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KTM 525 XC ATV EU, Owner'S Manual

The KTM 525 XC ATV EU is a powerful all-terrain vehicle designed for off-road adventures. Ensure a hassle-free setup with our comprehensive manual offering step-by-step Setup Instructions. Download the user manual for free from our website, providing you with all the necessary guidance to optimize your ATV experience.

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TROUBLESHOOTING

177

Faults

Possible cause

Action

Battery discharged

Undesired power consumer

–

Check the quiescent current.

x

Speedometer values deleted (time,
stop watch, lap times)

The battery in the speedometer is
empty.

–

Change the battery in the speedometer.

Summary of Contents for 525 XC ATV EU

Page 1: ...OWNER S MANUAL 2010 525 XC ATV EU Art no 3211487en ...

Page 2: ......

Page 3: ...deviations 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 sto...

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: ...ergency OFF switch with rip cord 27 Speedometer 28 Speedometer activation and test 28 Tripmaster switch 29 Setting kilometers or miles 29 Setting the clock 30 Adjusting the speedometer functions 31 Querying the lap time 32 Display mode SPEED speed 33 Display mode SPEED H operating hours 34 Display mode SPEED CLK clock 35 Display mode SPEED LAP lap time 35 Display mode SPEED ODO odometer 36 Display...

Page 6: ...djusting the cross over 75 Front shock absorber adjusting the spring preload 77 Rear shock absorber adjusting the compression damping 79 Rear shock absorber adjusting the rebound damping 80 Rear shock absorber adjusting the spring preload x 81 Removing the rear shock absorber x 83 Installing the rear shock absorber x 85 Checking the toe x 85 Adjusting the toe x 88 Checking adjusting the camber x 9...

Page 7: ...ving the radiator spoiler 137 Installing the radiator spoiler 138 Removing the front cover 140 Installing the front cover 140 Removing the front trim 141 Installing the front trim 142 Removing the rear fender 142 Installing the rear fender 144 Removing the engine guard 146 Installing the engine guard 146 Removing the air filter x 147 Installing the air filter x 149 Cleaning air filter x 150 Adjust...

Page 8: ...e oil 183 Capacity coolant 183 TECHNICAL DATA ENGINE TIGHTENING TORQUES 184 TECHNICAL DATA CARBURETOR 187 TECHNICAL DATA CHASSIS 188 Lighting equipment 190 Tires 190 Capacity fuel 191 TECHNICAL DATA FRONT SHOCK ABSORBER 192 TECHNICAL DATA REAR SHOCK ABSORBER 193 TECHNICAL DATA TIGHTENING TORQUES FOR CHASSIS 194 SUBSTANCES 196 AUXILIARY SUBSTANCES 200 STANDARDS 203 INDEX 204 ...

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: ... of components such as the trans mission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached Pay careful attention to the prescribed running in period inspection and maintenance intervals If you observe these exactly you will ensure a much longer service life for your vehicle Fuel oils etc You should...

Page 11: ...assembled should be cleaned and checked for damage and wear Replace damaged or worn parts After finishing the repair and maintenance work ensure that the vehicle is roadworthy Transport 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 apply the parking brakes Note Fire hazard Some vehicle components become...

Page 12: ... ATV legally display environmental consciousness and respect the rights of others Rider training If you have never ridden an ATV before it is important that you participate in a driver training course before you ride the vehicle for the first time A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain Your KTM dealer will be glad to...

Page 13: ...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 you can protect yourself from injury The owner s manual also contains important information on servicing the vehicle The o...

Page 14: ...VIEW OF VEHICLE 12 3 1 View of the vehicle from the left front example 601023 10 ...

Page 15: ...r 2 Fuse box 3 Headlight 4 Front left turn signal 5 Front bumper 6 Steering lock 7 Front left shock absorber 8 Clutch lever 9 Emergency OFF switch with rip cord 10 Heel protector 11 Left footrest 12 Shift lever 13 Outside brake disk guard ...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of the vehicle from the right rear example 601039 10 ...

Page 17: ...h horn button 2 Electric starter button 3 Parking brake lever 4 Filler cap 5 Main silencer 6 License plate holder 7 Rear shock absorber 8 Rear sprocket with chain 9 Rear brake 10 Foot brake lever 11 Oil level viewer 12 Fuel tap 13 Throttle lever 14 Ignition switch ...

Page 18: ... 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 601045 10 The type label is located on the frame tube on the right in front of the radiator ...

Page 19: ...0 The key number is indicated on the KEYCODECARD Info You need the key number to order a replacement key Keep the KEYCODECARD in a safe place 4 4 Engine number 601047 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 20: ...shock absorber part number 601024 10 The shock absorber part number is stamped on the top part of the shock absorber 4 6 Rear shock absorber part number 601083 10 The shock absorber part number is stamped on the top part of the shock absorber ...

Page 21: ...th the gear and the starting circuit is interrupted The electric starter does not turn over when the electric 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 the electric starter button is pressed The clutch is hydraulically operated and self adjusting ...

Page 22: ... is combined with the front parking brake which locks the front wheels to prevent the vehicle from rolling away To apply 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 The front wheels are not locked Hand brake lever pulled and locked in position The front wheels are locked ...

Page 23: ...NTROLS 21 5 3 Steering lock 601046 10 The steering lock is fitted on the steering column The steering lock can be used to lock the steering This makes steering impossible and the vehicle cannot be ridden ...

Page 24: ...r brakes The parking brake lever is combined with the parking brake which locks the rear wheels to prevent the vehicle from rolling away To apply the parking brake fold down the parking brake lever Possible states Parking brake lever in basic position The rear wheels are not locked Parking brake lever pulled The rear wheels are locked ...

