Page 1 OWNER'S MANUAL 2011 525 XC ATV EU Art. no. 3211604en...
Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous DEAR KTM CUSTOMER pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle! Enter the serial numbers of your vehicle below.
Page 4 Reproduction, even in part, as well as copying of all kinds, 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.
Page 5: Table Of Contents
TABLE OF CONTENTS Setting kilometers or miles ..........28 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Setting the clock .............. 29 IMPORTANT INFORMATION ........... 8 Adjusting the speedometer functions........30 VIEW OF VEHICLE..............12 Querying the lap time ............31 Vehicle view, front left ............
Page 6 TABLE OF CONTENTS RIDING INSTRUCTIONS ............50 Rear shock absorber - adjusting the spring preload ..81 Checks and maintenance measures when preparing for Handlebar position ............84 use ................. 50 Adjusting the handlebar position ........85 Starting ................51 MAINTENANCE WORK ON THE CHASSIS ......
Page 7 TABLE OF CONTENTS Checking the chain tension ..........115 WHEELS, TIRES ..............146 Adjusting chain tension........... 116 Removing wheel/wheels........... 146 Checking the chain, rear sprocket, engine sprocket, and Mounting wheel/wheels ........... 146 chain guide..............118 Checking the tire condition..........147 Greasing the rear wheel eccentric element ......
Page 8 TABLE OF CONTENTS MAINTENANCE WORK ON THE ENGINE......173 Option: KT 871.............. 203 Checking the engine oil level ........... 173 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ..205 Changing engine oil and oil filter, cleaning oil SUBSTANCES..............207 screens ..............
Page 9: Means Of Representation
All work marked with this symbol requires specialist knowledge and technical 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.
Page 10: Important Information
Spare parts, accessories For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Page 11 IMPORTANT INFORMATION The current KTM PowerParts for your vehicle can be found on the KTM website. International KTM Website: http://www.ktm.com Work rules Special tools are needed for certain tasks. They are not included with the vehicle but can be ordered under the number in parentheses.
Page 12 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 the notes/warnings.
Page 13 IMPORTANT INFORMATION Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Caution Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Page 14: View Of Vehicle
VIEW OF VEHICLE Vehicle view, front left B00460-10...
Page 15 VIEW OF VEHICLE Steering lock ( p. 45) Setting number, front shock absorber ( p. 18) Headlight Fuse box Hand brake lever, front parking brake ( p. 20) Clutch lever ( p. 19) Emergency OFF switch with rip cord ( p.
Page 16: View Of Vehicle, Rear Right
VIEW OF VEHICLE View of vehicle, rear right B00461-10...
Page 17 VIEW OF VEHICLE Rear brake Rear shock absorber License plate holder Filler cap Hazard warning flasher switch/hazard warning flasher ( p. 25) Electric starter button ( p. 25) Light switch, turn signal switch, kill switch, horn button Parking brake lever ( p.
Page 18: Serial Numbers
SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper  control arm. 100002-10 Type label The type label is located on the frame tube on the right in front of the radiator. ...
Page 19: Engine Number
SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket.  601047-10 Key number 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
SERIAL NUMBERS Setting number, front shock absorber The setting number is stamped into the top of the shock absorber.  100033-10 Setting number, rear shock absorber The setting number is stamped into the top of the shock absorber.  100032-10...
Page 21: Controls
CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  Possible states Clutch lever in neutral position – In this position, the engine is force-locked with the • gear and the starting circuit is interrupted. The electric starter does not turn over when the electric starter button is pressed.
Page 22: Hand Brake Lever, Front Parking Brake
CONTROLS Hand brake lever, front parking brake The hand brake lever is located on the right side of the handlebar and operates the front  brakes. The hand brake lever is combined with the front parking brake, which locks the front wheels to prevent the vehicle from rolling away.
Page 23: Parking Brake Lever
CONTROLS Parking brake lever The parking brake lever is located on the left side of the handlebar and operates the rear  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.
Page 24: Throttle Lever
CONTROLS Throttle lever The throttle lever is fitted on the right side of the handlebar.  The throttle lever is used to control the engine speed. 100007-10 Kill switch The kill switch is fitted on the left side of the handlebar. ...
Page 25: Light Switch
CONTROLS Light switch The light switch is fitted on the left side of the handlebar.  Possible states Lights off – The light switch is rocked to the right. In this position, the light is switched off. Low beam on – Light switch in the middle position. In this position, the low beam and tail lights are switched on.
