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KTM 545 XC ATV EU 2011, Owner'S Manual

The KTM 545 XC ATV EU 2011 is a powerful and versatile off-road vehicle. Explore its capabilities and unleash your adventurous spirit with the help of the comprehensive Owner's Manual. Unlock the full potential of your ATV by easily downloading the manual for free from manualshive.com, providing you with all the necessary guidance and information.

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TUNING THE CHASSIS

87

Guideline

Screw, handlebar clamp

M8

20 Nm
(14.8 lbf ft)

Info

Make sure cables and wiring are positioned correctly.

–

Position the instrument support on the handlebar.

Summary of Contents for 545 XC ATV EU 2011

Page 1: ...OWNER S MANUAL 2011 525 XC ATV EU Art no 3211604en ...

Page 2: ......

Page 3: ...deviations resulting from continuing devel opment and design can however not be completely excluded All specifications are not 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: ...ds is permitted 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: ...ord 26 Speedometer 27 Speedometer activation and test 27 Tripmaster switch 28 Setting kilometers or miles 28 Setting the clock 29 Adjusting the speedometer functions 30 Querying the lap time 31 Display mode SPEED speed 32 Display mode SPEED H service hours 33 Display mode SPEED CLK clock 34 Display mode SPEED LAP lap time 34 Display mode SPEED ODO odometer 35 Display mode SPEED TR1 trip master 1 3...

Page 6: ...ession damping 78 Rear shock absorber adjusting the rebound damping 80 Rear shock absorber adjusting the spring preload x 81 Handlebar position 84 Adjusting the handlebar position x 85 MAINTENANCE WORK ON THE CHASSIS 88 Raising the vehicle with the lifting gear 88 Removing the vehicle from the lifting gear 88 Removing the rear shock absorber x 88 Installing the rear shock absorber x 90 Removing th...

Page 7: ...ping up brake fluid of rear brake x 139 Checking rear brake linings 140 Changing rear brake linings x 141 Removing rear brake linings x 142 Mounting rear brake linings x 144 WHEELS TIRES 146 Removing wheel wheels 146 Mounting wheel wheels 146 Checking the tire condition 147 Checking the tire air pressure 148 ELECTRICAL SYSTEM 150 Removing the battery 150 Installing the battery 151 Recharging the b...

Page 8: ... Storage 184 Putting the vehicle into operation after storage 185 TROUBLESHOOTING 186 TECHNICAL DATA ENGINE 191 Capacity engine oil 192 Capacity coolant 192 TECHNICAL DATA ENGINE TIGHTENING TORQUES 193 TECHNICAL DATA CARBURETOR 196 TECHNICAL DATA CHASSIS 197 Lighting equipment 199 Tires 199 Capacity fuel 200 TECHNICAL DATA FRONT SHOCK ABSORBER 201 Option KT 770 201 Option KT 870 201 TECHNICAL DATA...

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 service intervals If you observe these exactly you will ensure a much longer service life for your vehicle Fuel oils etc You should use ...

Page 11: ...e 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 very hot when the vehicle is operated Do not park the vehicle nea...

Page 12: ...nd 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 advise you Notes warnings Pay close attention to ...

Page 13: ...age if the appropriate measures are not taken Warning Identifies a danger that will lead to environmental damage if the appropriate measures are not taken Owner s manual It is important that you read this owner s manual carefully and completely before making your first trip It contains a lot of information and tips to help you operate and handle your vehicle Only then will you find out how to cust...

Page 14: ...VIEW OF VEHICLE 12 3 1 Vehicle view front left B00460 10 ...

Page 15: ...k p 45 2 Setting number front shock absorber p 18 3 Headlight 4 Fuse box 5 Hand brake lever front parking brake p 20 6 Clutch lever p 19 7 Emergency OFF switch with rip cord p 26 8 Choke p 43 9 Hot start button p 43 10 Shift lever p 44 ...

Page 16: ...VIEW OF VEHICLE 14 3 2 View of vehicle rear right B00461 10 ...

Page 17: ...cap 5 Hazard warning flasher switch hazard warning flasher p 25 6 Electric starter button p 25 7 Light switch turn signal switch kill switch horn button 8 Parking brake lever p 21 9 Ignition switch p 24 10 Throttle lever p 22 11 Fuel tap p 42 12 Oil level viewer 13 Foot brake lever p 45 ...

Page 18: ...is number 100002 10 The chassis number is stamped on the right side of the frame in the vicinity of the upper control arm 4 2 Type label 100034 10 The type label is located on the frame tube on the right in front of the radiator ...

Page 19: ...he engine number is stamped on the left side of the engine under the engine sprocket 4 4 Key number 100089 10 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 ...

Page 20: ...Setting number front shock absorber 100033 10 The setting number is stamped into the top of the shock absorber 4 6 Setting number rear shock absorber 100032 10 The setting number is stamped into the top 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: ...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 24: ...e speed 5 5 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 a non running engine will not start ...