Page 25: ...ight switch is fitted on the left side of the handlebar Possible states Lights off The light switch is rocked to the right In this position the light is switched off Low beam on Light switch in the middle position In this position the low beam and tail lights are switched on High beam on The light switch is rocked to the left In this position the high beam and the tail light are switched on ...

Page 26: ...h is rocked to the left Right turn signal on The turn signal switch is rocked to the right 5 8 Kill switch 601029 10 The kill switch is fitted on the left side of the handlebar Possible states Kill switch in basic position In this position the ignition circuit is closed and the engine can be started Kill switch pressed In this position the ignition circuit is interrupted a running engine stops and...

Page 27: ...In this position the horn is actuated 5 10 Ignition switch 601032 10 The ignition switch is located to the right of the speedometer Possible states Ignition off In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started ...

Page 28: ... is fitted centrally below the indicator lamps The hazard warning flasher is used to indicate emergency situations Info The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 30 seconds after it is switched off Only activate the hazard warning flasher as long as absolutely necessary to avoid discharging the battery Possible states Hazard warning flash...

Page 29: ...s switched to idle 5 14 Emergency OFF switch with rip cord 601084 10 The emergency OFF switch is mounted on the left in front of the fuel tank The emergency OFF switch shuts the engine off if the rider falls off the vehicle Clip is attached to a rip cord that 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 ...

Page 30: ...ol different functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated 5 16 Speedometer activation and test 400313 01 To activate the speedometer The speedometer is activated when one of the buttons is activated or a pulse arrives from the wheel speed sensor Display test To test the display function all display segments light up briefly ...

Page 31: ...ges to the mode selected last 5 17 Tripmaster switch You can use the trip master switch to control the functions of the speedometer from the handlebar Info The trip master is an optional accessory 5 18 Setting kilometers or miles Info If you change the unit the value ODO is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condition ...

Page 32: ...ton repeatedly until the Km h Mph display flashes Km h adjusting Press the button Mph adjusting Press the button Press the button for 3 5 seconds The settings are stored and the setup menu is closed Info If no button is actuated for 20 seconds or there is no signal from the wheel speed sensor then the settings are automatically stored and the setup menu closed 5 19 Setting the clock Condition The ...

Page 33: ...gments in the same way as the hours by pressing the but ton and the button Info The seconds can only be set to zero Press the button for 3 5 seconds The settings are stored and the Setup menu is closed Info If no button is pressed for 20 seconds or if a pulse arrives from the wheel speed sensor the settings are stored automatically and the Setup menu is closed 5 20 Adjusting the speedometer functi...

Page 34: ...reen and the display changes to the next func tion Deactivating the function Press the button The symbol on the screen goes out and the display changes to the next func tion All desired functions are activated or deactivated accordingly Press the button for 3 5 seconds The settings are stored and the Setup menu is closed Info If no button is pressed for 20 seconds or if a pulse arrives from the wh...

Page 35: ...o If an impulse is received from the wheel speed sensor the left side of the dis play changes back to the SPEED mode 5 22 Display mode SPEED speed 400317 02 Press the button briefly and repeatedly until SPEED appears on the left side of the display The current speed is displayed in the SPEED display mode The current speed can be displayed in Km h or Mph Info Making the setting according to the cou...

Page 36: ...ter stores the total riding time Info The service hour counter is necessary for adhering to the maintenance schedule If the speedometer is in display mode H when the vehicle starts moving it automati cally changes to display mode ODO Display mode H is suppressed during the trip Press the button No function Press the button No function Press the button for 3 5 seconds The display changes to the Set...

Page 37: ...y mode 5 25 Display mode SPEED LAP lap time 400320 01 Press the button briefly and repeatedly until LAP appears at the bottom right of the display In the LAP display mode up to 10 lap times can be timed with the stop watch Info If the lap time continues after you press the button 9 memory locations are already occupied Lap 10 must be timed with the button Press the button Starts or stops the clock...

Page 38: ...button for 3 5 seconds Press the button briefly Next display mode 5 27 Display mode SPEED TR1 trip master 1 400323 01 Press the button briefly and repeatedly until TR1 appears at the top right of the dis play TR1 trip master 1 runs constantly and counts to 999 9 You can use it to measure trips or the distance between refueling stops TR1 is coupled with A1 average speed 1 and S1 stop watch 1 Info I...

Page 39: ...stantly and counts up to 999 9 The displayed value can be set manually with the button and the button A very practi cal function when riding using the road book Info The TR2 value can also be corrected manually during the journey with the button and the button If 999 9 is exceeded the value of TR2 is automatically reset to 0 0 Press the button Increases value of TR2 Press the button Reduces value ...

Page 40: ...ess the button No function Press the button No function Press the button for 3 5 seconds The TR1 A1 and S1 displays are reset to 0 0 Press the button briefly Next display mode 5 30 Display mode SPEED A2 average speed 2 400326 01 Press the button briefly and repeatedly until A2 appears at the top right of the dis play A2 average speed 2 shows the average speed on the basis of the current speed if t...

Page 41: ...stop watch 1 displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor The calculation of this value starts with the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button No function Press the button No function Press the button for 3 5 seconds Displays of TR1 A1 and S1 are reset to 0 0 Press the...

Page 42: ...Table of functions Display Press the button Press the button Press the button for 3 5 seconds Press the button briefly Display mode SPEED H operating hours No function No function The display changes to the Setup menu of the speedometer functions Next display mode Display mode SPEED CLK clock No function No function The display changes to the Setup menu of the clock Next display mode Display mode ...

Page 43: ...isplay mode SPEED A2 average speed 2 No function No function Next display mode Display mode SPEED S1 stop watch 1 No function No function Displays of TR1 A1 and S1 are reset to 0 0 Next display mode Display mode SPEED S2 stop watch 2 Starts or stops S2 No function Displays of S2 and A2 are reset to 0 0 Next display mode Table of conditions and menu activation Display The vehicle is sta tionary Men...