Page 26: Horn Button
CONTROLS Horn button The horn button is fitted on the left side of the handlebar.  Possible states • Horn button in basic position pressed – In this position, the horn is actuated. • Horn button 601030-10 Ignition switch The ignition switch is located to the right of the speedometer.
Page 27: Electric Starter Button
CONTROLS Electric starter button 5.10 The electric starter button is fitted on the left side of the handlebar.  Possible states • Electric starter button in basic position Electric starter button pressed – In this position, the electric starter is actuated. •...
Page 28: Indicator Lamp Overview
CONTROLS Indicator lamp overview 5.12 Possible states – No function. Reverse gear indicator lamp  flashes green with the flashing rhythm – The Turn signal indicator light  turn signal is switched on. lights up blue – The high beam is switched High beam indicator lamp ...
Page 29: Speedometer
CONTROLS Speedometer 5.14 – Press the key to change the display mode or change to one of the Setup menus. – Press the key to control different functions. – Press the key to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.
Page 30: Tripmaster Switch
CONTROLS WS (wheel size) After the display function test, the wheel size WS is displayed briefly. Info 1735 mm corresponds to a circumference of 10" for the front wheels with series tires. After this, the display changes to the mode selected last. 400740-01 Tripmaster switch 5.16...
Page 31: Setting The Clock
CONTROLS – briefly and repeatedly until H appears at the bottom right of the dis- Press the button play. – Press the button for 3 - 5 seconds. The Setup menu is displayed and the active functions are shown. – repeatedly until the Km/h/Mph display flashes.
Page 32: Adjusting The Speedometer Functions
CONTROLS – briefly and repeatedly until CLK appears at the bottom right of the Press the button display. – Press the button for 3 - 5 seconds. The hour display flashes. – Set the hour display with the button and/or button –...
Page 33: Querying The Lap Time
CONTROLS – briefly and repeatedly until H appears at the bottom right of the dis- Press the button play. – Press the button for 3 - 5 seconds. The Setup menu is displayed and the activated functions are shown. – Change to the desired function by pressing the button briefly.
Page 34: Display Mode Speed (Speed)
CONTROLS Condition The vehicle is stationary. – Press the button briefly and repeatedly until LAP appears at the bottom right of the display. – Press the button briefly. LAP 1 appears on the left side of the display. – Laps 1-10 can be displayed by pressing the button –...
Page 35: Display Mode Speed/H (Service Hours)
CONTROLS Display mode SPEED/H (service hours) 5.22 Condition • The vehicle is stationary. – Press the button briefly and repeatedly until H appears at the bottom right of the dis- play. In display mode H, the service hours of the engine are displayed. The service hour counter stores the total traveling time.
Page 36: Display Mode Speed/Clk (Clock)
CONTROLS Display mode SPEED/CLK (clock) 5.23 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button No function Press the button No function Press the button The display changes to the Setup menu of the clock.
Page 37: Display Mode Speed/Odo (Odometer)
CONTROLS Press the button Next display mode briefly. Display mode SPEED/ODO (odometer) 5.25 – Press the button briefly and repeatedly until ODO appears at the bottom right of the display. The total distance traveled is displayed in the ODO display mode. Press the button No function Press the button...
Page 38: Display Mode Speed/Tr2 (Trip Master 2)
CONTROLS Press the button The TR1, A1 and S1 displays are reset to 0.0. for 3 - 5 seconds. Press the button Next display mode briefly. Display mode SPEED/TR2 (trip master 2) 5.27 – Press the button briefly and repeatedly until TR2 appears at the top right of the dis- play.
Page 39: Display Mode Speed/A1 (Average Speed 1)
CONTROLS Display mode SPEED/A1 (average speed 1) 5.28 – Press the button briefly and repeatedly until A1 appears at the top right of the dis- play. A1 (average speed 1) shows the average speed calculated on the basis of TR1 (trip mas- ter 1) and S1 (stop watch 1).
Page 40: Display Mode Speed/S1 (Stop Watch 1)
CONTROLS – Press the button for 3 - 5 seconds. Press the button Next display mode briefly. Display mode SPEED/S1 (stop watch 1) 5.30 – Press the button briefly and repeatedly until S1 appears at the top right of the dis- play.
Page 41: Display Mode Speed/S2 (Stop Watch 2)
CONTROLS Display mode SPEED/S2 (stop watch 2) 5.31 – Press the button briefly and repeatedly until S2 appears at the top right of the dis- play. S2 (stop watch 2) is a manual stop watch. If S2 is running in the background, the S2 display flashes in the speedometer display. Starts or stops S2.