Page 25: ...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 5 7 Turn signal switch 601028 10 The turn signal switch is fitted on the left side of the handlebar Possible states Turn signal off The turn signal switch is in the central position Left turn signal on The turn signal switch is rocked to...

Page 26: ...In this position the horn is actuated 5 9 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 27: ... flasher switch 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 Hazar...

Page 28: ...s switched to idle 5 13 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 29: ...ol different functions Info When the vehicle is delivered only the SPEED H and SPEED ODO display modes are activated 5 15 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 30: ... the mode selected last 5 16 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 17 Setting kilometers or miles Info If you change the unit of measure the ODO value is retained and converted accordingly The values TR1 TR2 A1 A2 and S1 are cleared when the unit of measure is changed Condi...

Page 31: ...button repeatedly until the Km h Mph display flashes Adjusting Km h Press the button Adjusting Mph 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 pressed for 20 seconds or if no impulse comes from the wheel speed sensor the settings are automatically saved and the Setup menu is closed 5 18 Setting the clock Condition The ...

Page 32: ...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 19 Adjusting the speedometer functi...

Page 33: ...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 34: ...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 21 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 35: ...aveling time Info The service hour counter is necessary for ensuring that maintenance work is carried out at the right intervals If the speedometer is in H display mode at the start of the journey it automatically changes to the ODO display mode The H display mode is suppressed during the journey Press the button No function Press the button No function Press the button for 3 5 seconds The display...

Page 36: ...y mode 5 24 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 37: ...ton for 3 5 seconds Press the button briefly Next display mode 5 26 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 If 9...

Page 38: ...tly and counts up to 999 9 The displayed value can be set manually with the button and the button This is a very practical 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 val...

Page 39: ...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 29 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 40: ...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 41: ... 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 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 S...

Page 42: ...Display 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 Me...

Page 43: ... filler cap 100012 10 Press release button turn filler cap counterclockwise and lift it free 5 33 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 44: ...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 45: ...p Choke function deactivated The choke lever is pushed in to the stop 5 36 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 46: ...4 5 37 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 47: ...ront of the right footrest The foot brake lever activates the brakes of all four wheels 5 39 Steering lock B00462 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 48: ... position 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 41 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 t...

Page 49: ...se you Warning Risk of injury Missing or poor protective clothing present an increased safety risk Wear protective clothing helmet boots gloves pants and jacket with protectors every time you ride the vehicle Always wear protective clothing which must be undamaged and meet legal requirements Warning Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear whe...

Page 50: ...hicle 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 124 Adjust the basic...

Page 51: ... allowable 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 operating hour 7 000 rpm Maximum engine performance During the first 3 service hours 75 Avoid fully opening the throttle ...

Page 52: ...e fluid level p 138 Check the front brake linings p 131 Check the rear brake linings p 140 Check that the brake system is functioning properly Check the coolant level p 160 Check the chain dirt accumulation p 114 Check the chain rear sprocket engine sprocket and chain guide p 118 Check the chain tension p 115 Check the tire condition p 147 Check the tire air pressure p 148 Check the air filter Che...

Page 53: ... 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 starter for a maximum of 5 seconds Wait for a least 5 seconds b...

Page 54: ...stem that switches off the engine in case of a malfunction in the throttle 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 engin...

Page 55: ...hot start button in as far as possible when the engine is running 7 3 Starting up Info Switch on the light before riding the vehicle You will then be seen earlier by other motorists Move the parking brake lever to the basic position Figure 601044 10 p 21 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 park...

Page 56: ... seen in the illustration First gear is used for starting off or for steep inclines To shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again 7 5 Braking Warning Danger of accidents If you brake too hard the wheels can lock When the front wheels lock the vehicle can...

Page 57: ...rheat 7 6 Riding Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop If the vehicle goes out of control and you fall off the vehicle the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing This short circuits the ignition circuit and the engine switches off During normal operation you sit er...

Page 58: ...er of accidents Excessive speed and turning at sharp angles can cause the vehicle to roll over Decrease your speed before entering into bends Handling of the ATV is strongly influenced by shifts in the position of your body weight Always shift your body weight toward the inside of the bend and forward The faster you ride and the tighter the bend the more you need to shift your body weight Always e...

Page 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 26 Info When the engine is switched off using the emergency OFF switch the powe...

Page 65: ... the 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 61 Remove the ignition ...

Page 66: ...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 67: ...ff the engine Open the filler cap p 41 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 209 Close the filler cap p 41 ...

Page 68: ...d leakage Check the rear brake fluid level p 138 Check the free travel of the foot brake lever p 136 Check the frame and swingarm x Check the swingarm bearing x Check the heim joints on the upper and lower shock absorbers x Check the tire condition p 147 Check the tire air pressure p 148 Check the wheel bearing for play x Check the wheel hubs x Check for rim run out x Check the front wheel suspens...

