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KTM 530 EXC EU, Owner'S Manual

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KTM 530 EXC EU Owner'S Manual Download Page 45

MAINTENANCE WORK ON CHASSIS AND ENGINE

43

9.26

Installing the fork legs

x

100021-10

–

Position the fork legs.

Info

The topmost sunk nut in the fork leg must be flush to the upper edge of the
upper triple clamp.
Position the bleeder screw

to the front.

500094-11

–

Fully tighten screw

.

Guideline

Screw, top triple clamp

M8

17 Nm
(12.5 lbf ft)

–

Fully tighten screw

.

Guideline

Screw, bottom triple clamp

M8

12 Nm (8.9 lbf ft)

500093-11

–

Position brake caliper, mount and tighten screws

.

Guideline

Screw, front brake caliper

M8

25 Nm
(18.4 lbf ft)

Loctite

®

243™

–

Mount cable clip

.

–

Position the brake line and cable harness. Put the clamp on, mount and tighten
screws

.

–

Install the front wheel.

x

(

p. 61)

9.27

Removing the fork protector

x

–

Remove the fork legs.

x

(

p. 42)

500105-10

–

Remove screws

on the left fork leg. Remove the fork protector upwards.

–

Remove the screws on the right fork leg. Remove the fork protector upwards.

9.28

Installing the fork protector

x

500105-10

–

Position the fork protection on the left fork leg. Mount and tighten screws

.

Guideline

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

–

Position the fork protection on the right fork leg. Mount and tighten the screws.
Guideline

Remaining screws, chassis

M6

10 Nm (7.4 lbf ft)

–

Install the fork legs.

x

(

p. 43)

Summary of Contents for 530 EXC EU

Page 1: ...OWNER S MANUAL 2010 450 EXC USA 530 EXC USA ART NO 3211485en ...

Page 2: ......

Page 3: ...ical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop production of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as misprints and other errors The models portrayed partly...

Page 4: ...ized KTM workshop as additional order 32 Important checks and maintenance work to be carried out by the rider 32 MAINTENANCE WORK ON CHASSIS AND ENGINE 34 Jacking up the motorcycle 34 Removing the motorcycle from the work stand 34 Checking the basic chassis setting with the rider s weight 34 Compression damping of shock absorber 34 Adjusting high speed compression damping of the shock absorber 34 ...

Page 5: ...l 70 Draining coolant x 70 Refilling coolant x 71 Glass fiber yarn filling of main silencer 71 Removing main silencer 71 Installing the main silencer 72 Dismounting the air filter box lid 72 Installing the air filter box lid 72 Removing the air filter x 72 Installing the air filter x 73 Cleaning air filter x 73 Adjusting basic position of clutch lever 73 Checking fluid level of hydraulic clutch 73...

Page 6: ...derstanding In the interest of your own safety have these jobs done in an authorized KTM workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained in the following Specific name Identifies...

Page 7: ...e Fuel oils etc You should use the fuels oils and greases according to specifications as listed in the owner s manual Spare parts accessories For your own safety only use spare parts and accessory products that have been approved and or recommended by KTM and have them installed by an authorized KTM workshop KTM accepts no liability for other products and any resulting damage or loss Some spare pa...

Page 8: ...nsure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your motorcycle legally display environmental consciousness and respect the rights of others 2 1 Overview of labels 300401 10 1 Type label for Canada 2 Type label for the USA 3 Fuel evaporative system information 4 Chain tension information 5 Information on putting into oper...

Page 9: ... NOTES 7 500251 01 Type label for the USA 500254 01 Fuel evaporative system information 500255 01 Chain tension information 700210 01 Information on putting into operation 500252 01 Emission control information ...

Page 10: ...component of the motorcycle and should be handed over to the new owner if the vehicle is sold Reporting of safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying KTM North America Inc If NHTSA receives similar complaints it m...

Page 11: ... components which conducts exhaust gases Removal or puncturing of any part of the intake system Lack of proper maintenance Replacement of any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer Operating noise warning This product should be checked for repair or replacement if the motorcycle noise has increased significantl...