Page 42 CONTROLS Table of functions Display Press the button Press the button Press the button for 3 - Press the button briefly. 5 seconds. Display mode SPEED/TR1 No function No function The TR1, A1 and S1 dis- Next display mode (trip master 1) plays are reset to 0.0.
Page 43: Opening Filler Cap
CONTROLS Table of conditions and menu activation Display The vehicle is sta- Menu can be acti- tionary. vated Display mode SPEED/S2 (stop watch 2) • Opening filler cap 5.32 – Press release button , turn filler cap counterclockwise and lift it free. ...
Page 44: Fuel Tap
CONTROLS Fuel tap 5.34 The fuel tap is on the right of the fuel tank. With the tap handle on the fuel tap, you can open or close the supply of fuel to the car-  buretor. Possible states Fuel supply off OFF – No fuel can flow from the tank to the carburetor. •...
Page 45: Choke
CONTROLS Choke 5.35 The choke is fitted on the left side of the carburetor.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.
Page 46: Shift Lever
CONTROLS Shift lever 5.37 The shift lever is mounted on the left side of the engine.  100018-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 601043-10...
Page 47: Foot Brake Lever
CONTROLS Foot brake lever 5.38 The foot brake lever is located in front of the right footrest.  The foot brake lever activates the brakes of all four wheels. 100016-10 Steering lock 5.39 The steering lock is fitted on the steering column. ...
Page 48: Locking The Steering
CONTROLS Locking the steering 5.40 Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Park the vehicle. – Move the handlebar to the straight-ahead position. –...
Page 49: Putting Into Operation
– 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. Warning Risk of injury Missing or poor protective clothing present an increased safety risk.
Page 50 When using your vehicle, remember that others may feel disturbed by excessive noise. – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover.
Page 51: Running In The Engine
PUTTING INTO OPERATION – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum allowable axle load Front 160 kg (353 lb.) Rear 190 kg (419 lb.) – Run the engine in.
Page 52: Riding Instructions
RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the engine oil level. ( p.
Page 53: Starting
RIDING INSTRUCTIONS Starting 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.
Page 54 RIDING INSTRUCTIONS – Mount the vehicle. – Check the steering angle. » If steering is not possible. – Unlock the steering. ( p. 46) – Insert the clip into the emergency OFF switch and fasten the rip cord to the clothing ...
Page 55: Starting Up
RIDING INSTRUCTIONS – Pull the clutch lever. – Press the electric starter button. Info When the clutch lever is not pulled, the starting circuit is not closed. The elec- tric starter does not turn over when the electric starter button is pressed. Do not open the throttle.
Page 56: Shifting
Adapt your braking to the traffic situation and the road conditions. Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Page 57: 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.
Page 58: Riding In Bends
RIDING INSTRUCTIONS Guideline ≥ 2 min – Avoid slipping the clutch frequently and for prolonged periods. This heats the engine oil, the engine and the cooling system. – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch. Riding in bends Info When riding in bends, the outer wheels cover a greater distance than the inner wheels.
Page 59: Riding Downhill
RIDING INSTRUCTIONS Riding downhill Warning Danger of accidents Danger of accidents when riding uphill and downhill. – Always check the terrain before riding uphill or downhill. – Never ride on a road or path with an uphill or downhill inclination of more than 25°.
Page 60: Riding Uphill
RIDING INSTRUCTIONS Riding uphill Warning Danger of accidents Danger of accidents when riding uphill and downhill. – Always check the terrain before riding uphill or downhill. – Never ride on a road or path with an uphill or downhill inclination of more than 25°.
Page 61: Riding Perpendicular To The Slope
RIDING INSTRUCTIONS Riding perpendicular to the slope 7.10 Warning Danger of accidents When riding perpendicular to a slope, the vehicle can tip easily and roll over. – Avoid riding perpendicular to the slope if possible. – Ride slowly and shift you weight toward the slope. –...
Page 62 RIDING INSTRUCTIONS – If you come to a stop on a slope with your vehicle, dismount from the vehicle and turn – Switch off the engine and apply the parking brakes. Info A gear must be engaged. – Dismount from the vehicle on the uphill side. –...
Page 63: Riding Through Water
After riding through water, dry the brakes by lightly activating both brakes until normal braking power is available again. – If the vehicle became submerged, an authorized KTM workshop must perform a thor- ough check and comprehensive service. Do not start the engine. Switching off the engine 7.13...