Page 69: ...ainage and sleeves for tearing tightness and correct rout ing x Check the antifreeze and coolant level p 159 Check the cables for damage and routing without sharp bends x Check the cables for damage routing without sharp bends and correct adjustment Clean the air filter and air filter box x Change glass fiber yarn filling of main silencer x Check the screws and nuts for tightness x Check the headl...

Page 70: ...s x Service the front shock absorber x Service the rear shock absorber x Change the spark plug and spark plug connector x Change the piston x Check measure the cylinder x Check the cylinder head x Check the valves valve springs and valve spring seats x Check the camshaft and rocker arm x Change the connecting rod conrod bearing and crank pin x Check the transmission and shift mechanism x Check the...

Page 71: ...SERVICE SCHEDULE 69 S45A Every 45 operating hours S90A Every 90 operating hours every 45 operating hours after sporting use J1A Annually ...

Page 72: ...oad but in the case of large weight differences the springs must be replaced Tip When changing the chassis settings always start with the standard setting Between test rides always change only one setting This will enable you to better assess the effect of the setting on vehicle han dling Do not make radical changes to the settings proceed in small steps instead Even small changes can have a large...

Page 73: ...10 Turn adjusting wheel clockwise up to the last perceptible click Turn back counterclockwise by the number of clicks corresponding to the shock absorber type Guideline Option KT 770 Compression damping Standard 14 clicks Maximum deviation from standard value 5 5 clicks Option KT 870 Compression damping Standard 15 clicks Maximum deviation from standard value 5 5 clicks Tip Experience has shown th...

Page 74: ...djustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber is filled with high density nitrog...

Page 75: ... deviation from standard value 5 5 clicks Option KT 870 Rebound damping Standard 20 clicks Maximum deviation from standard value 5 5 clicks Tip Experience has shown that settings outside of this range are detrimental to vehi cle handling When changing the chassis settings always start with the standard setting Info Turn clockwise to increase damping turn counterclockwise to reduce damping The left...

Page 76: ...rst to get the feel of the new ride behavior Caution 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 Info Increasing the spring preload raises the center of gravity of the vehicle This can have a large impact on vehicle handling Tip Be...

Page 77: ... pack and measure the length of the unloaded spring pack 0 0 A A 400347 10 Press together the spring pack position the securing clip in the corresponding groove and release the spring pack Guideline Option KT 770 Clip position spring preload Standard 7 th position from top Corresponds to a spring preload of 5 mm 0 2 in Option KT 870 Clip position spring preload Standard 8th position from top Corre...

Page 78: ...e same settings Remove the vehicle from the lifting gear p 88 9 5 Front shock absorber adjusting the cross over Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make ad...

Page 79: ...n at the front harder and the front of the vehicle lies higher Adjust the spring preload for the front shock absorbers p 74 Raise the vehicle with the lifting gear p 88 Clean the shock absorber thoroughly 100084 10 Loosen adjusting rings and Hook wrench 83019001000 0 0 0 B B 4 3 400348 11 The cross over setting is measured between sliding bushing and the collar of spring retainer Guideline Option ...

Page 80: ...vior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new ride behavior Caution Danger of accidents Disassembly of pressurized parts can lead to injury The shock absorber...

Page 81: ...mping Standard 15 clicks Maximum deviation from standard value 5 5 clicks Option KT 871 Compression damping Standard 17 clicks Maximum deviation from standard value 5 5 clicks Tip Experience has shown that settings outside of this range are detrimental to vehi cle handling When changing the chassis settings always start with the standard setting Info Turn clockwise to increase damping turn counter...

Page 82: ...ts ride slowly at first to get the feel of the new ride behavior Caution 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 Info The rebound damping setting has an impact on the rebound of the shock absorber 100081 10 Turn the adjusting w...

Page 83: ... Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle s ride behavior Extreme modifications to the adjustment of the spring elements can cause a serious deterioration in the handling characteris tics and overload some components Only make adjustments within the recommended range After making adjustments ride slowly at first to get the feel of the new...

Page 84: ...reload make a note of the present setting e g by measuring the length of the spring Remove the rear shock absorber x p 88 After removing the shock absorber clean it thoroughly 100082 10 Release lock nut while holding adjusting ring Hook wrench 83019002000 Info Do not loosen lock nut at the top of the shock absorber Turn the adjusting ring until the spring is no longer under tension ...

Page 85: ...ting ring to specified measurement Guideline Option KT 771 Spring preload Standard 3 mm 0 12 in Option KT 871 Spring preload Standard 3 mm 0 12 in Tighten the lock nut and the adjusting ring Info The adjusting ring is made of plastic Therefore do not lock the adjusting ring too tightly to avoid damaging the thread If you increase the spring preload you should also slightly increase the rebound dam...

Page 86: ...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 87: ...10 Adjusting the handlebar position x 302816 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 88: ...sired 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 M10 45 ...

Page 89: ...TUNING THE CHASSIS 87 Guideline Screw handlebar clamp M8 20 Nm 14 8 lbf ft Info Make sure cables and wiring are positioned correctly Position the instrument support on the handlebar ...