Page 44: ... filler cap 100012 10 Press release button turn filler cap counterclockwise and lift it free 5 34 Closing filler cap 100012 11 Replace the filler cap and turn clockwise until the release button locks in place Check the fuel tank breather to ensure it is properly seated If the fuel tank breather is at an angle or loose Correctly mount the fuel tank breather ...

Page 45: ... left Insert the key into the steering lock turn it to the left press it in and turn it to the right Pull out the key Steering is no longer possible Info Never leave the key in the steering lock 5 36 Unlocking the steering 400731 01 Insert the key into the steering lock turn it to the left pull it out and turn it to the right Pull out the key The vehicle can be steered again Info Never leave the k...

Page 46: ...se 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 fuel tank emp ties down to the reserve Reserve fuel supply on RES Fuel can flow from the tank to the carburetor The fuel tank empties completely ...

Page 47: ...p Choke function deactivated The choke lever is pushed in to the stop 5 39 Hot start button 100015 10 The hot start button red is fitted on the left side of the carburetor Activating the hot start function frees an opening in the carburetor through which the engine can draw extra air This gives a leaner fuel air mixture which is needed for a hot start Info If the engine is cold the hot start funct...

Page 48: ...6 5 40 Shift lever 100018 10 The shift lever is mounted on the left side of the engine 601043 10 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears ...

Page 49: ...CONTROLS 47 5 41 Foot brake lever 100016 10 The foot brake lever is located in front of the right footrest The foot brake lever activates the brakes of all four wheels ...

Page 50: ...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 meet legal requirements Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels The...

Page 51: ...using your vehicle remember that others may feel disturbed by excessive noise Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop You receive a delivery certificate and the service record at vehicle handover Before your first trip read the entire owner s manual thoroughly Get to know the controls Adjust the basic position of the clutch lever p 151 Adj...

Page 52: ...able axle load Front 160 kg 353 lb Rear 190 kg 419 lb Run the engine in 6 2 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Guideline Maximum engine speed During the first 3 service hours 7 000 rpm Maximum engine performance During the first 3 service hours 50 During the next 12 service hours 75 Avoid fully opening the throttle ...

Page 53: ... 100 Check the chain dirt accumulation p 99 Check the tire condition p 127 Check the tire air pressure p 128 Check the front brake fluid level p 107 Check the rear brake fluid level p 117 Check the front brake linings p 110 Check the rear brake linings p 120 Check brake system function Check that the rear hubs are tight Check that the footrests are tight Check the handlebar bridge bearing for exce...

Page 54: ...gh engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine 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 if the fuel stands for an extended period If the float chamber is filled with fresh fuel the engine starts immediately Press the s...

Page 55: ...hrottle lever throttle cable or carburetor When the igni tion is switched on a system check is performed during which the throttle lever must be in its basic position If not the safety system detects a malfunction and blocks the ignition current When the electric starter button is activated the electric starter turns over the engine but the engine does not start because there is no ignition spark ...

Page 56: ...le You will then be seen earlier by other motorists Move the parking brake lever to the basic position Figure 601044 10 p 22 The parking brake in the rear is deactivated Pull the hand brake lever and release it again Locking pawl moves into its basic position front parking brake is deactivated Pull the clutch lever engage 1st gear release the clutch lever slowly and simultaneously open the throttl...

Page 57: ... slowly and open the throttle or shift again 7 5 Braking Warning Danger of accidents If you brake too hard the wheels can lock When the front wheels lock the vehicle can no longer be steered Adapt your braking to the traffic situation and the road conditions Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake Check the brake system and do n...

Page 58: ...d off by the rip cord attached to your clothing This short circuits the ignition circuit and the engine switches off During normal operation you sit erect on the vehicle with both hands on the handlebar and both feet on the footrests If the choke function was activated deactivate it after the engine has warmed up After reaching maximum speed by fully opening the throttle close the throttle so it i...

Page 59: ... before entering into bends Handling of the ATV is strongly influenced by shifts in the position of your body weight Always shift your body weight toward the inside of the bend and forward The faster you ride and the tighter the bend the more you need to shift your body weight Always exert pressure on the footrest on the inside of the bend Look in the direction of the bend while you are riding The...

Page 60: ...Never ride on a road or path with a slippery surface The vehicle can easily go out of control and roll over Note Material damage Damage to vehicle after fall or rollover Perform a vehicle check as is done every time before you start to ride Always ride straight up or down a slope and never at a slant Engage a gear with which you can ride all the way down the slope without shifting Shift your body ...

Page 61: ...a slippery surface 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 without shifting Shift ing on the slope can cause the vehicle to roll over Shift your body weight to the front and ride cautiously Keep your vehicle speed and engine speed as constant as possible Drive ...

Page 62: ...d immediately dis mount on the uphill side 7 11 Turning on slopes Warning Danger of accidents Danger of accidents from turning the vehicle on a slope Never ride down a slope backward The vehicle can roll over easily Always position yourself next to the vehicle in a location where you cannot be caught by a wheel When turning on a slope always stand on the uphill side of the vehicle to avoid injury ...

Page 63: ...u reach a location where you can turn it Control its speed using the clutch 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 apply the parking brakes Mount the vehicle start the engine pull the clutch lever and engage 1s...

Page 64: ...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 65: ...e kill switch the power consumers are not switched off All power consumers that are switched on headlights tail lights etc continue consuming electricity This uses battery power and causes it to discharge Alternative 3 Switch off the engine using the emergency OFF switch with a rip cord Pull off clip Figure 601084 10 p 27 Info When the engine is switched off using the emergency OFF switch the powe...