Page 64 RIDING INSTRUCTIONS Alternative 1 Switch off the engine using the ignition key. – Turn the key in the ignition switch to the position while the engine is idling. Info All power consumers are switched off. Alternative 2 Switch off the engine using the kill switch. –...
Page 65: Stopping, Parking
RIDING INSTRUCTIONS Stopping, parking 7.14 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them. Note Danger of damage Danger of damage from accidental rolling of vehicle.
Page 66: Refueling
RIDING INSTRUCTIONS No more fuel flows from the tank to the carburetor. – If the vehicle must be parked on an incline, additionally secure the rear wheels against rolling (see illustration). Refueling 7.15 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first.
Page 67 RIDING INSTRUCTIONS – Switch off 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 13.5 l Super unleaded (ROZ 95 / RON 95 / capacity approx.
Page 68: Service Schedule
SERVICE SCHEDULE Service schedule S15A S30A Check that the electrical equipment is functioning properly. • • • • • Check and charge the battery. • • • Change the engine oil and oil filter, clean the oil screens. p. 174) Check the front brake linings.
Page 69 Check that the radiator fan is functioning properly. Final inspection: check the vehicle for operating safety and take a test ride. • • • • • • Create a service entry in the KTM DEALER.NET and in the service record. S1N: Once after one operating hour...
Page 70: Maintenance Work (As An Additional Order)
SERVICE SCHEDULE S15A: Every 15 operating hours S30A: Every 30 operating hours Maintenance work (as an additional order) S45A S90A • Change the brake fluid. • Change the sealing sleeves of the foot brake cylinder. • Change the hydraulic clutch fluid. Lubricate the steering column bearing.
Page 71 SERVICE SCHEDULE S45A: Every 45 operating hours S90A: Every 90 operating hours/every 45 operating hours after sporting use J1A: Annually...
Page 72: Tuning The Chassis
TUNING THE CHASSIS Basic information on changing the chassis settings The standard setting of the chassis is the result of many fine tuning tests. It is laid out for the weight of the average rider (with a full set of protective clothing) and for a sporty driving style.
Page 73 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 compression damping setting has an impact on the compression of the shock absorber.
Page 74: Front Shock Absorber - Adjusting The Rebound Damping
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.
Page 75 TUNING THE CHASSIS – Turn adjusting screw 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...) Rebound damping Standard 20 clicks −5… 5 clicks Maximum deviation from standard value 100028-10...
Page 76: Front Shock Absorber - Adjusting The Spring Preload
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.
Page 77 TUNING THE CHASSIS – Press the spring pack and the spring retainer down to make the securing clip   accessible. – Using pliers, position the locking clip in one of the upper grooves. Do not overstrain the securing clip. –...
Page 78: Front Shock Absorber - Adjusting The Cross Over
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 nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Page 79 TUNING THE CHASSIS Info The cross over setting is used to adjust the suspension travel of the short (soft) spring. Greater cross over makes the spring action at the front softer and the front of the vehicle lies lower. The suspension travel and the progressive part of the long (hard) spring is not fully utilized.
Page 80: Rear Shock Absorber - Adjusting The Compression Damping
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 compression damping setting has an impact on the compression of the shock absorber.
Page 81 TUNING THE CHASSIS – 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 771...) Compression damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value 100080-10...
Page 82: Rear Shock Absorber - Adjusting The Rebound Damping
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.
Page 83: Rear Shock Absorber - Adjusting The Spring Preload
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 nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Page 84 TUNING THE CHASSIS Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling. Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. –...
Page 85 TUNING THE CHASSIS – Measure the overall spring length in an unloaded state. Info The spring preload is the difference in length between the spring when it is  unloaded and when it is installed. – Tighten the spring by turning the adjusting ring to specified measurement. Guideline (Option: KT 771...) Spring preload...
Page 86: Handlebar Position
TUNING THE CHASSIS Handlebar position The handlebar position can be adjusted 4-fold by turning the handlebar support and the  handlebar support  The holes on the handlebar support are placed at a distance of from the center.  Distance between holes 3.5 mm (0.138 in) ...
Page 87: Adjusting The Handlebar Position
TUNING THE CHASSIS Adjusting the handlebar position 9.10 – 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. 302816-10...
Page 88 TUNING THE CHASSIS – Remove the four screws . Remove handlebar clamps , swing the handlebar forward   and set it down. – Remove nuts and remove handlebar support with the screws.   – Remove screws   –...
Page 89 TUNING THE CHASSIS Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure cables and wiring are positioned correctly. – Position the instrument support on the handlebar.