Page 90: ...Raise the vehicle on the frame underneath the engine The wheels must no longer touch the ground Secure the vehicle 10 2 Removing the vehicle from the lifting gear Note Danger of damage The parked vehicle may roll away or fall over Always place the vehicle on a firm and even surface Lower the vehicle Remove the lifting gear 10 3 Removing the rear shock absorber x Raise the vehicle with the lifting ...

Page 91: ...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 rear...

Page 92: ...Screw rear top shock absorber M12 60 Nm 44 3 lbf ft Position the shock absorber in the swingarm Mount and tighten the bottom screw Guideline Screw rear bottom shock absorber M12 70 Nm 51 6 lbf ft Remove the tension belt Install the rear fender p 95 Remove the vehicle from the lifting gear p 88 10 5 Removing the radiator spoiler Info The operations are the same on the left and right Remove the seat...

Page 93: ...SIS 91 100056 10 Remove the screws on the fuel tank B00467 10 Remove the screws on the radiator Detach the radiator spoiler and remove it 10 6 Installing the radiator spoiler Info The operations are the same on the left and right ...

Page 94: ...er into holder of the fuel tank and position it on the radiator B00468 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 97 ...

Page 95: ...S 93 10 7 Removing the front cover 302878 10 Remove screw Slide the front cover up and remove it 10 8 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 96: ...MAINTENANCE WORK ON THE CHASSIS 94 10 9 Removing the rear fender Remove the seat p 97 601078 10 Remove screws ...

Page 97: ...ender at the rear and remove it 10 10 Installing the rear fender 601081 10 Raise the rear of the air filter box lid At the same time use your other hand to press on the carburetor connection boot to kink it at that location Info This prevents the carburetor connection boot from disconnecting from the carbu retor Position front fender Fix the air filter box lid in the fender Info If the air filter ...

Page 98: ...MAINTENANCE WORK ON THE CHASSIS 96 601079 10 Mount and tighten screws Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft Mount the seat p 97 ...

Page 99: ...at 601070 10 Pull the release hook back Lift up the seat at the rear pull it back and then remove from above 10 12 Mounting the seat 100046 10 Hook slot on the seat into collar sleeve of the fuel tank lower the rear of the seat and slide tab under fuel tank ...

Page 100: ...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 of as stipulated in applicable regulations Remove the seat ...

Page 101: ...hand to press on the carburetor connection boot to kink it at that location Info This prevents the carburetor connection boot from disconnecting from the carbu retor 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 102: ...ase p 211 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 97 ...

Page 103: ...not clean the air filter with fuel or petroleum since these substances attack the foam Remove the air filter x p 98 Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly Air filter cleaner p 210 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 211 Clean the air filter box Che...

Page 104: ...oisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister according to regul...

Page 105: ...hen warm and can escape if the tank is overfilled See the notes on refueling Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor imm...

Page 106: ...ank Mount and tighten screw with the bushing Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft 600150 11 Connect fuel hose Position hose clip Install the radiator spoiler p 91 Install the front trim p 106 10 18 Removing the front trim Remove the front cover p 93 ...

Page 107: ...NTENANCE WORK ON THE CHASSIS 105 100075 10 Remove screws Raise the front trim and disconnect the plug in connectors from the head light and the emergency OFF switch with the rip cord Remove the front trim ...

Page 108: ...n 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 93 10 20 Checking the toe x Park the vehicle on a horizontal surface Check the tire condition p 147 Check the tire air pressure p 148 Check the chassis parts for damage play and wear ...

Page 109: ...S 107 302865 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 110: ...MAINTENANCE WORK ON THE CHASSIS 108 400333 10 Measure distances and If distances and are not equal Adjust the toe x p 109 Measure distances and Guideline Toe Front 0 mm 0 in ...

Page 111: ...s not meet specifications Adjust the toe x p 109 10 21 Adjusting the toe x Park the vehicle on a horizontal surface Check the tire condition p 147 Check the tire air pressure p 148 Check the chassis parts for damage play and wear Replace damaged or worn parts 302865 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 112: ... THE CHASSIS 110 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 113: ...f 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 10 22 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 Raise the vehicle with ...

Page 114: ...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 115: ...n screws Guideline Screw A arm top M10x52 45 Nm 33 2 lbf ft 600128 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 lifting gear p 88 ...

Page 116: ... is very dirty Clean the chain p 114 10 24 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 117: ...he 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 corr...

Page 118: ...6 Adjusting chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bearings in transmission and rear wheel eccentric element are under additional load Apart from premature wear in extreme transmission output shaft or the drive chain may snap Conversely if the...

Page 119: ...sing the spe cial 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 t...

Page 120: ...ocket and chain guide 400227 01 Shift gear to neutral Check the rear sprocket and engine sprocket for wear If the rear sprocket and engine sprocket are worn Change the rear sprocket or engine sprocket x Info The engine sprocket rear sprocket and chain should always be replaced together ...