Page 12: ...w of the vehicle from the left front example 300399 10 1 Side stand 2 Shift lever 3 Chain guide 4 Fuel tap 5 Air filter box lid 6 Clutch lever 7 Light switch headlight flasher button flasher switch horn button 8 Hand brake lever ...

Page 13: ...ear example 300398 10 1 Level viewer for brake fluid rear 2 Fork compression adjustment 3 Foot brake pedal 4 Kickstarter 5 Horn 6 Ignition switch 7 Fork rebound adjustment 8 Filler cap 9 Shock absorber compression adjustment 10 Shock absorber rebound adjustment ...

Page 14: ...to the front of the steering head 300403 10 The type label Canada is fixed to the front of the front pipe 4 3 Key number 300397 10 The key number is provided on the KEYCODECARD Info You need the key number to order a spare key Keep the KEYCODECARD in a safe place 4 4 Engine number 500072 10 The engine number is stamped on the left side of the engine under the engine sprocket ...

Page 15: ... number 500082 10 The fork part number is stamped on the inner side of the fork stub 4 6 Shock absorber part number 500129 10 The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side ...

Page 16: ...ops and a non running engine will not start Ignition on In this position the ignition circuit is closed and the engine can be started 5 4 Ignition switch 300396 10 The ignition switch is on the right behind the headlight mask Possible states Ignition off In this position the ignition circuit is interrupted a run ning engine stops and a non running engine will not start Ignition on In this position...

Page 17: ...Horn button is fitted on the left side of the handlebar Possible states Horn button is in home position Horn button is pressed The horn is sounded in this position 5 9 Flasher switch 500142 12 Flasher switch is fitted on the left side of the handlebar Possible states Flasher light off Flasher light left on Flasher switch is pressed to the left The flasher switch returns to the middle position afte...

Page 18: ...5 mm corresponds to the size of the 21 front wheel with a series produc tion tire The display then changes to the last selected mode 5 13 Tripmaster switch Option 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 14 Setting kilometers or miles Info If you change the unit the value ODO ...

Page 19: ...ton for 3 5 seconds The settings are saved and the Setup menu closed Info If no button is pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu closed 5 16 Adjusting the speedometer functions Info Upon delivery only the SPEED H and SPEED ODO display modes are activated Condition The motorcycle is standing 400318 01 Press t...

Page 20: ...PEED 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 country When an impulse comes from the front wheel the left side of the speedometer display changes to the SPEED mode and the current speed is shown 5 19 Display mode SPEED H service hours 400316 01 Conditio...

Page 21: ...ss the button Stops the current lap time and saves it and the stop watch starts the next lap Press the button for 3 5 seconds The stop watch and the lap time are reset Press the button briefly Next display mode 5 22 Display mode SPEED ODO odometer 400317 01 Press the button briefly and repeatedly until ODO appears at the bottom right of the display In ODO display mode the total number of kilometer...

Page 22: ...ly mode SPEED A1 average speed 1 400325 01 Press the button briefly and repeatedly until A1 appears at the top right of the display A1 average speed 1 shows the average speed calculated using TR1 trip master 1 and S1 stop watch 1 The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse Press the button No function Press the...

Page 23: ...isplay mode SPEED H service 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 SPEED LAP lap time Starts or stops the clock Stops the current lap time and saves it and the stop watch starts the next la...

Page 24: ...he tap handle on the fuel tap you can open or close the supply of fuel to the carburetor Possible states Fuel supply closed OFF No fuel can flow from the tank to the carburetor Fuel supply open ON Fuel can flow from the tank to the carburetor The fuel tank empties down to the reserve Reserve fuel supply open RES Fuel can flow from the tank to the carburetor The fuel tank empties completely 5 30 Op...

Page 25: ...o the stop 5 33 Shift lever 500138 10 Shift lever is mounted on the left side of the engine 500138 11 The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears 5 34 Foot brake pedal 500139 10 Foot brake pedal is located in front of the right footrest The foot brake pedal is used to activate the rear brake 5 35 Kickstarter 500148 10 Kickstar...

