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ENGLISH

13

Only give as much gas as the engine can handle. Through
quick and high reving of throttle, the fuel usage increases.
By shifting down, use the brakes if necessary and close throttle
at the same time. Pull clutch lever and shift down to the next
gear. Let clutch lever go slowely and open throttle or shift
down again.

NOTE:
D

EDICATED

TO

NOTHING

BUT

OFFROAD

RACING

, 400/520

SX/MXC/EXC R

ACING MODELS MAKE NO COMPROMISES IN THEIR

DESIGN

. A

S SUCH

THEY DO NOT INCLUDE ANY RADIATOR FAN

AND THE

SIZE OF THE RADIATOR IS DIMENSIONED FOR OPTIMUM ERGONOMICS

I

N NORMAL RACING

THE COOLING SYSTEM IS SUFFICIENT

I

F YOU USE YOUR MOTORBIKE IN OTHER CONDITIONS

PLEASE NOTE THAT

THE

E-

STARTER ALLOWS YOU TO START

MXC/EXC R

ACING MODELS

AGAIN AT ANY TIME

. T

HEREFORE

TURN OFF THE ENGINE IF YOU

INTEND TO RUN YOUR MOTORCYCLE IN IDLE OR AT STANDSTILL FOR
LONGER PERIODS OF TIME

(

MORE THAN

MINUTES

). 

– A

VOID LETTING THE CLUTCH SLIP FREQUENTLY AND FOR EXTENDED

PERIODS

. T

HIS WOULD CAUSE THE ENGINE OIL TO HEAT UP

THEREBY

HEATING UP THE ENGINE AND THE COOLING SYSTEM

. R

ATHER

YOU

SHOULD DRIVE AT LOW SPEEDS

(4-

STROKE STYLE

LETTING THE

ENGINE PULL YOU

AND NOT AT HIGH SPEEDS NOT BY LETTING THE

CLUTCH SLIP

(2-

STROKE STYLE

).

WARNING

– O

BSERVE THE TRAFFIC REGULATIONS

DRIVE DEFENSIVELY AND TRYING

TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE
RECOGNIZED AS EARLY AS POSSIBLE

.

– A

DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND

YOUR DRIVING SKILLS

.

– D

RIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS

.

– W

HEN DRIVING OFF

-

ROAD

ALWAYS HAVE A FRIEND ON A SECOND

MOTORCYCLE TO KEEP YOU COMPANY

SO THAT YOU CAN HELP EACH

OTHER SHOULD DIFFICULTIES ARISE

.

– R

EPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR

DAMAGED

IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR

LENS

THE OPERATOR WILL BE BLINDED

.

– A

FTER FALLING WITH THE MOTORCYCLE

CHECK ALL FUNCTIONS

THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN

.

– A 

TWISTED HANDLEBAR MUST ALWAYS BE REPLACED

. D

O NOT ADJUST

THE HANDLEBAR

IT WILL LOSE STA

-

BILITY

.

!

CAUTION

!

– H

IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE

EFFECT ON THE LIFE OF YOUR ENGINE

. W

E RECOMMEND YOU RUN

THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT
A CHANCE TO WARM UP

. A

FTER THAT NO FURTHER PRECAUTIONS IN

THIS RESPECT NEED BE TAKEN

. T

HE ENGINE HAS REACHED ITS OPERA

-

TING TEMPERATURE AS SOON AS THE RADIATORS BECOME WARM

– N

EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO

A LOWER GEAR

. T

HE ENGINE WILL OVER

-

REV

DAMAGING THE VALVES

.

I

N ADDITION

THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE

CAN EASILY GET OUT OF CONTROL

.

– I

F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING

CHECK THAT

THE ENGINE FASTENING BOLTS ARE TIGHT

.

– I

N THE EVENT THAT

WHILE RIDING ON YOUR MOTORCYCLE

YOU

NOTICE ANY UNUSUAL OPERATION

-

RELATED NOISE

STOP IMMEDIA

-

TELY

TURN THE ENGINE OFF

AND CONTACT AN AUTHORIZED

KTM

DEALER

.

– N

EVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN

-

TED

OTHERWISE

DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE

INCREASED WEAR

.

Braking

Close throttle and apply the hand and foot brakes at the same
time. When driving on sandy, wet or slippery ground use
mainly the rear wheel brake. Always brake with feeling,
blocking wheels can cause you to skid or fall. Also change
down to lower gears depending on your speed.
When driving down hill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the
engine. In this way, you will not need to brake so much and
the brakes will not overheat.