Page 121: ...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 x Info When you replace the chain you should also change the rear sprocket and engine sprocket New chains wear out faster on old worn s...

Page 122: ...NANCE WORK ON THE CHASSIS 120 B00465 01 Check the chain sliding guard at the top for wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard x ...

Page 123: ...or wear If the lower edge of the chain pins is in line with or below the chain sliding guard Change the chain sliding guard x Check the chain sliding guard for tightness If the chain sliding guard is loose Tighten the chain sliding guard Guideline Remaining screws chassis M6 10 Nm 7 4 lbf ft ...

Page 124: ...If the lower edge of the chain pins is in line with or below the chain sliding piece Change the chain sliding piece x Check the chain sliding piece for tightness If the chain sliding piece is loose Tighten the chain sliding piece Guideline Screw chain sliding piece M8 15 Nm 11 1 lbf ft ...

Page 125: ...l ring Long life grease p 209 10 29 Checking the throttle cable routing Remove the fuel tank x p 102 B00469 01 Check the throttle cable routing The throttle cable must be routed along the front of the handlebar through the cable guide on the steering column and along the upper frame tube to the carburetor If the throttle cable is not routed as specified Correct the throttle cable routing Install t...

Page 126: ...ge of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding 10 31 Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid 302833 10 Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover wit...

Page 127: ... 32 Removing the engine guard 302825 10 Remove screws and Remove the engine guard 10 33 Installing the engine guard 302825 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 128: ...ravel on hand brake lever according to specifications 302855 10 Push the hand brake lever forward and check free travel Free travel of hand brake lever 3 mm 0 12 in If the free travel does not meet specifications Adjust the basic position of hand brake lever p 126 11 2 Adjusting basic position of hand brake lever 302857 10 Check the free travel of the hand brake lever p 126 Adjust the basic settin...

Page 129: ...rce Do not make any adjustments while riding 11 3 Checking brake 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 thi...

Page 130: ... or worn out brake lin ings Check the brake system and not continue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 302858 10 Move the brake fluid reservoir mounted on the handleb...

Page 131: ...rake 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 contact Avoid contact with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a ...

Page 132: ... etc should be disposed of as stipulated in applicable regulations Info Never use DOT 5 brake fluid It is silicone based and purple in color Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid is corrosive Use only clean brake fluid from a sealed container ...

Page 133: ... container 5 mm 0 2 in Brake fluid DOT 4 DOT 5 1 p 207 Position the cover with the membrane Mount and tighten screws Info Clean up overflowed or spilt brake fluid immediately with water 11 6 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 to help Remo...

Page 134: ...ritation 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 comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to t...

Page 135: ...id reservoir mounted on the handlebar to a horizontal position Remove screws Remove cover with membrane Press the brake piston back to its basic position and make sure that no brake fluid over flows from the brake fluid reservoir Mount the front brake linings x p 135 Correct the brake fluid level to level Guideline Dimension brake fluid level below top edge of container 5 mm 0 2 in Brake fluid DOT...

Page 136: ...to help Info The operations are the same on the left and right Remove the wheel wheels p 146 Pull the hand brake lever and release it again Locking pawl moves into its basic position parking brake is deactivated 100071 10 Push the brake piston back to release pressure on the brake linings Remove the locking split pins withdraw the bolt and take out the brake linings Clean the brake caliper and bol...

Page 137: ...M vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Info The operations...

Page 138: ...el 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 on foot brake lever according to specifications 601085 10 Disconnect spring Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel Guideline Free travel at foot brake lever 3 5 mm 0 12 ...

Page 139: ... nut and turn it back with push rod until you have maximum free travel To adjust the basic position of the foot brake lever individually loosen nut and turn screw accordingly Info The range of adjustment is limited Turn push rod accordingly until you have free travel If necessary adjust the basic position of the foot brake lever Guideline Free travel at foot brake lever 3 5 mm 0 12 0 2 in Hold scr...

Page 140: ...ntinue riding Your authorized KTM workshop will be glad to help Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authorized KTM workshop will be glad to help 302828 10 Park the vehicle on a horizontal surface Check the brake fluid level in the viewer When the brake fluid level has ...

Page 141: ...act with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake 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 f...

Page 142: ...unt the screw cap with the membrane and tighten Info Clean up overflowed or spilt brake fluid immediately with water 11 14 Checking rear 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 to help ...

Page 143: ...t with skin and eyes and keep out of the reach of children Wear suitable protective clothing and goggles If brake fluid comes into contact with the eyes flush the eyes thoroughly with water and consult a physician immediately Warning Danger of accidents Reduced braking effect caused by old brake fluid Change the brake fluid of the front and rear brake according to the service schedule Your authori...

Page 144: ...h membrane Press the brake piston back to its basic position and make sure that no brake fluid over flows from the brake fluid reservoir Mount the rear brake linings x p 144 Add brake fluid to level Brake fluid DOT 4 DOT 5 1 p 207 Mount the screw cap with the membrane and tighten Info Clean up overflowed or spilt brake fluid immediately with water 11 16 Removing rear brake linings x Warning Danger...