Page 90: Maintenance Work On The Chassis
MAINTENANCE WORK ON THE CHASSIS Raising the vehicle with the lifting gear 10.1 Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. – Raise the vehicle on the frame underneath the engine.
Page 91 MAINTENANCE WORK ON THE CHASSIS Note Danger of damage The chain sliding piece and frame can be damaged from incorrect handling. – When removing the rear shock absorber, secure the swingarm with a tension belt to prevent it from swinging down further. –...
Page 92: Installing The Rear Shock Absorber
MAINTENANCE WORK ON THE CHASSIS Installing the rear shock absorber 10.4 – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw  Guideline Screw, rear top shock absorber 60 Nm (44.3 lbf ft) –...
Page 93: Installing The Radiator Spoiler
MAINTENANCE WORK ON THE CHASSIS – Remove the screws on the fuel tank.  100056-10 – Remove the screws on the radiator.  – Detach the radiator spoiler and remove it. B00467-10 Installing the radiator spoiler 10.6 Info The operations are the same on the left and right.
Page 94 MAINTENANCE WORK ON THE CHASSIS – Hook catch of the radiator spoiler into holder of the fuel tank and position it on   the radiator. 100058-10 – Mount and tighten screws on the radiator.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –...
Page 95: Removing The Front Cover
MAINTENANCE WORK ON THE CHASSIS Removing the front cover 10.7 – Remove screw  – Slide the front cover up and remove it. 302878-10 Installing the front cover 10.8 – Position the front cover in slots on both sides of the front trim. ...
Page 96: Removing The Rear Fender
MAINTENANCE WORK ON THE CHASSIS Removing the rear fender 10.9 – Remove the seat ( p. 97) – Remove screws  601078-10...
Page 97: Installing The Rear Fender
MAINTENANCE WORK ON THE CHASSIS – 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.
Page 98 MAINTENANCE WORK ON THE CHASSIS – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( p. 97) 601079-10...
Page 99: Removing The Seat
MAINTENANCE WORK ON THE CHASSIS Removing the seat 10.11 – Pull the release hook back. Lift up the seat at the rear, pull it back and then remove  from above. 601070-10 Mounting the seat 10.12 – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the seat ...
Page 100: Removing The Air Filter
MAINTENANCE WORK ON THE CHASSIS – Push down the rear of the seat until release hook engages.  – Make sure that the seat is correctly locked in. 601071-10 Removing the air filter 10.13 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –...
Page 101 MAINTENANCE WORK ON THE CHASSIS – 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.
Page 102: Installing The Air Filter
MAINTENANCE WORK ON THE CHASSIS Installing the air filter 10.14 – Mount the clean air filter onto the air filter support. – Grease the air filter in area  Long-life grease ( p. 211) 301262-10 – Put in both parts together, position them and fix them with the air filter support ...
Page 103: Cleaning The Air Filter And Air Filter Box
MAINTENANCE WORK ON THE CHASSIS Cleaning the air filter and air filter box 10.15 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 Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Page 104: Removing The Fuel Tank
MAINTENANCE WORK ON THE CHASSIS Removing the fuel tank 10.16 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
Page 105: Installing The Fuel Tank
MAINTENANCE WORK ON THE CHASSIS – Remove screw and take off the fuel tank.  600151-10 Installing the fuel tank 10.17 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
Page 106: Removing The Front Trim
MAINTENANCE WORK ON THE CHASSIS – Position the fuel tank. Mount and tighten screw with the bushing.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 600151-11 – Connect fuel hose  – Position hose clip  – Install the radiator spoiler. ( p.
Page 107 MAINTENANCE WORK ON THE CHASSIS – 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. 100075-10...
Page 108: Installing The Front Trim
MAINTENANCE WORK ON THE CHASSIS Installing the front trim 10.19 – Connect the plug-in connectors of the head light and the emergency OFF switch with the rip cord and position the front trim. – Mount all screws. – Fully tighten screws ...
Page 109 MAINTENANCE WORK ON THE CHASSIS – 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) 302865-10...
Page 110 MAINTENANCE WORK ON THE CHASSIS 400333-10 – Measure distances   » If distances are not equal:   – Adjust the toe. p. 109) – Measure distances   Guideline Front 0 mm (0 in)
Page 111: Adjusting The Toe
MAINTENANCE WORK ON THE CHASSIS Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv-   ing straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. »...
Page 112 MAINTENANCE WORK ON THE CHASSIS 400333-11 – Loosen nuts   – Adjust the distances to the same value by rotating the tie rods    – Adjust the distances to the specified value by evenly rotating the tie rods ...