Page 26: ...ground and lean the motorcycle on it 500141 10 When you are riding the side stand must be folded up and secured with the rubber band 5 37 Steering lock 500126 10 Steering lock is fitted on the left side of the steering head The steering lock is used to lock the steering Steering and therefore riding is no longer possible 5 38 Locking the steering Note Danger of damage The parked vehicle can roll a...

Page 27: ...5 39 Unlocking the steering Insert the key in the steering lock turn it to the left pull it out and turn it to the right Remove the key You can now steer the bike again Info Never leave the key in the steering lock ...

Page 28: ... not want to brake Warning Danger of accidents Unstable riding behavior Do not exceed the maximum permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure...

Page 29: ... load 190 kg 419 lb Check the spoke tension p 64 Info The spoke tension must be checked after half an hour of operation 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 ...

Page 30: ...o not start or run the engine in a closed space without an effective exhaust extraction system Note Engine failure High 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 motorcycle is unwilling to start the cause can be old fuel in the float chamber The flammable elements of the fuel evaporate after a l...

Page 31: ...siderably Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption To shift down brake and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Guideline 2 min Avoid frequent...

Page 32: ...al Turn the key in the ignition switch to the position while the engine is idling Turn handle of the fuel tap to the OFF position Figure 500137 10 p 22 Park the motorcycle on firm ground 7 7 Refueling Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on ho...

Page 33: ...ithout sharp bends Check that the electrical equipment is functioning properly Check the headlight adjustment p 66 Brakes Check the front brake linings p 54 Check the rear brake linings p 58 Check the brake discs p 52 Check the front brake fluid level p 53 Check the rear brake fluid level p 57 Check brake lines for damage and leakage Check the free play of the hand brake lever p 52 Check the free ...

Page 34: ...rollers x Check the timing chain tensioner function x Check the balancer shaft x Check the crankshaft run out at the bearing pin x Change conrod bearing x Change the crankshaft main bearing x Check the transmission x Check the shift mechanism x Check the spring length of the oil pressure regulator valve x Change glass fiber yarn filling of main silencer x Replace foot brake cylinder seals x Check ...

Page 35: ... Clean the air filter x p 73 Check the tire air pressure p 63 Check the tire condition p 63 Check the coolant level p 70 Empty the carburetor float chamber x p 76 Check that all operating elements for smooth operation Check braking Check all screws nuts and hose clamps regularly for tightness NB1A Depending on conditions of use according to requirements ...

Page 36: ...es are adjusted for a standard rider weight with full protective clothing Guideline Standard rider weight 75 85 kg 165 187 lb If your weight is above or below the standard range you have to adjust the basic setting of the suspension components accord ingly Small weight differences can be compensated by adjusting the spring preload but in the case of large weight differences the springs must be rep...

Page 37: ...ismantle the shock absorber or carry out any main tenance on it yourself Info The low speed setting can be seen during the slow to normal compression of the shock absorber 400209 10 Turn adjusting screw clockwise with a screwdriver up to the last perceptible click Info Do not loosen nut Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Compressio...

Page 38: ...istance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement Remove the motorcycle from the work stand p 34 9 9 Checking static sag of shock absorber 0 0 0 B B 0 0 A A 400221 10 Measure distance of rear wheel unloaded p 36 Ask someone to help you by holding the motorcycle upright Measure the distance between th...

Page 39: ...rber x Danger Danger of accidents The shock absorber is under high pressure The shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove shock absorber x p 38 After removing the shock absorber ...

Page 40: ...k absorber p 35 9 13 Removing the shock absorber x Jack up the motorcycle p 34 800023 10 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw push splash protector to the side and remove the shock absorber 9 14 Installing the shock absorber x 800023 11 Push splash protector to the side and posit...

Page 41: ...ection covers Turn adjusting screws clockwise until they stop Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise the number of clicks corresponding to the fork type Guideline Compression damping Comfort 26 clicks Standard 22 clicks Sport 20 clicks Info Turn clockwise to increase damping turn counterclockwis...