Page 145: ...by approx 10 turns and use the screw to press the bearing bolt out of the brake caliper Remove screw 601056 10 Note Danger of damage Kinking of brake line Position and handle the brake line without straining it The brake line must be replaced if it is kinked Swing the brake caliper up unhook it from the brake caliper support and set it down Remove the brake linings Clean brake caliper and brake ca...

Page 146: ... use on KTM vehicles The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin ings If brake linings are used that differ from the originals there is no guarantee that they comply with the original license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Check the...

Page 147: ... the brake caliper support Lubricant T625 p 211 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 is a pressure point ...

Page 148: ...with the lifting gear p 88 Remove the wheel nuts Remove the wheel Info Carefully remove the wheel making sure it does not become jammed with the threads of the screws 12 2 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 moun...

Page 149: ...hand brake lever Figure 302856 10 p 20 Tighten the wheel nuts crosswise Guideline Wheel nut M10x1 25 45 Nm 33 2 lbf ft 12 3 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 th...

Page 150: ... markings and is indi cated by the last four digits of the DOT marking The first two digits indicate the week of manufacture and the last two digits the year of manufacture KTM recommends that the tires be changed after 5 years at the latest regard less of the actual state of wear If the tire is older than five years Change the tire 12 4 Checking the tire air pressure Info Low tire air pressure le...

Page 151: ...emove the dust cap Check the tire air pressure when the tires are cold Tire pressure gauge 83519001000 Tire air pressure 1 0 bar 15 psi If the tire pressure does not meet specifications Correct the tire pressure Mount the dust cap ...

Page 152: ... or open fire Charge only in well ventilated rooms Flush with copious amounts of water in case of skin contact If battery acid comes into contact with the eyes flush the eyes with water for at least 15 minutes and consult a physician Switch off all power consumers and switch off the engine Remove the rear fender p 94 200150 10 Disconnect the negative minus cable of the battery Pull back the plus p...

Page 153: ...uitable 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 Flush with copious amounts of water in case of skin contact If battery acid comes into contact with the eyes flush the eyes with water for at least 15 minutes and consult a physician Warning Environmental hazard Battery parts ...

Page 154: ... 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 battery...

Page 155: ...is 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 95 13...

Page 156: ...lectrical 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 13 5 Changing the fuses of individual power consumers Remove the front cover p 93 Swit...

Page 157: ...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 spare fuses Info You can recognize a blown fuse by its broken filament Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never...

Page 158: ...er 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 exactly at the...

Page 159: ... the headlight range of the headlight by moving it up or 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 ...

Page 160: ... 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 14 2 Radiator fan 600117 10 The radiator fan is located on the radiator under the fuel tank Working range within which radiator fan is switched on and off Th...

Page 161: ...g 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 Condition The e...

Page 162: ...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 rinse immediat...

Page 163: ... 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 and skin e...

Page 164: ...COOLING SYSTEM 162 Remove the front trim p 104 Place a suitable container under the vehicle 601072 10 Remove screw 600119 10 Remove screw ...

Page 165: ...ct 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 the hand b...

Page 166: ...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 167: ...COOLING SYSTEM 165 600123 10 Completely fill the radiator and close the radiator cap Place the vehicle on the ground Install the front trim p 106 Make a short test ride Check the coolant level p 160 ...

Page 168: ...6 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 enclosed space without an effective exhaust extraction system Start the engine and let it run idle Move the handlebar to and fro over the entire steer ing range The idl...

Page 169: ... adjusting idle x 600145 10 Screw in the idle adjusting screw until it stops and then to the prescribed basic set ting Guideline Idle mixture adjusting screw Open 1 0 turn Adjustment tool for mixture control screw 59029034000 Run the engine until warm Guideline Warm up time 5 min Adjust the idle speed with the adjusting screw Guideline Choke function deactivated The choke lever is pushed in to the...

Page 170: ...bove steps The extremely sporty rider will set the mixture about 1 4 of a turn back from this ideal value leaner in a clockwise direction since the engine becomes hotter in sporting use If the procedure described here does not lead to satisfactory results the cause may be a wrongly dimensioned idling jet If you can turn the idle adjusting screw to the end without any change of engine speed you hav...

Page 171: ...soning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doc tor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ac...

Page 172: ...able idling and the response to throttle opening That 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 act...

Page 173: ...ine the distance between the upper edge of your boot and the 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 specifications Adjust the basic position of the shift lever x p 171 15 7 Adjusting the basic position of the shift lever x 601068 10 Remove screw and take off shift lever ...

Page 174: ... 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 175: ...ure 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 does not reach the middle of the viewer Add engine oil p 180 600131 11 Condition The engine is cold Check the engine oil level The engine oil reaches the bottom of the viewer When the engine oil does not reach the bottom of...