WARNING

– I

N CASE OF RAIN

AFTER WASHING THE MOTORCYCLE

AFTER RIDES

THROUGH WATER AND IN CASE OF RIDES ON WET OFF

-

ROAD TRACKS

,

HUMID OR DIRTY BRAKE DISCS CAN DELAY THE BRAKING EFFECT

. T

HE

BRAKES MUST BE PULLED UNTIL THEY ARE DRY OR CLEAN

.

– R

IDES ON SALT

-

STREWED OR DIRTY ROADS CAN ALSO DELAY THE BRA

-

KING EFFECT

. T

HE BRAKES MUST BE PULLED UNTIL THEY ARE CLEAN

.

– D

IRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND

BRAKE DISCS

.

– W

HEN YOU BRAKE

THE BRAKE DISCS

BRAKE PADS

BRAKE CALIPER

AND BRAKE FLUID HEAT UP

. T

HE HOTTER THESE PARTS GET

THE WEA

-

KER THE BREAKING EFFECT

. I

N EXTREME CASES

THE ENTIRE BRAKING

SYSTEM CAN FAIL

.

Stopping and parking

Apply the brakes fully and put the engine into neutral. To turn
off the engine, push the short-circuit button or the emergency-
OFF button with the engine at idling speed until the engine
stops. Turn the fuel tap to the OFF position, park on an area
where the ground is firm, and lock the motorcycle.

WARNING

– N

EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE

ENGINE IS RUNNING

.

– M

OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE

RUNNING

. T

HE ENGINE

EXHAUST PIPE

MUFFLER

BRAKE ROTORS

AND

SHOCK ABSORBERS CAN BECOME VERY HOT

. D

O NOT TOUCH ANY OF

THESE PARTS AFTER OPERATING THE MOTORCYCLE

AND TAKE CARE TO

PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET
BURNED

.

!

CAUTION

!

– N

EVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE

ENGINE

. R

ATHER

USE THE SHORT

-

CIRCUIT BUTTON OR THE EMER

-

GENCY

-

OFF BUTTON

.

– C

LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE

.O

THERWISE THE

CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE

.

– N

EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE

HAZARDS

DUE

TO

DRY

GRASS

OR

OTHER

EASILY

FLAMMABLE

MATERIALS

.

NOTE REGARDING THE SIDE STAND:
Use your foot to kick side stand forward up to the stop and
lean the motorcycle sideways. Make sure that the ground is
solid and that your motorcycle is standing securely. Just in
case, you can shift into first gear.

!

CAUTION

!

T

HE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE

MOTORCYCLE

. T

HE SIDE STAND AND

/

OR THE FRAME CAN BE DAMAGED

AND THE MOTORCYCLE CAN FALL OVER IF YOU MOUNT THE MOTOR

-

CYCLE

THUS PUTTING AN ADDITIONAL LOAD ON THE SIDE STAND

.

Содержание 2002 400 EXC Racing

Страница 1: ...OWNERS HANDBOOK MANUALE D USO MANUEL D UTILISATION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG Art Nr 3 210 17 06 2001 400 520 SX MXC EXC RACING ...

Страница 2: ... by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person COMSUMER INFORMATION...

Страница 3: ... in case you decide to sell it Many motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform those steps marked described in the chapter entitled M...

Страница 4: ...el at the hand brake lever 21 Page Checking of brake fluid level front brake 21 Refilling the front brake fluid reservoir 21 Checking the front brake pads 21 Replacing the front brake pads 22 Changing the basic position of the brake pedal 22 Checking rear brake fluid level 22 Refilling the rear brake fluid reservoir 22 Checking the rear brake pads 23 Replacing the rear brake pads 23 Dismounting an...

Страница 5: ...re The outer end of the lever must at all times provide for a backlash of approx 10mm 0 4 in Only thereafter may it cause valve motion to be recognized by the stronger resistance which the hand decompression level encounters CAUTION NEVER USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE RATHER USE THE SHORT CIRCUIT BUTTON OR THE EMERGENCY OFF BUTTON THE SETTING OF THE DECOMPRESSION CABLE SH...