Page 113: Checking/Adjusting The Camber
MAINTENANCE WORK ON THE CHASSIS Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv-   ing straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. –...
Page 114 MAINTENANCE WORK ON THE CHASSIS – Loosen nuts  600128-10 – Remove screws with bushings   600126-10 – Insert tool in the heim joint and clip onto the A-arm.  Camber gauge (83019014000) – Check the camber on both heim joints. »...
Page 115 MAINTENANCE WORK ON THE CHASSIS – Position the A-arm with bushings . Mount and tighten screws   Guideline Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) 600126-10 – Align the heim joint at right angles to screws and tighten nut ...
Page 116: Checking Chain Dirt
MAINTENANCE WORK ON THE CHASSIS Checking chain dirt 10.23 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 114) 400678-01 Cleaning the chain 10.24 Warning Environmental hazard Hazardous substances cause environmental damage. –...
Page 117: Checking The Chain Tension
MAINTENANCE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 210) Chain lube for road use ( p. 210) 400725-01 Checking the chain tension 10.25 Warning Danger of accidents Danger caused by incorrect chain tension. –...
Page 118: Adjusting Chain Tension
MAINTENANCE WORK ON THE CHASSIS – Push the upper chain section at the end of the chain sliding component upwards to measure the chain tension  Info The lower chain section must be taut. Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
Page 119 MAINTENANCE WORK ON THE CHASSIS – Loosen the screws by four turns.  Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric ele-   ment. Alternative 2 – Position the special tool at the rear wheel eccentric element. Hook wrench (83019011000) –...
Page 120: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide
MAINTENANCE WORK ON THE CHASSIS Checking the chain, rear sprocket, engine sprocket, and chain guide 10.27 – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. » If the rear sprocket and engine sprocket are worn: –...
Page 121 MAINTENANCE WORK ON THE CHASSIS – Pull on the lower part of the chain with the specified weight  Guideline Chain-wear measuring weight 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the upper chain section. ...
Page 122 MAINTENANCE WORK ON THE CHASSIS – 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. B00465-01...
Page 123 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding guard at the bottom 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. –...
Page 124 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness. »...
Page 125: Greasing The Rear Wheel Eccentric Element
MAINTENANCE WORK ON THE CHASSIS Greasing the rear wheel eccentric element 10.28 – Use a grease gun to fill the rear wheel eccentric element via the grease nipple until  grease emerges from the left shaft seal ring  Long-life grease ( p.
Page 126: Adjusting Basic Position Of Clutch Lever
MAINTENANCE WORK ON THE CHASSIS Adjusting basic position of clutch lever 10.30 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar.
Page 127: Removing The Engine Guard
MAINTENANCE WORK ON THE CHASSIS – Position the cover with the membrane. Mount and tighten screws. Removing the engine guard 10.32 – Remove screws . Remove the engine guard.   302825-10 Installing the engine guard 10.33 – Position the engine guard on the frame bearer. Mount and tighten screws ...
Page 128: Brakes
BRAKES Checking the free travel of the hand brake lever 11.1 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.
Page 129: Checking Brake Discs
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.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...
Page 130: Checking Front Brake Fluid Level
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.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Page 131: Topping Up The Front Brake Fluid
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 authorized KTM workshop will be glad to help.)
Page 132 BRAKES Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. Info Never 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.
Page 133: Checking The Front Brake Linings
302838-10 Checking the front brake linings 11.6 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.) – Remove the wheel/wheels. ( p. 146)
Page 134: Changing The Front Brake Linings
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.
Page 135 BRAKES 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 136: Removing Front Brake Linings
11.8 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Info The operations are the same on the left and right. – Remove the wheel/wheels. ( p.
Page 137: Mounting Front Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
Page 138: Checking Free Travel Of Foot Brake Lever
BRAKES – Mount the locking split pins  – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. – Mount the wheel/wheels. ( p. 146) 100073-10 Checking free travel of foot brake lever 11.10 Warning...
Page 139: Adjusting Basic Position Of Foot Brake Lever
BRAKES Adjusting basic position of foot brake lever 11.11 Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to over- heating.
Page 140: Checking Rear Brake Fluid Level
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.) – Park the vehicle on a horizontal surface.
Page 141: Topping Up Brake Fluid Of Rear Brake
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.
Page 142: Checking Rear Brake Linings
Clean up overflowed or spilt brake fluid immediately with water. 100050-10 Checking rear brake linings 11.14 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: Changing Rear Brake Linings
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.