Page 42: ...rease spring preload turn counterclockwise to reduce spring preload Adjusting the spring preload has no influence on the absorption setting of the rebound damping Basically however you should set the rebound damping higher with a higher spring preload 9 19 Bleeding fork legs Jack up the motorcycle p 34 100021 10 Remove bleeder screws briefly Any excess pressure escapes from the interior of the for...

Page 43: ...t fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Position the brake line and cable harness Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 23 Checking steering head bearing play Warning Danger of accidents Unsafe riding behavior du...

Page 44: ...ve screw Loosen and retighten screw Guideline Screw top steering head M20x1 5 10 Nm 7 4 lbf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Guideline Screw top triple clamp M8 17 Nm 12 5 lbf ft Mount and tighten screw Guideline Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Check the steering head bearing play p 41 9 25 Removing the fo...

Page 45: ...18 4 lbf ft Loctite 243 Mount cable clip Position the brake line and cable harness Put the clamp on mount and tighten screws Install the front wheel x p 61 9 27 Removing the fork protector x Remove the fork legs x p 42 500105 10 Remove screws on the left fork leg Remove the fork protector upwards Remove the screws on the right fork leg Remove the fork protector upwards 9 28 Installing the fork pro...

Page 46: ... stem Remove the upper steering head bearing 9 30 Installing the lower triple clamp x 0 0 2 2 0 0 1 1 0 0 3 3 500098 10 Clean the bearing and sealing elements check for damage and grease Long life grease p 100 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing Info Check whether the top steering head seal is correctly positioned Push up protective ring and o...

Page 47: ...e front fender 500092 10 Remove screws Remove the front fender Make sure that the distance bushings remain in place 9 33 Installing the front fender 500092 10 Ensure that the spacing sleeves are mounted in the fender Position the front fender Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Info Take care with the contact between the holding lugs and the start number...

Page 48: ... a distance of to each other Distance between holes 15 mm 0 59 in 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 handlebar supports can be mounted in 4 different positions 9 37 Adjusting the handlebar position x 0 0 2 2 0 0 1 1 400271 10 Remove the four screws Remove the handlebar clamp Remove the handlebar and lay it to on...

Page 49: ...able play x p 47 Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient venti lation and do not start or run the engine in a closed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle...

Page 50: ...its maintenance Clean the chain regularly and then treat with chain spray Chain cleaner p 100 Offroad chain spray p 100 9 43 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load...

Page 51: ... tension does not meet specifications Adjust the chain tension when fitting rear wheel p 51 9 45 Checking the rear sprocket engine sprocket for wear 400227 01 Check the rear sprocket engine sprocket for wear If the rear sprocket engine sprocket are worn Replace rear sprocket engine sprocket Info When fitting the chain joint always make sure that the closed side of the joint faces forward riding di...

Page 52: ...ain sliding component upwards to measure chain tension Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions 400225 10 Loosen nut Loosen nuts Adjust the chain tension by turning the left and right adjusting screws Guideline Chain tension 8 10 mm 0 31 0 39 in Turn the left and right adjusting screws so that the mar...

Page 53: ... are fitted correctly on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters can be turned by 180 9 49 Adjusting chain tension fitting rear wheel 400225 11 Loosen nuts Adjust the chain tension by turning the adjus...

Page 54: ...0 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 linings Brake discs wear limit Front 2 5 mm 0 098 in Rear 3 5 mm 0 138 in If the brake disc thickness is less than the specified value Change the brake disc Check the front and rear brake discs...

Page 55: ... worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop 400231 10 Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid lev...

Page 56: ...Guideline Measurement of 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 99 Position the cover with the membrane Mount and tighten the screws Info Clean up overflowed or spilt brake fluid immediately with water 9 56 Checking the front brake linings Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop 400235 10...

Page 57: ...gi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Check the brake discs p 52 500091 10 Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly Info The arrow on the leaf spring points in the rotation direction of the brake disc 500089 12 Insert the brake pads insert bolt and moun...

Page 58: ...nts Brake system failure If there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications 500139 11 Disconnect spring Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free t...