Page 66: ...e vehicle is operated Do not park the vehicle near flammable or explosive substances Do not place objects on the vehicle while it is still warm from being run Always let the vehicle cool first 400296 01 Stop the vehicle and park it on a surface that is as horizontal as possible Shift gear to neutral The green idling speed indicator lamp N light up Switch off the engine p 62 Remove the ignition key...

Page 67: ...el in the fuel 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 of the fuel with 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 sw...

Page 68: ...ff the engine Open the filler cap p 42 Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm 1 38 in Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 199 Close the filler cap p 42 ...

Page 69: ...oses for damage and routing without sharp bends Check the idle Attachments Check the cooling system for leakage Check the antifreeze and coolant level p 153 Check the exhaust system for leakage and faulty attachment Check the control cables for damage smooth operation and routing without sharp bends Check the fluid level of the hydraulic clutch p 151 Clean the air filter x p 150 Check the cables f...

Page 70: ...ation Clean and grease the bearing and sealing elements of the steering column Check the handlebar for smooth operation and play Check the handlebar bridge bearing for excessive play Check the tie rods and tie rod ends for damage and play Check the front wheel suspension for wear and tightness Check that the front and rear wheel hubs are tight Check the frame and swingarm for damage and leakage Ch...

Page 71: ...0A S90A S160A J1A Change the oil in the front shock absorber x Service the front shock absorber x Change the oil in the rear shock absorber x Service the rear shock absorber x Clean and adjust carburetor Treat electric contacts with contact spray Change hydraulic clutch fluid Change brake fluid Clean spark arrestor Check for wear on the clutch discs Check the length of the clutch springs Check the...

Page 72: ...nd crankshaft journal for run out Change the conrod bearing Change the crankshaft main bearing Change the balancer bearing Check for wear of all transmission components including the shafts and bearings Check the length of the bypass valve spring Change the glass fiber yarn filling of main silencer Replace the foot brake cylinder seals Check the carburetor components S30A Every 30 operating hours ...

Page 73: ... and adjust control cables Clean the chain p 99 Check the chain tension p 100 Check the chain wear p 102 Check rear sprocket engine sprocket for wear p 101 Clean the air filter x p 150 Check the tire air pressure p 128 Check the tire condition p 127 Check the coolant level p 154 Check that all controls for smooth operation Check braking force incl parking brake Check all screws nuts and hose clamp...

Page 74: ... 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 75: ... 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 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 Dang...

Page 76: ...ings always start with the standard setting Info Turn clockwise to increase damping turn counterclockwise to reduce damping The left and right shock absorbers should have the same settings 9 5 Front shock absorber adjusting the rebound damping Danger Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrogen Adhere to the descrip...

Page 77: ...erience has shown that settings outside of this range are detrimental to vehi cle handling When changing the chassis settings always start with the standard setting Info Turn clockwise to increase damping turn counterclockwise to reduce damping The left and right shock absorbers should have the same settings 9 6 Front shock absorber adjusting the cross over Danger Danger of accidents Disassembly o...

Page 78: ... 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 72 Clean the shock absorber thoroughly 601038 10 Loosen adjusting ring Hook wrench T304 Hook wrench T157S 601091 01 Measure the cross over setting between sliding bushing and the collar of adjusting ring Guideline Cross over 19 mm 0 75 in Info Mea...

Page 79: ... 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 adjustments in small steps only Info Increasing the spring preload raises the center of gravity of the vehicle This can have a large impa...

Page 80: ... preload Comfort 4 mm Standard 5 mm Sport 8 mm Info The spring preload is the difference in length between the spring pack when it is unloaded and when it is installed The spring pack should never be installed loosely without preload The comfort setting is the lowest permissible spring preload If you increase the spring preload you should also slightly increase the rebound damping The left and rig...

Page 81: ...rning 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 compression damping setting has an impact on the compression of the shock absorber Remove the rear fender p 142 601077 10 Turn adjusting screw clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corr...

Page 82: ...ock absorber adjusting the rebound damping 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 Only make adjustments within the rec...

Page 83: ... When changing the chassis settings always start with the standard setting Info Turning to the right increases damping while turning to the left lessens damp ing 9 10 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 authori...

Page 84: ...g Tip Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove the rear shock absorber x p 83 After removing the shock absorber clean it thoroughly 601076 10 Loosen screw Info Do not loosen lock nut at the top of the shock absorber Turn adjusting ring until the spring is fully relaxed Hook wrench T157S ...

Page 85: ...e spring to specified measurement by turning the adjusting ring Guideline Spring preload Comfort 0 mm Standard 3 mm Sport 3 mm Tighten screw Guideline Screw shock absorber adjusting ring M6 5 Nm 3 7 lbf ft Info If you increase the spring preload you should also slightly increase the rebound damping Install the rear shock absorber x p 85 9 11 Removing the rear shock absorber x Jack up the vehicle p...

Page 86: ... 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 87: ...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 144 Remove the vehicle from the work stand p 72 9 13 Checking the toe x Park the vehicle on a horizontal surface Check the tire condition p 127 Check the tire air pressure p 128 Check th...

Page 88: ...INE 86 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 89: ...MAINTENANCE ON CHASSIS AND ENGINE 87 400333 10 Measure distances and If distances and are not equal Adjust the toe x p 88 Measure distances and Guideline Toe Front 0 mm 0 in ...

Page 90: ...es not meet specifications Adjust the toe x p 88 9 14 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 127 Check the tire air pressure p 128 Check the chassis parts for damage play and wear Replace damaged or worn parts 300272 10 Load the vehicle with the specified weight Guideline Average rider weight 70 80 kg 154 176 lb Move the handlebar into the straight ...

Page 91: ...SIS AND ENGINE 89 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 92: ...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 15 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 93: ...00127 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 94: ...en screws Guideline Screw A arm top M10x52 45 Nm 33 2 lbf ft 601042 10 Align the heim joint at right angles to screws and tighten nut Guideline Nut A arm top M12x1 25 30 Nm 22 1 lbf ft Info All four heim joints must be checked and adjusted if necessary Remove the vehicle from the work stand p 72 ...