Страница 6: ... stop function DST Total distance up to 99 999 km CLK Clock See maintenance work for change of battery and basic setting Odometer EXC USA The odometer is a mileage indicator and can be set to 0 by means of the adjustment wheel 4 Speedometer indicator lamps EXC AUS The mileage indicator A in the speedometer 5 indicates overall mileage When the turn indicator is on the green indicator lamp 6 will be...

Страница 7: ...tton 5 actuates the E starter WARNING ALWAYS VERIFY THAT THE TRANSMISSION HAS BEEN SET TO IDLE NEUTRAL BEFORE ACTUATING THE STARTER BUTTON IF YOU START THE MOTORCYCLE WITH A GEAR ENGAGED THE MOTORCYCLE WILL MOVE FORWARD Emergency OFF switch EXC Australia The red emergency OFF switch 6 is arranged adjacent to the throttle grip In this position the E starter is operational and the engine can be star...

Страница 8: ...PTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON During operation the twist grip must be turned to ON This means that the fuel can flow to the carburetor With the twist grip in th...

Страница 9: ...LE GRIP INCREASE THE KICK BACK HAZARD Foot brake pedal The foot brake pedal is disposed in front of the right foot rest Its basic posi tion can be adjusted to your seat position see maintenance work WARNING IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE W...

Страница 10: ...er on the SX models can synchronize the compression damping in the low and high speed range separately Dual Compression Control Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle The low and high speed technology overlaps The low speed setting is primarily for slow to normal shock absorber com pression rates The high speed sett...

Страница 11: ... of shock absorber SX MXC EXC By using the adjusting screw 3 the degree of damping of the rebound can be adjusted Turn the knob to the right side to increase damping turn it to the left side to reduce damping during rebounding STANDARD ADJUSTMENT Turn the adjusting screw clockwise to the stop Then turn the adjusting screw counterclockwise counting the number of clicks that corresponds to the respe...

Страница 12: ...cha nical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap check that the tank venting hose is free of ki...

Страница 13: ...tuate the E starter What to do when the engine is flooded In the event of a fall more fuel than necessary may get into the engine In order to pump the engine free pull the hand decompression lever fully rev up the engine actuate the kickstarter 5 to 10 times or actuate the E starter 2 times for 5 seconds each Then start the engine as described above If the engine fails to start unscrew the spark p...

Страница 14: ...E ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER NEVER START YOUR MOTORCYCLE IF NO AIR FILTER HAS BEEN MOUN TED OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Al...

Страница 15: ...d lamp setting Check function of electric systems low high beam break light indicator indicator lamps speedometer illumination horn emergency OFF switch or button Check brake fluid level lining thickness brake discs Check brake lines for damage and leaks Check smooth operation and adjust free travel of handbrake foot brake lever Check tightness of brake system screws Check shock absorber and fork ...

Страница 16: ...htness of screws nuts and hose clamps regular For cross country use After every cleaning Befor each start Continued tests of the 400 520 racing motor for KTM s specialized workshop additional order for KTM s specialized workshop a 100 l fuel consumption is equivalent to approx 15 operating hours Force fit of clutch drive shaftestsitz Clutch disk wear Cylinder and piston wear Groove piston pin reta...

Страница 17: ...E WORK ON CHASSIS AND ENGINE Changing the original position of the clutch lever The adjusting screw 1 can be used for individual adjustment of the original position of the clutch lever thus allowing adjustment to an optimal position for every hand size Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar Turning the adjusting screw counterclock wise...

Страница 18: ...me time dirt may also get in behind the dust protection bellows If this dirt is not removed the oil sealing rings located behind it may start to leak Use a screwdriver to lever the dust protection bellows out of the outer tubes and slide them downward Clean dust protection bellows outer tubes and fork tubes thoroughly and oil them thoroughly with silicone spray or engine oil Then push dust pro tec...

Страница 19: ...smount the shock absorber and clean it thoroughly NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring 5 changes the spring pretension by approximately 1 75 mm 0 07 in Loosen the clamping screw 6 and use the hook wrench contained in the vehicle tool set to turn the adjusting ring as desired ...

Страница 20: ... to 80 Nm 60 ft lb WARNING IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE TIGHTEN THE COLLAR NUT WITH THE REQUIRED TORQUE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE BEHAVIOR OF YOUR MOTORCYCLE NOTE The large adjusting range of the c...