Page 59: ...op 400234 10 Stand the vehicle upright Check the brake fluid level in the viewer When in the viewer an air bubble is visible Add brake fluid for the rear brake x p 57 9 63 Adding brake fluid for the rear brake x Warning Danger of accidents Brake system failure If the brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake sys...

Page 60: ...orn brake linings should be replaced immediately in an authorized KTM workshop 400238 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 59 Check the brake linings for damage and cracking If damage or cracking is visible Change the rear brake linings x p 59 9 65 Removing rear brake lining...

Page 61: ... rotation direction of the brake disc 400237 10 Fit the brake pads insert bolt and mount locking split pins Info Make sure that the decoupling plate is mounted on the piston side of the brake pad Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot 9 67 Changing the rear brake linings x Warning Skin irritations Brake fluid can cause skin i...

Page 62: ... up overflowed or spilt brake fluid immediately with water 9 68 Removing the front wheel x Jack up the motorcycle p 34 500089 10 Press the brake caliper by hand on to the brake disc in order to press back the brake pistons Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes 500084 10 Remove screw Loosen screw 500085 10 Holding the front whe...

Page 63: ...e from the work stand p 34 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Fully tighten screw Guideline Screw fork stub M8 15 Nm 11 1 lbf ft 9 70 Removing rear wheel x Jack up the motorcycle p 34 400258 10 Press the brake caliper by hand on to the brake disc in order to press back the brake piston Info Make sure when pushing back the brake piston tha...

Page 64: ...he swing arm position it and insert the wheel spindle Put the chain on 400225 12 Position the chain adjuster Mount nut but do not tighten it yet Check chain tension when fitting rear wheel p 49 Make sure that the chain adjusters are fitted correctly on the adjusting screws Tighten nut Guideline Nut rear wheel spindle M20x1 5 80 Nm 59 lbf ft Info The wide adjustment range of the chain adjusters 32 ...

Page 65: ...s less than the minimum allowable depth Change the tire Check the age of the tires Info The tire s date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking The first two digits refer to the week of manufacture and last two digits refer to the year of manufac ture KTM recommends that the tires are changed regardless of the actual wear ...

Page 66: ...poke tension x Check the spoke torque Guideline Spoke nipple front wheel M4 5 5 6 Nm 3 7 4 4 lbf ft Spoke nipple rear wheel M5 5 6 Nm 3 7 4 4 lbf ft Torque wrench with various accessories in set 58429094000 9 75 Removing the battery x Warning Risk of injury Battery acid and battery gases cause serious chemical burns Keep batteries out of the reach of children Wear suitable protective clothing and ...

Page 67: ...e filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info Even if there is no load on the battery it loses power every day The charge state and the type of charge are very important for the service life of the battery Fast recharging with a high charge current shortens the battery s service life If the charge current the charge voltage and the charg...

Page 68: ...10 Info A reserve fuse is located in the starter relay Replace a burned out fuse only by an equivalent fuse If the new fuse burns out contact an authorized KTM workshop Replace the protection cover Install the air filter box lid p 72 9 80 Checking headlight adjustment 400558 10 On a light colored wall behind a horizontal area make a mark as high as the center of the headlight Make another mark a d...

Page 69: ... screw of the seat fixing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 9 84 Dismounting the fuel tank x Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when...

Page 70: ...always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel ...

Page 71: ...87 Checking antifreeze and coolant level Warning Scalding hazard During motorcycle operation the coolant gets very hot and is under pressure Do not open the radiator the radiator hoses or other components of the cooling system when the engine is hot Allow the engine and radiator to cool down If you are scalded hold the affected part under cold water immediately Warning Danger of poisoning Coolants...

Page 72: ...at have come into contact with coolants Keep coolants out of the reach of children 400243 10 Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check the coolant level in the radiator Coolant level above radiator fins 10 mm 0 39 in If the level of the coolant does not meet specifications Correct the coolant level Alternative 1 Coolant p 99 Alternative 2 Coolant mixed read...

Page 73: ...ntact with coolants Keep coolants out of the reach of children 400244 10 Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Guideline 10 mm 0 39 in Coolant 0 95 l 1 qt Coolant p 99 Coolant mixed ready to use p 99 Refit the radiator cap Make a short test ride Check the coolant level p 70 9 91 Glass fiber yarn filling of main sil...