Page 95: ...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 96: ...NE 94 9 17 Adjusting the handlebar position x 100100 10 Pull the instrument support off the handlebar and swing it to the side Info Protect the vehicle and its attachments from damage by covering them Do not bend the cables and lines ...

Page 97: ... the desired position Mount and tighten screw Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount and tighten screw Guideline Screw steering column top M20x1 5 25 Nm 18 4 lbf ft Mount and tighten screws Guideline Screw steering bridge M8 20 Nm 14 8 lbf ft Mount handlebar support in the desired position using the screws Mount new self locking nuts and tighten Guideline Nut handlebar support ...

Page 98: ...ottle 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 97 Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and or death When running the engine always make sure there is sufficient ventilation and do not start or run the engine in an enclose...

Page 99: ...to adjust the play in the throttle cable Guideline Play in throttle cable 3 5 mm 0 12 0 2 in Tighten nut 9 20 Checking the basic setting of the shift lever 0 0 0 A A 400692 10 Sit on the vehicle in the riding position and measure the distance between the upper edge of your boot and shift lever Distance between shift lever and upper edge of boot 10 20 mm 0 39 0 79 in If the distance does not meet s...

Page 100: ... gear teeth of the shift lever and shift shaft Position the shift lever in the desired position on the shift shaft and engage the gearing Info The range of adjustment is limited The shift lever should not come into contact with other vehicle components dur ing shifting Mount and tighten the screw Guideline Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 ...

Page 101: ...n is very dirty Clean the chain p 99 9 23 Cleaning the chain Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The service life of the chain depends largely on its maintenance ...

Page 102: ...the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain may snap Conversely if the chain 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 cor...

Page 103: ...5 51 5 71 in If the chain tension does not meet specifications Adjust the chain tension p 103 9 25 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 the joint faces forward riding dire...

Page 104: ...33 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 sp...

Page 105: ...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 106: ...e 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 ...

Page 107: ...e 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 lini...

Page 108: ...travel 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 in the front brake circuit The front brake can fail due to overheating Adjust free travel on hand brake lever according to specifications 601088 01 Push the hand brake lever forward and check free travel Free travel of hand brake lever 3 mm 0 12 in I...

Page 109: ...rake 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 32 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 Check the...

Page 110: ...cle on a horizontal surface again Check the brake fluid level in the viewer If the brake fluid level drops below the bottom of the viewer Add front brake fluid x p 108 9 33 Topping up the front 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 Check the...

Page 111: ... 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 It is silicone based and purple in color Oil seals a...

Page 112: ...w top edge of container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 196 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 9 34 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 113: ...age or cracking is visible Change the front brake linings x p 113 Mount the wheel wheels p 126 9 35 Removing front brake linings x Warning Danger of accident Brake system failure Maintenance work and repairs must be carried out professionally Your authorized KTM workshop will be glad to help Info The operations are the same on the left and right Remove the wheel wheels p 125 Pull the hand brake le...

Page 114: ...ry 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 th...

Page 115: ...he hand brake lever repeatedly until the brake linings lie on the brake disc and there is a pressure point Mount the wheel wheels p 126 9 37 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...

Page 116: ...azard 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...

Page 117: ...2 Correct 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 196 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 9 38 Checking free travel of foot brake lever Warning Danger of accidents Brake system failure If there is no free travel on the...

Page 118: ...5 mm 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the foot brake lever x p 116 Reconnect spring 9 39 Adjusting basic position of foot brake lever x Warning Danger of accidents Brake system failure If there is no free travel on the foot brake lever pressure builds up on the rear brake circuit The rear brake can fail due to over heating Adjust free travel ...

Page 119: ...f the foot brake lever Guideline Free travel 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 40 Checking rear brake fluid level Warning Danger of accidents Brake system failure If the brake fluid level falls below the bottom ...

Page 120: ...ar brake fluid x p 118 9 41 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 Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Skin irritation Brake fluid can cause skin irritation on c...

Page 121: ...bstances 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 su...

Page 122: ... of accidents Reduced braking efficiency caused by worn brake linings Change worn brake linings immediately Your authorized KTM workshop will be glad to help 601053 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 124 Check the brake linings for damage and cracking If damage or cracking...

Page 123: ...ut professionally Your authorized KTM workshop will be glad to help 601054 01 Press the brake caliper by hand on to the brake disc in order to press back the brake piston 601055 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 124: ...ep 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 conside...

Page 125: ...ton side of the brake lining 601058 10 Grease the bearing bolt and insert the brake caliper with the bearing bolt into the brake caliper support Lubricant T625 p 201 601059 01 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 ...

Page 126: ...d Change 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 col...

Page 127: ...m the brake fluid reservoir Mount the rear brake linings x p 122 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 196 Refit screw with membrane Info Clean up overflowed or spilt brake fluid immediately with water 9 46 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 1...

Page 128: ...making sure it does not become jammed with the threads of the screws 9 47 Mounting 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 Info Proceed in the same way on the other wheels if necessary ...

Page 129: ...45 Nm 33 2 lbf ft 9 48 Checking the tire condition Info Only mount tires that have been approved and or recommended by KTM Other tires could have a negative effect on vehicle handling The type condition and air pressure of the tires all have an important impact on the handling characteristics of the vehicle The tires mounted on the front and rear wheels must have similar profiles Worn tires have a...

Page 130: ...of the actual state of wear If the tire is older than five years Change the tire 9 49 Checking the tire air pressure Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Check the tire pressure on all wheels and correct it if necessary 400695 01 Remove the dust cap Check the tire air pre...

Page 131: ...ery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Switch off all power consumers and switch off the engine Remove the rear fender p 142 200150 10 Disconnect the negative minus cable of the battery Pull back the plus pole ...