Page 144: Removing Rear Brake Linings
Clean up overflowed or spilt brake fluid immediately with water. Removing rear brake linings 11.16 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.)
Page 145 BRAKES – Press the brake caliper onto the brake disc by hand in order to push back the brake pis- ton. 601054-01 – Loosen the screw while holding the hexagonal head of the bearing bolt. Unscrew   the screw by approx. 10 turns and use the screw to press the bearing bolt out of the brake caliper.
Page 146: Mounting Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
Page 147 BRAKES – Grease the bearing bolt and insert the brake caliper with the bearing bolt into the  brake caliper support  Lubricant (T625) ( p. 211) 601058-10 – Swing the brake caliper downward. Mount and tighten the screw. Guideline Screw, rear brake caliper 10 Nm Loctite...
Page 148: Wheels, Tires
WHEELS, TIRES Removing wheel/wheels 12.1 Info Proceed in the same way on the other wheels if necessary. – Pull the hand brake lever, push the locking pawl down and release the hand brake  lever. (Figure 302856-10 p. 20) – Loosen the wheel nuts ...
Page 149: Checking The Tire Condition
12.3 Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on vehicle handling. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the vehicle.
Page 150: Checking The Tire Air Pressure
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.
Page 151 WHEELS, TIRES – Remove 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. –...
Page 152: Electrical System
ELECTRICAL SYSTEM Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious cauterization. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...
Page 153: Installing The Battery
Environmental hazard Battery parts and acid are harmful to the environment. – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Page 154 ELECTRICAL SYSTEM 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 Even if there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery.
Page 155: Changing The Main Fuse
ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the open-circuit current, the start ability of the battery and the alternator. With this device, you cannot overcharge the battery.
Page 156: Changing The Fuses Of Individual Power Consumers
ELECTRICAL SYSTEM – The main fuse is located in the starter relay in front of the battery.   – Remove protection covers  – Remove the faulty main fuse. Info You can recognize a blown fuse by its broken filament ...
Page 157 ELECTRICAL SYSTEM – Open cover of fuse box   Info The designation of the fuses is located on the inside cover of fuse box  – Remove the faulty fuse. Guideline Fuse - 1 10A - ignition, CDI controller, indicator lamps ON, N, R Fuse - 2 10A - high beam, low beam, parking light, tail light, brake light, high beam indicator lamp Fuse - 3 10A - radiator fan...
Page 158: Checking The Headlight Setting
ELECTRICAL SYSTEM The replacement fuses should always be present in the fuse box to make sure they are available when needed. – Close the cover of the fuse box. – Install the front cover. ( p. 93) Checking the headlight setting 13.6 –...
Page 159: Adjusting The Headlight Range Of The Headlight
ELECTRICAL SYSTEM Adjusting the headlight range of the headlight 13.7 – Check the headlight setting. ( p. 156) – Loosen screw  – Adjust 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).
Page 160: Cooling System
COOLING SYSTEM Cooling system 14.1 The water pump in the engine forces the coolant to flow.  The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
Page 161: Checking The Antifreeze And Coolant Level
COOLING SYSTEM Checking the antifreeze and coolant level 14.3 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.
Page 162: Checking The Coolant Level
COOLING SYSTEM – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in)  » If the coolant level does not meet specifications: – Correct the coolant level. Alternative 1 Coolant ( p. 207) Alternative 2 400243-10 Coolant (mixed ready to use) (...
Page 163: Draining Coolant
COOLING SYSTEM – Park the vehicle on a horizontal surface. – Remove the front trim. ( p. 104) – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above the radiator fins. 10 mm (0.39 in) ...
Page 164 COOLING SYSTEM – Remove the front trim. ( p. 104) – Place a suitable container under the vehicle. – Remove screw  601072-10 – Remove screw  600119-10...
Page 165: Filling Coolant / Bleeding Cooling System
COOLING SYSTEM – Remove the radiator cap . Completely drain the coolant.  600123-11 Filling coolant / bleeding cooling system 14.6 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 immediately with water and contact a doctor.
Page 166 COOLING SYSTEM – Fill the coolant into the radiator  Coolant 1.30 l (1.37 qt.) Coolant ( p. 207) Coolant (mixed ready to use) ( p. 207) 600120-10 – Open the screw to bleed the cylinder head. Tighten the screw when coolant ...
Page 167 COOLING SYSTEM – 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.
Page 168: Tuning The Engine
TUNING THE ENGINE Checking the play in the throttle cable 15.1 – Move the handlebar to the straight-ahead position. Move the throttle lever back and forth slightly to ascertain the play in the throttle cable  Guideline Play in throttle cable 3…...