Page 74: ...t area 9 96 Removing the air filter x Note Engine failure Unfiltered intake air has a negative effect on the service 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 o...

Page 75: ...Oil for foam air filter p 101 Clean the air filter box Check carburetor connection boot for damage and tightness Install the air filter x p 73 9 99 Adjusting basic position of clutch lever 500133 11 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw Info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Tur...

Page 76: ...use environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as stipulated in applicable regulations Info The fluid level rises with increasing wear of the clutch lining disc Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container 400339 10 Move the clutch fluid reservoir mounted on the hand...

Page 77: ...41 10 Screw in the idle adjusting screw until it stops and then to the prescribed basic setting Guideline Idle mixture adjusting screw 450 EXC USA Open 1 75 turns Idle mixture adjusting screw 530 EXC USA Open 2 0 turns Adjustment tool for mixture control screw 77329034000 Run the engine until warm Guideline Warm up time 5 min Danger Danger of poisoning Exhaust gases are poisonous and can result in...

Page 78: ...h fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health haza...

Page 79: ...ne oil cleaning engine oil screen x Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Hazardous substances cause environmental damage Oil grease filters fuel cleaners brake fluid etc should be disposed of as s...

Page 80: ...ns Place a suitable container under the engine 200113 10 Remove screws Remove oil filter cover with O ring 200114 10 Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area 9 109 Installing the oil filter x 200114 11 Lay the motorcycle on its side and fill the oil filter housing to about full...

Page 81: ...n premature wear to the engine 200115 10 Remove the screw cap on the generator cover and fill up with engine oil Engine oil SAE 10W 50 p 99 Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient venti lation and do not start or run the engine in a closed space wi...

Page 82: ... gear oil screen Completely drain the gear oil Thoroughly clean the gear oil drain plug with a magnet Thoroughly clean the drain plug and gear oil screen with a magnet Clean the sealing area on the engine Refit gear oil drain plug with seal ring and tighten it Guideline Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Mount and tighten the plug of gear oil screen Guideline Plug gear oil s...

Page 83: ... the gear oil level screw Engine oil SAE 10W 50 p 99 Mount and tighten the gear oil level check screw Guideline Screw gear oil level check M6 8 Nm 5 9 lbf ft Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient venti lation and do not start or run the engine in...

Page 84: ...m Check the ignition system x Short circuit cable in cable harness frayed short circuit button or emer gency OFF switch defective Check the wiring harness visual check Check the electrical system Plug connector of CDI control device pulse generator or ignition coil oxi dized Clean the plug connector and treat it with con tact spray Water in carburetor or jets blocked Check adjust the carburetor co...

Page 85: ...stem for leakage Check the coolant level p 70 Too little air stream Switch off engine when standing Radiator fins very dirty Clean radiator fins Foam formation in cooling system Drain the coolant x p 70 Refill the coolant x p 71 Bent radiator hose Change the radiator hose x Thermostat defective Check the thermostat x Guideline Opening temperature 70 C 158 F High oil consumption Engine vent hose be...

Page 86: ...cle cleaner p 100 Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber x p 76 Warning Danger of accidents Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance u...

Page 87: ...il and oil filter and clean the engine oil screen x p 77 Change the gear oil and clean the gear oil screen x p 80 Check the antifreeze and coolant level p 69 Drain the fuel from the tanks into a suitable container Empty the carburetor float chamber x p 76 Check the tire air pressure p 63 Remove the battery x p 64 Recharge the battery x p 65 Guideline Storage temperature of battery without direct s...

Page 88: ...t a bearing bush DLC plated piston pins Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 2 rotor pumps engine 1 rotor pump transmission Primary transmission 33 76 Clutch Multidisc clutch in oil bath hydraulically activated Transmission ratio 1st gear 14 36 2nd gear 17 32 3rd gear 19 28 4th gear 22 26 5th gear 24 ...

Page 89: ...TECHNICAL DATA ENGINE 87 13 3 Capacity coolant Coolant 0 95 l 1 qt Coolant p 99 Coolant mixed ready to use p 99 ...