Page 132: ...ch of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms In the event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Battery parts and ...

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

Page 134: ...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 144 9 ...

Page 135: ... 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 54 Changing the fuses of individual power consumers Remove the front cover p 140 S...

Page 136: ...ight high beam indicator lamp Fuse 3 10A radiator fan Fuse 4 10A for auxiliary devices permanent positive Fuse 5 10A for auxiliary devices plus switched on with ignition switch Fuse res 10A 15A replacement 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 ampe...

Page 137: ...ke another mark a distance under the first mark Guideline Distance 5 cm 2 in Position the vehicle a distance vertically in front of the wall Now the rider wearing a full set of protective clothing sits on the vehicle in the normal sitting position feet on the footrests Guideline Distance 5 m 16 ft Switch on the low beam Check the headlight setting The boundary between light and dark must be exactl...

Page 138: ... down Guideline The boundary between light and dark must be exactly on the lower mark for an opera tional vehicle with a rider to prepare the mark see Checking the headlight setting Info A change in weight on the vehicle may require a correction of the headlight range Tighten screw 9 57 Removing the seat 601070 10 Pull the release hook back Lift up the seat at the rear pull it back and then remove...

Page 139: ...sleeve of the fuel tank lower the rear of the seat and slide tab under fuel tank 601071 10 Push down the rear of the seat until release hook engages Make sure that the seat is correctly locked in 9 59 Removing the radiator spoiler Info The operations are the same on the left and right Remove the seat p 136 ...

Page 140: ...GINE 138 100056 10 Remove the screws on the fuel tank 601060 10 Remove the screws on the radiator Detach the radiator spoiler and remove it 9 60 Installing the radiator spoiler Info The operations are the same on the left and right ...

Page 141: ...ler into holder of the fuel tank and position it on the radiator 601061 10 Mount and tighten screws 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 137 ...

Page 142: ...E 140 9 61 Removing the front cover 601062 10 Remove screw Slide the front cover up and remove it 9 62 Installing the front cover 100055 10 Position the front cover in slots on both sides of the front trim Mount and tighten the screw ...

Page 143: ... 141 9 63 Removing the front trim Remove the front cover p 140 601063 10 Remove screws Raise the front trim and disconnect the plug in connectors from the head light and the emergency OFF switch with the rip cord Remove the front trim ...

Page 144: ...light and the emergency OFF switch with the rip cord and position the front trim Mount all screws Fully tighten screws Guideline Screw on fuel tank M6 6 Nm 4 4 lbf ft Fully tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Install the front cover p 140 9 65 Removing the rear fender Remove the seat p 136 ...

Page 145: ... 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 146: ...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 147: ...MAINTENANCE ON CHASSIS AND ENGINE 145 601079 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 137 ...

Page 148: ...600133 10 Remove screws and Remove the engine guard 9 68 Installing the engine guard 600133 10 Position the engine guard on the frame bearer Mount and tighten screws and Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Remaining screws chassis M8 25 Nm 18 4 lbf ft ...

Page 149: ...e life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Remove the seat p 136 ...

Page 150: ...her 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 swing it to the side Remove the air filter with the air filter support Remove the air filter from the air filter support ...

Page 151: ...ase p 201 100086 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 137 ...

Page 152: ...e air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 147 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 200 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 202 Clean the air filter box Check carburet...

Page 153: ...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 73 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 601066 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover wit...

Page 154: ...ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions 120 C 248 F Cooling is effected by the air stream The radiator fan provides extra cooling The lower the speed the less the cooling effect Dirty cooling fins also reduce the cooling effect 9 75 Radiator fan 600117 10 The radiator fan is located on the radiator under the fuel tank Working range within whic...

Page 155: ...f poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children Condi...

Page 156: ...ed Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under lukewarm water immediately Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant and skin eyes and clothing If it gets into your eyes rins...

Page 157: ...hot and is under high pressure when the vehicle is operated Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under lukewarm water immediately Warning Danger of poisoning Coolant is poisonous and a health hazard Avoid contact between coolant ...

Page 158: ...MAINTENANCE ON CHASSIS AND ENGINE 156 Remove the front trim p 141 Place a suitable container under the vehicle 601072 10 Remove screw 600119 10 Remove screw ...

Page 159: ... and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor immediately Change clothes that have come into contact with coolants Keep coolant out of the reach of children 0 0 A A 400360 10 Position the vehicle as shown and secure it against rolling away The height difference must be achieved Guideline Height difference 50 cm 19 7 in Pull ...

Page 160: ... to bleed the cylinder head Tighten the screw when coolant emerges from the opening Guideline Remaining screws 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 from the opening Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 161: ...at means that an engine 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 in malfunctioning If the idle speed is set significantly higher the engine does not start When the elec tric starter button is activated the electric starter turns over the engine b...

Page 162: ...oke function deactivated The choke lever is pushed in to the stop p 45 Idle speed 1 500 1 600 rpm Info If the idle speed is set significantly higher the engine does not start When the electric starter button is activated the electric starter turns over the engine but the engine does not start because there is no ignition spark Turn the idle mixture control screw slowly clockwise until the idle spe...

Page 163: ...ay 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 adjusting screw must not be opened more than two turns If more than two turns are necessary rich mixture use a larger idling jet After changing the idling jet start from the beginning with the adjusting steps Adjust the idle spe...

Page 164: ...tween fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of childr...

Page 165: ...loat chamber Tighten screw 9 83 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 600131 10 Condition The engine is at operating temperature Check the engine oil level Info After switching off the engine wait one minute before checking the level The engine oil reaches the middle of the viewer When the engine oil ...

Page 166: ...ne oil and oil filter cleaning oil screens x 601086 01 Drain engine oil clean oil screens x p 164 Remove the oil filter x p 168 Install the oil filter x p 170 Fill up with engine oil x p 170 9 85 Draining engine oil cleaning oil screens 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 hol...