Page 176: ... 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 Info Drain the ...

Page 177: ...0 Place a suitable container under the engine Remove the oil drain plug 302844 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 178: ...y 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 179: ...nger 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 180: ...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 case Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area ...

Page 181: ... 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 16 6 Filling up with engine oil x Info Too little engine oil or poor quality engine oil results in premature wear to the engine ...

Page 182: ...ases 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 p 1...

Page 183: ... up with engine oil Condition External temperature 0 C 32 F Engine oil SAE 10W 50 p 208 Condition External temperature 0 C 32 F Engine oil SAE 5W 40 p 208 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 184: ... as stipulated in applicable regulations Info If you clean the vehicle regularly its value and appearance will be 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 off t...

Page 185: ...ons in the engine and the brakes to evaporate Push back the protection covers from the handlebar controls to allow any water that may have entered there to evaporate After the vehicle has cooled off lubricate all moving parts and bearings Clean the chain p 114 Treat bare metal parts except for brake discs and exhaust system with a corrosion inhibitor Cleaning and preserving materials for metal rub...

Page 186: ...following actions 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 182 Change the engine oil and oil filter clean the oil screens x p 174 Check the antifreeze and...

Page 187: ...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 18 2 Putting the vehicle into operation after storage Recharge the battery x p 151 Install the battery p 151 Fill up with fuel p 64 Set the clock p 29 Perform checks and maintenance measures when preparing for...

Page 188: ...trode 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 is blocked Check adjust the carburetor components x Idle sp...

Page 189: ...Change the fuses of individual power consumers p 154 Engine cannot be cranked electric starter Operating error Follow the instructions on starting the engine p 51 Battery discharged Recharge the battery x p 151 Check the charging voltage x Check the quiescent current x Check the alternator x Blown fuse Change the main fuse p 153 Start relay faulty Check the starter relay x Starter motor faulty Che...

Page 190: ...nge spark plug Ignition system defective Check the spark plug connector x Check the ignition coil x Check the ignition pulse generator x Check the alternator x Check the CDI controller x Engine stalls or is backfiring into the carburetor Lack of fuel Turn the handle of the fuel tap to ON Figure 100013 10 p 42 Fill up with fuel p 64 Intake system air leak Check rubber sleeves and carburetor for tig...

Page 191: ...r Clean the fuel tap Check adjust the carburetor components x Air filter excessively dirty Clean the air filter and air filter box x p 101 Exhaust system leaky deformed or too little glass fiber yarn filling in main silencer Check exhaust system for damage Valve clearance too little Adjust the valve clearance x Ignition system defective Check the spark plug connector x Check the ignition coil x Ch...

Page 192: ... of the electrical system are not functional Fault in the electrical system Change the fuses of individual power consumers p 154 Check the electrical system Battery discharged Battery is not charged by alternator Check the charging voltage x Check the alternator x Undesired power consumer Check the quiescent current x Speedometer values deleted time stop watch lap times The battery in the speedome...

Page 193: ... 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 194: ...park plug electrode gap 0 6 mm 0 024 in Cooling Water cooling permanent circulation of coolant by water pump Starting aid Electric starter 20 1 Capacity engine oil Engine oil 1 7 l 1 8 qt External temperature 0 C 32 F Engine oil SAE 10W 50 p 208 External temperature 0 C 32 F Engine oil SAE 5W 40 p 208 20 2 Capacity coolant Coolant 1 30 l 1 37 qt Coolant p 207 Coolant mixed ready to use p 207 ...

Page 195: ... lbf ft Loctite 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...

Page 196: ...sioner 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 4 l...

Page 197: ...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 Loctite...

Page 198: ...buretor identification number 3925H Needle position 2 th position from top Idle mixture adjusting screw Open 1 0 turn Pump membrane stop 2 15 mm 0 0846 in Main jet 170 Jet needle OBDVT Idling jet 42 Main air jet 200 Idle air jet 100 Cold start jet 85 Throttle slide 15 ...

Page 199: ...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 200: ...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 201: ...12 V 35 35 W Parking light W5W socket W2 1x9 5d 12 V 5 W Indicator lights W1 2W socket W2x4 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 23 2 Tires Front tire Rear tire 21 x 7 00 10 20 x 11 00 9 Additional information is available in the Service section under http www ktm com ...

Page 202: ...TECHNICAL DATA CHASSIS 200 23 3 Capacity fuel Total fuel tank capacity approx 13 5 l 3 57 US gal Super unleaded ROZ 95 RON 95 PON 91 p 209 Fuel reserve approx 3 l 3 qt ...

Page 203: ...licks Cross over 17 1 5 mm 0 67 0 059 in Clip position spring preload Standard 7 th position from top Corresponds to a spring preload of 5 mm 0 2 in Spring preload 5 mm 0 2 in Spring rate main spring 21 30 N mm 120 171 lb in Spring rate auxiliary spring 30 N mm 171 lb in Spring length main spring 275 mm 10 83 in Spring length auxiliary spring 60 mm 2 36 in Fitted length 463 mm 18 23 in 24 2 Option...