Page 90: ...w gear oil level check M6 8 Nm 5 9 lbf ft Screw idler M6 10 Nm 7 4 lbf ft Loctite 243 Screw kickstarter spring hanger M6 10 Nm 7 4 lbf ft Screw kickstarter stop M6 10 Nm 7 4 lbf ft Loctite 243 Screw oil filter cover M6 10 Nm 7 4 lbf ft Screw shift drum locating M6 10 Nm 7 4 lbf ft Loctite 243 Screw shift lever M6 10 Nm 7 4 lbf ft Loctite 243 Screw starter motor M6 10 Nm 7 4 lbf ft Screw stator bra...

Page 91: ...ft Spark plug M12x1 25 15 20 Nm 11 1 14 8 lbf ft Gear oil drain plug with magnet M12x1 5 20 Nm 14 8 lbf ft Oil pressure control valve plug M12x1 5 20 Nm 14 8 lbf ft Plug SLS M12x1 5 20 Nm 14 8 lbf ft Plug rocker arm M14x1 25 20 Nm 14 8 lbf ft Plug gear oil screen M16x1 5 20 Nm 14 8 lbf ft Plug engine oil screen M17x1 5 20 Nm 14 8 lbf ft Nut inner clutch hub M18x1 5 80 Nm 59 lbf ft Nut primary gear...

Page 92: ... 2 15 mm 0 0846 in Main jet 180 Jet needle OBDYU Idling jet 48 Idle air jet 100 Cold start jet 85 Leakage nozzle 40 15 2 530 EXC USA Carburetor type KEIHIN FCR MX 39 Carburetor identification number 3900Y Needle position 3rd position from top Idle mixture adjusting screw Open 2 0 turns Pump membrane stop 2 15 mm 0 0846 in Main jet 180 Jet needle OBDZT Idling jet 48 Idle air jet 100 Cold start jet ...

Page 93: ...essure Front 1 5 bar 22 psi Rear 2 0 bar 29 psi Final drive 15 45 Chain 5 8 x 1 4 Rear sprockets available 38 40 42 45 48 49 50 51 52 Steering head angle 63 5 Wheelbase 1 475 10 mm 58 07 0 39 in Seat height unloaded 985 mm 38 78 in Ground clearance unloaded 380 mm 14 96 in Weight without fuel approx 114 8 kg 253 1 lb Maximum permissible front axle load 145 kg 320 lb Maximum permissible rear axle l...

Page 94: ...MCE 6 DAYS EXTREME 140 80 18 M C 70M M S TT Metzeler MCE 6 DAYS EXTREME Additional information is available in the Service section under http www ktm com 16 3 Capacity fuel Total fuel tank capacity approx 9 2 l 2 43 US gal Super unleaded ROZ 95 RON 95 PON 91 p 99 Fuel reserve approx 2 l 2 qt ...

Page 95: ...s Spring length with preload spacer s 510 mm 20 08 in Spring rate Weight of rider 65 75 kg 143 165 lb 4 4 N mm 25 1 lb in Weight of rider 75 85 kg 165 187 lb 4 6 N mm 26 3 lb in Weight of rider 85 95 kg 187 209 lb 4 8 N mm 27 4 lb in Air chamber length 110 20 30 mm 4 33 0 79 1 18 in Spring preload Preload Adjuster Comfort 2 turns Standard 2 turns Sport 4 turns Fork length 940 mm 37 01 in FORK OIL ...

Page 96: ...ns Standard 1 5 turns Sport 1 turn Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Spring preload 9 mm 0 35 in Spring rate Weight of rider 65 75 kg 143 165 lb 69 N mm 394 lb in Weight of rider 75 85 kg 165 187 lb 72 N mm 411 lb in Weight of rider 85 95 kg 187 209 lb 76 N mm 434 lb in Spring length 250 mm 9 84 in Gas pressure 10 bar 145 psi Static sag 35 mm 1 38 in Riding sag 1...