Page 167: ...Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Drain the engine oil only when the engine is warm Park the vehicle on a horizontal surface Remove the engine guard p 146 600134 10 Place a suitable container under the engine Remove the oil drain plug ...

Page 168: ...ENANCE ON CHASSIS AND ENGINE 166 600135 10 Remove the plug screw and small oil screen with both O rings 601067 10 Remove the plug screw and large oil screen with both O rings Completely drain the engine oil ...

Page 169: ...key insert them until the O ring is seated in the housing with the oil screen Fit plug screw with the seal ring and tighten it Guideline Locking screw oil sieve long M20x1 5 15 Nm 11 1 lbf ft 600140 10 Insert oil screen with O rings into plug screw and tighten Guideline Locking screw oil sieve short M16x1 5 10 Nm 7 4 lbf ft lubricated with engine oil ...

Page 170: ...anger 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 fluid etc should be disposed of as stipulated in applicable regulations Place a...

Page 171: ...e ground cable from the engine Remove screws and Take off the oil filter cover with the O ring 600138 10 Pull the oil filters and out of the engine housing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area ...

Page 172: ...s 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 ground cable on the engine and tighten the screw Guideline Screw starter engine M6 10 Nm 7 4 lbf ft 9 88 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 173: ...t gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system Start the engine and check that it is oil tight Guideline Switch off the engine when the radiator fan switches on Check the engine oil level ...

Page 174: ...ll up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 197 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 197 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 175: ...distance plug gap of spark plug too wide Adjust the plug gap Guideline Spark plug electrode gap 0 6 mm 0 024 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 is se...

Page 176: ...he battery x p 130 Check the charging voltage x Check the quiescent current x Check the alternator x Blown fuse Change the main fuse p 132 Start relay faulty Check the starter relay x Starter motor faulty Check the starter motor x 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 carbu...

Page 177: ...ap to ON Figure 100013 10 p 44 Fill up with fuel p 65 Intake system air leak Check rubber sleeves and carburetor for tight ness Loose contact or 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 154 Radiator fins excessively dirty Clean radiato...

Page 178: ... coil x Check the ignition pulse generator x Check the alternator x Check the CDI controller 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 163 Engine oil too thin low viscosity Change the engine oil and oil filter clean the oil screens x p 164 Piston or cylinder worn Check the piston ...

Page 179: ... Possible cause Action Battery discharged Undesired power consumer Check the quiescent current x Speedometer values deleted time stop watch lap times The battery in the speedometer is empty Change the battery in the speedometer ...

Page 180: ...isposed 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 181: ...porate Push back the protection 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 99 Treat bare metal parts except for brake discs and exhaust system with a corrosion inhibitor Cleaning and polishing materials for metal rubber and plastic p 200 Treat all plas...

Page 182: ...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 178 Ch...

Page 183: ...s materials since they prevent humidity from escaping thus causing corrosion Avoid running the engine of a vehicle in storage for a short time only Because the engine will not warm up sufficiently the water vapor produced during 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 130 Fill up with f...

Page 184: ... 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 bearing 2 cylinder roller bearing Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 rotor pumps Primary transmissio...

Page 185: ...rk plug electrode gap 0 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 Engine oil SAE 10W 50 p 197 External temperature 0 C 32 F Engine oil SAE 5W 40 p 197 13 2 Capacity coolant Coolant 1 30 l 1 37 qt Coolant p 196 Coolant mixed ready to use p 196 ...

Page 186: ...ite 243 Screw timing chain securing guide M5 6 Nm 4 4 lbf ft Loctite 243 Screw on cylinder head top 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 7 4 lbf ft Screw bearing stud starter engine M6 10 Nm 7 4 lbf ft Loctite 243 Screw clutch cover M6 10...

Page 187: ... tensioner M6 10 Nm 7 4 lbf ft Screw valve cover M6 10 Nm 7 4 lbf ft Screw vent hose bracket M6 10 Nm 7 4 lbf ft Loctite 243 Screw water pump cover M6 10 Nm 7 4 lbf ft Nut adjusting screw valve clearance M6x0 75 11 Nm 8 1 lbf ft Oil jet piston cooling M6x0 75 4 Nm 3 lbf ft Loctite 243 Banjo bolt oil line M8 10 Nm 7 4 lbf ft Jet screw oil line M8 10 Nm 7 4 lbf ft Plug crankshaft location M8 10 Nm 7...

Page 188: ... 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 lbf ft Loctite 243 Locking screw oil sieve long M20x1 5 15 Nm 11 1 lbf ft Nut primary gear M20LHx1 5 150 Nm 110 6 lbf ft Loctite 243 Screw in fitting cooling system in cylin der head top M20x1 5 Loc...

Page 189: ...uretor identification 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 Main jet 175 Jet needle OBEKR Idling jet 42 Main air jet 200 Idle air jet 100 Cold start jet 85 Throttle slide 15 ...

Page 190: ...l 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 50 39 0 39 in Turning radius 5 625 mm 221 46 in Fording depth 330 mm 12 99 in Seat height unloaded 820 mm 32 28 in Ground clearance unloaded 290 mm 11 42 in Weight Fuel tank empty 168 kg 370 lb Fuel tank full 17...

Page 191: ...44 29 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 1 0 bar 15 psi Rim Front 5x10 DWT Al 6061 Rear 8x9 DWT Al 6061 Rear wheel gearing 15 37 Chain 5 8 x 1 4 R...

Page 192: ...ght W5W socket W2 1x9 5d 12 V 5 W Indicator lights W1 2W socket W1x4 6d 12 V 1 2 W Turn signal R10W socket BA15s 12 V 10 W Brake tail light LED License plate lamp W5W socket W2 1x9 5d 12 V 5 W 16 2 Tires Front tire Rear tire AT21 x 7 10 25N TL Kenda K572 ROADGO 20 x 11 9 38N TL Kenda K572 ROADGO Additional information is available in the Service section under http www ktm com ...