Page 204: ...icks Cross over 14 1 5 mm 0 55 0 059 in Clip position spring preload Standard 8th position from top Corresponds to a spring preload of 9 mm 0 35 in Spring preload 9 mm 0 35 in Spring rate main spring 21 30 N mm 120 171 lb in Spring rate auxiliary spring 30 N mm 171 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 ...

Page 205: ...5 clicks Maximum deviation from standard value 5 5 clicks Spring preload Standard 3 mm 0 12 in Spring rate 62 N mm 354 lb in Spring length 250 mm 9 84 in Fitted length 457 mm 17 99 in 25 2 Option KT 871 Shock absorber type 46PRCQ Setting number KT 871 Compression damping Standard 17 clicks Maximum deviation from standard value 5 5 clicks Rebound damping Standard 15 clicks Maximum deviation from st...

Page 206: ...TECHNICAL DATA REAR SHOCK ABSORBER 204 Spring preload Standard 3 mm 0 12 in Spring rate 62 N mm 354 lb in Spring length 250 mm 9 84 in Fitted length 449 mm 17 68 in ...

Page 207: ... M8 15 Nm 11 1 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 Screw su...

Page 208: ... 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 M1...

Page 209: ...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 210: ...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 213 SAE p 213 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 211: ... properties KTM recommends Motorex products Supplier Motorex Hydraulic Fluid 75 Long life grease According to NLGI Guideline Use only grease that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Fett 2000 Super unleaded ROZ 95 RON 95 PON 91 According to DIN EN 228 ROZ 95 RON 95...

Page 212: ...mover Chain cleaner Guideline KTM recommends Motorex products Supplier Motorex Chain Clean Chain lube for road use Guideline KTM recommends Motorex products Supplier Motorex Chainlube Road Cleaning and preserving materials for metal rubber and plastic Guideline KTM recommends Motorex products Supplier Motorex Protect Shine ...

Page 213: ...ike Grease 2000 Lubricant T625 Guideline KTM recommends Molykote products Supplier Molykote 33 Medium Motorcycle cleaner Guideline KTM recommends Motorex products Supplier Motorex Moto Clean 900 Oil for foam air filter Guideline KTM recommends Motorex products Supplier Motorex Twin Air Liquid Bio Power ...

Page 214: ... polish for high gloss and matte finishes bare metal and plastic surfaces Guideline KTM recommends Motorex products Supplier Motorex Clean Polish Universal oil spray Guideline KTM recommends Motorex products Supplier Motorex Joker 440 Synthetic ...

Page 215: ...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 216: ...ke checking 128 Brake fluid of front brake topping up 129 Brake fluid of rear brake checking 138 topping up 139 Brake linings of front brake changing 132 checking 131 installing 135 removing 134 Brake linings of rear brake changing 141 checking 140 installing 144 removing 142 C Camber adjusting 111 checking 111 Carburetor adjusting idle 167 emptying the float chamber 169 idle 170 Chain checking 11...

Page 217: ...d installing 125 removing 125 Engine number 17 Engine oil adding 180 changing 174 draining 174 refilling 179 Engine oil level checking 173 Engine sprocket checking 118 Environment 10 F Fender rear installing 95 removing 94 Filler cap closing 41 opening 41 Filling up fuel 64 Foot brake lever 45 basic position adjusting 137 free travel checking 136 Front cover installing 93 removing 93 Front shock a...

Page 218: ...e travel checking 126 Handlebar position 84 adjusting 85 Hazard warning flasher 25 Hazard warning flasher switch 25 Headlight setting checking 156 headlight range adjusting 157 Horn button 24 Hot start button 43 I Ignition switch 24 Indicator lamp overview 26 K Key number 17 Kill switch 22 L Light switch 23 M Main fuse changing 153 O Oil filter changing 174 installing 179 removing 177 Oil screens ...

Page 219: ... adjusting 81 Rear sprocket checking 118 Rear wheel eccentric element greasing 123 Rider training 10 Riding bends 56 brakes 54 downhill 57 engine switching off 61 general information 55 perpendicular to the slope 59 riding through water 61 starting up 53 stopping parking 63 turning on slopes 59 uphill 58 S Seat mounting 97 removing 97 Service 8 Service schedule 66 69 Shift lever basic position adj...

Page 220: ...sorber 201 202 rear shock absorber 203 204 Throttle cable routing checking 123 Throttle lever 22 Tire air pressure checking 148 Tire condition checking 147 Toe adjusting 109 checking 106 Transport 9 Troubleshooting 186 190 Turn signal switch 23 Type label 16 U Use definition 8 V Vehicle cleaning 182 lifting gear raising with 88 lifting gear removing from 88 W Wheel wheels installing 146 removing 1...

Page 221: ...KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com 06 2010 Photo Mitterbauer 3211604en 3211604en ...

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