Page 97: ...f ft Screw fork stub M8 15 Nm 11 1 lbf ft Screw front brake caliper M8 25 Nm 18 4 lbf ft Loctite 243 Screw handlebar clamp M8 20 Nm 14 8 lbf ft Screw side stand fixing M8 40 Nm 29 5 lbf ft Loctite 243 Screw subframe M8 35 Nm 25 8 lbf ft Loctite 243 Screw top steering stem M8 17 Nm 12 5 lbf ft Loctite 243 Screw top triple clamp M8 17 Nm 12 5 lbf ft Engine carrying screw M10 60 Nm 44 3 lbf ft Remain...

Page 98: ...2 3 2 4 2 2 1 3 1 1 1 1 2 2 1 2 2 2 CR1 1 CR 1 1 1 1 2 3 3 3 4 3 2 1 4 2 1 5 6 7 1 1 0 1 2 1 4 1 3 1 2 1 2 1 1 2 3 4 4 re wh re bl gn re re gn re bl re wh bu wh br ye bl bu wh br ye wh gn or pu bl or ye re br re ye gn bu wh u b n g ye re br ye re br ye wh bu ye bl bl ye bu bl wh re ye re ye re br or ye re ye re ye bl br br ye bl bl gr gr bl wh e r e y e y h w r b r b l b h w n g h w r b r b u p r ...

Page 99: ... L2 Ignition coil M1 Starter motor N2 Voltage regulator rectifier P1 Speedometer S1 Rear brake light switch S2 Front brake light switch S5 Tripmaster switch optional S6 Light switch S7 Horn button S8 Flasher switch S10 Electric starter button S11 Emergency OFF switch S12 Headlight flasher button S13 Ignition switch X1 Ignition curve plug connection X2 Radiator fan plug connection optional bl Black...

Page 100: ...WIRING DIAGRAM 98 ye Yellow ye bl Yellow black ye re Yellow red ...

Page 101: ...50 Corrosion antifreeze 50 Distilled water Coolant mixed ready to use Antifreeze 40 C 40 F Supplier Motorex Anti Freeze Engine oil SAE 10W 50 According to JASO T903 MA p 102 SAE p 102 SAE 10W 50 Guideline Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Synthetic engine o...

Page 102: ...x products Supplier Motorex Protect Shine 645 Contact spray Specification KTM recommends Motorex products Supplier Motorex Accu Contact High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Moto Polish Long life grease Specification KTM recommends Motorex products Supplier Motorex Fett 2000 Motorcycle cleaner Specification KTM recommends Motorex products Suppl...

Page 103: ...S 101 Oil for foam air filter Specification KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power Universal oil spray Specification KTM recommends Motorex products Supplier Motorex Joker 440 Universal ...

Page 104: ...ice intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the same oil as the engine The JASO MA Standard meets these special requirements SAE The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils...

Page 105: ...wear checking 49 Chassis number 12 Choke 23 Cleaning 84 Clutch changing fluid 74 fluid level checking 73 Clutch lever 14 adjusting basic position 73 Compression damping fork adjusting 39 Compression damping high speed of shock absorber adjusting 34 Compression damping low speed shock absorber adjusting 35 Coolant draining 70 refilling 71 Coolant level checking 69 70 Cooling system 69 E Electric st...

Page 106: ...78 removing 78 Overview of indicator lamps 15 Owner s manual 8 P Play in gas Bowden cable adjusting 47 checking 47 Putting into operation advice on first use 26 after storage 85 checks before putting into operation 28 R Rear sprocket engine sprocket checking for wear 49 Rear wheel installing 62 removing 61 Rebound damping fork adjusting 39 shock absorber adjusting 35 Riding sag adjusting 38 S Seat...

Page 107: ...engine 86 87 engine tightening torques 88 89 fork 93 shock absorber 94 Tire air pressure checking 63 Tire condition checking 63 Transport 5 Troubleshooting 82 83 Type label 12 U Use definition 5 V View of vehicle left front 10 right rear 11 W Warranty 5 Wiring diagram 96 98 Work rules 5 ...

Page 108: ... 3211485en 3211485en KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 12 2008 Photo Mitterbauer ...

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