Страница 21: ... ID 450 ORGANIC easy to dose good brake per formance short life for dry terrain low price BRAKE DISCS Due to wear the thickness of the brake disc in the area of the contact face 1 of the brake pads decreases At their thinnest point A the brake discs must not be more than 0 40 mm 0 016 in thinner than the pad s nominal thickness Measure the nominal thickness in a location B outside the contact face...

Страница 22: ...voir Loosen screws 2 and remove lid 3 and membrane 4 Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with clean brake fluid DOT 5 1 i e Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water WARNING NEVER USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A P...

Страница 23: ...in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING THE REAR WHEEL TO BRAKE THE BRAKING SYSTEM OVERHEATS AND MAY EVEN FAIL COMPLETELY IN EXTREME CASES Checking rear brake fluid level The reservoir for the rear disc brake is disposed on the engine in the vicini...

Страница 24: ...ON THE BRAKING SYSTEM ONE MUST ALWAYS ACTUATE THE HAND BRAKE LEVER OR FOOT BRAKE LEVER RESPECTIVELY SO AS TO ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel jack the motorcycle up on its frame so that the front wheel no longer touches the ground Loosen the 2 clamping screws 5 on the ...

Страница 25: ...n the collar nut 1 remove chain tensioner 2 hold the rear wheel and pull out the wheel spindle 3 until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the chain wheel and carefully take the rear wheel out of the swingarm CAUTION DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED MAKE SURE THE B...

Страница 26: ...have come loose Check spoke tension especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a screwdriver see photo A clear tone must be the result Dull tones are indicators of loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer WARNING SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN U...

Страница 27: ...3 by pushing the right but ton you jump to the next figure 4 repeat nos 2 3 until correct time is indicated 5 push the button on the back approx 1 second to terminate the setting procedure 2 push the left button until the right figure is showed in the display 3 by pushing the right but ton you jump to the next figure 4 repeat nos 2 3 until the previously noted total mileage is indicated 5 push the...

Страница 28: ...he indication TRP is active and push the but ton on the back approx 5 seconds WS appears 2 use the right button to select the position to be changed 3 push the left button until the right figure is showed in the display 4 repeat nos 2 3 until correct wheel circumfe rence is indicated 5 push the button on the back for approx 1 second to terminate the setting procedure 5 sec 1 sec mm x 3 14 km h WS ...

Страница 29: ...NE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT AS SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE When preparing the motorcycle for a longer period of standstill remove the battery and recharge it Storage temperature 0 35 C 30 95 F Do not expose to direct sun radiation Charging the battery Remove ...

Страница 30: ...XPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Replacing headlight lamp parking light lamp Loosen both rubber bands and tilt headlight mask to the front Pull the par king light lamp with holder 4 carefully out of the reflector Pull connector 5 off the headlamp and remove rubber cap 6 Disengage retaining clip and take bulb out of reflector When changing the parking light lamp sim pl...

Страница 31: ...SARY TO BLEED THE COOLING SYSTEM DURING FILLING SEE BELOW FOR THE COOLING SYSTEM USE ONLY WITH HIGH GRADE ANTIFREEZE I E SHELL ADVANCE COOLANT USING LOWER GRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING EXTREM CLIMATE CONDITIONS OR STOP AND GO TRAFFIC MAY CAUSE OVERHEATING PROBLEMS TO AVOID THIS AN ELECTRIC BLOWER 4 IS OFFERED FOR MODELLS WITH ELECTRIC STARTERS ASK YOUR KTM DEALER ...

Страница 32: ... with glass fiber yarn to muffle noise The effect of heat causes the glass fiber yarn to become loose This may lead to a loss of performance and reduce the silencer s muffling power By experi ence the front glass fiber yarn packing 5 needs to be replaced more often than the rear silencing mat 6 For this purpose remove the silencer from the vehicle and dismount the front cap 7 Pull the front glass ...

Страница 33: ... together with the rubber boot 9 The oil level in the horizontal standing master cylin der should be 4 mm below the upper edge If necessary fill up with biodegradable hydraulic oil SAE 10 e g Shell Naturelle HF E15 Biodegradable hydraulic oil is available from your KTM dealer 50ml CAUTION KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL NEVER MIX BIODEGRADABLE HYDRAULIC OILS W...

Страница 34: ... screwed in up to the stop without causing any change in rotational speed a smaller idling jet has to be installed b the engine dies when the mixture control screw is still open by 2 turns a larger idling jet needs to be selected Naturally in cases of jet changes you have to start your adjusting work from the beginning 5 Then use the adjusting wheel to set the desired idle speed 6 In cases of grea...

