 checking 108 installing 110 removing 109 Brake linings of rear brake...

Page 204: ...d installing 144 removing 144 Engine number 27 Engine oil changing 163 draining 163 refilling 168 topping up 169 Engine oil level checking 162 Environment 10 F Fender rear installing 142 removing 140...

Page 205: ...38 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 130 Maintenance 8 O Oil filter changing 16...

Page 206: ...ndicular to the slope 55 riding through water 57 starting up 48 uphill 54 S Seat mounting 134 removing 134 Service schedule 61 65 Shifting disengaging reverse gear 49 forward gears 48 shifting to reve...

Page 207: ...r toe width adjusting 89 Toe width of rear axle 88 Transport 9 Troubleshooting 171 176 Turning on slopes 55 Type label 26 V Vehicle cleaning 177 jacking up 66 removing from work stand 66 W Wheel wheel...

Page 208: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 05 2008 Photo Mitterbauer 3211377en 3211377en...

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