Page 193: ...TECHNICAL DATA CHASSIS 191 16 3 Capacity fuel Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 199 Fuel reserve approx 3 l 3 qt ...

Page 194: ...andard 15 clicks Sport 15 clicks Cross over 19 mm 0 75 in Info Measured at the tension free main spring Spring preload Comfort 4 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 Spring length main spring 275 mm 10 83 in Spring length auxiliary spring 60 mm 2 36 in Fitted length 460 mm 18 11 in Shock absorber oil Shock absor...

Page 195: ...ort 20 clicks Standard 15 clicks Sport 15 clicks Spring preload Comfort 0 mm Standard 3 mm Sport 3 mm Spring rate main spring Rider weight 65 75 kg 143 165 lb 45 N mm 257 lb in Rider weight 75 85 kg 165 187 lb 48 N mm 274 lb in Rider weight 85 95 kg 187 209 lb 50 N mm 286 lb in Spring length main spring 260 mm 10 24 in Fitted length 435 5 mm 17 146 in Shock absorber oil Shock absorber oil SAE 2 5 ...

Page 196: ...eering M8 25 Nm 18 4 lbf ft Screw front brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw front brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw rear brake caliper M8 20 Nm 14 8 lbf ft Loctite 243 Screw rear brake disc M8 25 Nm 18 4 lbf ft Loctite 243 Screw rear wheel eccentric element M8 20 Nm 14 8 lbf ft Screw steering bridge M8 20 Nm 14 8 lbf ft Sc...

Page 197: ...eel hub M12 70 Nm 51 6 lbf ft Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Screw rear top shock absorber M12 60 Nm 44 3 lbf ft Lock nut tie rod inside M12LHx1 25 20 Nm 14 8 lbf ft Lock nut tie rod outside M12x1 25 20 Nm 14 8 lbf ft Nut A arm top M12x1 25 30 Nm 22 1 lbf ft Nut ball head A arm bottom M12x1 5 40 Nm 29 5 lbf ft Nut swingarm pivot M16x1 5 100 Nm 73 8 lbf ft Nut rear wheel hub...

Page 198: ...x products Supplier Castrol RESPONSE BRAKE FLUID SUPER DOT 4 Motorex Brake Fluid DOT 5 1 Coolant Guideline Use only suitable coolant also in countries with high temperatures Use of low quality antifreeze can lead to corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze protection 25 45 C 13 49 F 50 corrosion inhibitor antifreeze 50 distilled water Coolant mixed ready to us...

Page 199: ...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 203 SAE p 203 SAE 5W 40 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corresponding properties KTM recommends Motorex products Synthetic engine oil Supplier M...

Page 200: ...lic Fluid 75 Long life grease According to NLGI Guideline Use only grease that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Fett 2000 Shock absorber oil SAE 2 5 50180342S1 According to SAE p 203 SAE 2 5 Guideline Use only oils that comply with the specified standards see sp...

Page 201: ...SUBSTANCES 199 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95 PON 91 ...

Page 202: ...hain cleaner Guideline KTM recommends Motorex products Supplier Motorex Chain Clean 611 Chain lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chain Lube 622 Strong Cleaning and polishing materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine 645 ...

Page 203: ...er Motorex Accu Contact Long life grease Guideline KTM recommends Motorex products Supplier 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 ...

Page 204: ...ANCES 202 Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 205: ...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 206: ...ake fluid of front brake topping up 108 Brake fluid of rear brake checking 117 topping up 118 Brake linings of front brake changing 113 checking 110 installing 112 removing 111 Brake linings of rear brake changing 124 checking 120 installing 122 removing 121 C Camber adjusting 90 checking 90 Carburetor adjusting idle 160 emptying the float chamber 162 idle 159 Chain cleaning 99 Chain tension adjus...

Page 207: ... removing 146 Engine number 17 Engine oil adding 171 changing 164 draining 164 refilling 170 Engine oil level checking 163 Environment 10 F Fender rear installing 144 removing 142 Filler cap closing 42 opening 42 Filling up fuel 65 Foot brake lever 47 basic position adjusting 116 free travel checking 115 Front cover installing 140 removing 140 Front shock absorber compression damping adjusting 73 ...

Page 208: ...6 Headlight setting checking 135 headlight range adjusting 136 Horn button 25 Hot start button 45 I Ignition switch 25 Indicator lamp overview 27 K Key number 17 Kill switch 24 L Light switch 23 M Main fuse changing 132 Maintenance 8 O Oil filter changing 164 installing 170 removing 168 Oil screens cleaning 164 Owner s manual 11 P Parking 64 Parking brake 22 front 20 rear 22 Play in throttle cable...

Page 209: ...55 downhill 58 engine switching off 62 general information 56 perpendicular to the slope 60 riding through water 62 starting up 54 stopping parking 64 turning on slopes 60 uphill 59 S Seat mounting 137 removing 136 Service schedule 67 71 Shift lever basic position adjusting 98 basic setting checking 97 Shifting forward gears 54 Shock absorber front shock absorber part number 18 rear shock absorber...

Page 210: ... shock absorber 192 rear shock absorber 193 Throttle lever 23 Tire air pressure checking 128 Tire condition checking 127 Toe adjusting 88 checking 85 Transport 9 Troubleshooting 173 177 Turn signal switch 24 Type label 16 U Use definition 8 V Vehicle cleaning 178 jacking up 72 removing from work stand 72 W Wheel wheels installing 126 removing 125 Work rules 9 ...

Page 211: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 06 2009 Photo Mitterbauer 3211487en 3211487en ...

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