Страница 35: ... draws engine oil from the oil sump of the transmission This engine oil flows through an oil line 3 into the cylinder head for camshaft lubrication 4 the oil quantity is controlled by the jet screw 5 An oil duct branches off to the long oil filter 6 where the coarser particles contained in the engine oil are filtered away Then the engine oil arrives at the short oil filter 7 which also filters the...

Страница 36: ...om Insert a pin type key into the plug and tap on the key a few times with a hammer in order to relieve the stress acting on the plug Dis mount the oil screen clean the components thoroughly and blow compres sed air through them Check the O rings for damage and if necessary replace them Mount the oil screen together with the plug again and tigh ten the plug to 10 Nm 7 ft lb CLEANING THE LONG OIL S...

Страница 37: ...orcycle on its side and fill the oil filter housings about halfway with engine oil Insert the long oil filter at the front and the short oil filter at the back of the housing Grease the O rings 4 of the oil filter covers and mount the covers Mount the screws and tighten them to 8 Nm 6 ft lb Position the brake fluid container and tighten the screw to 8 Nm 6 ft lb Return the motorcycle to its uprigh...

Страница 38: ...ents of the new fuels evaporate during longer periods of standstill When the motorcycle has been out of operation for more than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start off when the float chamber is filled with new fuel Close fuel tap loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out the ca...

Страница 39: ...elay The battery isn t charged by the generator because REMEDY Dismount carburettor and check if worn out Tighten jets Have ignition system checked Clean and check fuel system as well as carburettor Replace the float Clean or replace air filter Check if exhaust is damaged replace glas fibre yarn in exhaust silencer Adjust valve gap Check setting of the hand decompression cable Have ignition system...

Страница 40: ...beginning of the next biking season STORAGE Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal brand name washing detergent and a sponge The hard dirt can be removed before washing with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A ...

Страница 41: ...lve diameter Exhaust 30 mm Valve clearence cold Intake 0 10 mm Valve clearence cold Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston alluminium alloy cast alluminium alloy forged Piston rings 1 compression ring 1 oil scraper ring Engine lubrication pressure circulation lubrication with two rotorpumps Engine oi...

Страница 42: ...Nm 6 ft lb Allan head screw shift roller locking piece M6 Loctite 243 10 Nm 6 ft lb Hexagon collar screw locking lever M5 Loctite 243 6 Nm 6 ft lb Hexagon collar screw shift roller M5 Loctite 243 6 Nm 6 ft lb Hexagon collar screw securing guide chain guide chain tensioner M6 Loctite 243 8 Nm 6 ft lb Hexagon collar screw clip M5 Loctite 243 6 Nm 4 ft lb Hexagon collar screw chain adjuster M6 8 Nm 6...

Страница 43: ...mm 0 04 in Valves seat sealing intake max 1 50 mm 0 06 in seat sealing exhaust max 2 00 mm 0 078 in run out of valve heads max 0 05 mm 0 002 in valve guides diameter max 6 05 mm 0 238 in spring washer min 0 4 mm 0 016 in new 0 5 mm 0 019 in valve spring Interior min 36 5 mm 1 423 in new 37 45 mm 1 46in Exterior min 39 7 mm 1 548 in new 40 2 mm 1 567 in balancer shaft Journal runout max 0 06 mm 0 0...

Страница 44: ...b M 10 45 Nm 33ft lb Other collar nuts on chassis M 6 15 Nm 11ft lb M 8 30 Nm 22ft lb M 10 50 Nm 37ft lb TIGHTENING TORQUES CHASSIS Dead weight without fuel 400 520 SX RACING 400 520 EXC RACING 400 520 MXC EXC USA Frame Central tube chrom moly steel frame Fork WP USD 4860 MXMA WP Up Side Down 4357 MXMA Wheel travel front rear 295 320 mm Rear suspension WP Progressive Damping System shock absorber ...

Страница 45: ...g system 30 Correct chain tension 19 Damping action during compression of shock absorber SX 9 Digital speedometer EXC 5 Digital speedometer indicator lamps EXC 5 Dismounting and mounting the front wheel 23 Page Dismounting and mounting the rear wheel 24 Draining of float chamber of the carburetor 34 Driving instructions 11 Emergency OFF button EXC 6 Emergency OFF switch EXC Australia 6 Engine numb...

Страница 46: ...KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet www ktm at 321017 ...

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