Page 169: Carburetor - Adjusting Idle
TUNING THE ENGINE – Move the handlebar to the straight-ahead position. – Loosen the nut and use the screw to adjust the play in the throttle cable    Guideline Play in throttle cable 3… 5 mm (0.12… 0.2 in) –...
Page 170 TUNING THE ENGINE Info If the idle speed is set significantly higher, the engine does not start. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark. –...
Page 171: Emptying The Carburetor Float Chamber
TUNING THE ENGINE Info Following extreme air temperature or altitude changes, adjust the idle speed again. Emptying the carburetor float chamber 15.4 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
Page 172: Carburetor - Idle
TUNING THE ENGINE No more fuel flows from the tank to the carburetor. – Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the ...
Page 173: Checking The Basic Setting Of The Shift Lever
TUNING THE ENGINE Checking the basic setting of the shift lever 15.6 – Sit on the vehicle in the riding position and determine the distance between the  upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...
Page 174 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft.  – Position the shift lever in the desired position on the shift shaft and engage the gearing. Info The range of adjustment is limited. The shift lever should not come into contact with other vehicle components dur- ing shifting.
Page 175: Maintenance Work On The Engine
MAINTENANCE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level can be checked on a cold or hot engine. – Park the vehicle on a horizontal surface. Condition The engine is at operating temperature. –...
Page 176: Changing Engine Oil And Oil Filter, Cleaning Oil Screens
MAINTENANCE WORK ON THE ENGINE Changing engine oil and oil filter, cleaning oil screens 16.2 – Drain engine oil, clean oil screens. p. 174) – Remove the oil filter. p. 177) – Install the oil filter. p. 179) – Fill up with engine oil. p.
Page 177 MAINTENANCE WORK ON THE ENGINE – Place a suitable container under the engine. – Remove the oil drain plug  302845-10 – Remove the plug screw and small oil screen with both O-rings.  302844-10 – Remove the plug screw and large oil screen with both O-rings.
Page 178 MAINTENANCE WORK ON THE ENGINE – Thoroughly clean parts and sealing area. – Oil O-rings , mount them on oil screen and, using a long hexagon key, insert them   until the O-ring is seated in the housing with the oil screen. ...
Page 179: Removing The Oil Filter
MAINTENANCE WORK ON THE ENGINE – Fit oil drain plug with the seal ring and tighten it.  Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) – Install the engine guard. ( p. 125) 302845-11 Removing the oil filter 16.4 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven.
Page 180 MAINTENANCE WORK ON THE ENGINE – Disconnect the ground cable from the engine.  – Remove screws . Take off the oil filter cover with the O-ring.   600137-10 – Pull the oil filters out of the engine case. ...
Page 181: Installing The Oil Filter
MAINTENANCE WORK ON THE ENGINE Installing the oil filter 16.5 – Fill oil filters with engine oil and insert them in the oil filter housing.   600147-10 – Oil the O-rings of the oil filter covers and mount them with the oil filter covers. Mount and tighten screws ...
Page 182: Adding Engine Oil
MAINTENANCE WORK ON THE ENGINE – Remove the screw cap on the clutch cover and fill up with engine oil.  Engine oil 1.7 l (1.8 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 208) External Engine oil (SAE temperature:...
Page 183 MAINTENANCE WORK ON THE ENGINE – Check the engine for leakage. – Remove the filler cap on the clutch cover and fill up with engine oil.  Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p.
Page 184: Cleaning, Care
CLEANING, CARE Cleaning the vehicle 17.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
Page 185 CLEANING, CARE – After rinsing the vehicle with a gentle spray of water, allow it to dry thoroughly. – Clean the air filter box. – Empty the carburetor float chamber. p. 169) Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes. –...
Page 186: Storage
STORAGE Storage 18.1 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 immediately.
Page 187: Putting The Vehicle Into Operation After Storage
STORAGE – Cover the vehicle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine of a vehicle in storage for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust.
Page 188: Troubleshooting
TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Operating error Follow the instructions on starting the engine. p. 51) – Vehicle was out of use for a long time Empty the carburetor float chamber. and there is old fuel in the float cham- p.
Page 189 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Emergency OFF switch with rip cord Check the wiring harness. (visual check) faulty – Check the electrical system. – Throttle lever activated Do not activate the throttle lever. –...
Page 190 TROUBLESHOOTING Faults Possible cause Action – Engine does not speed up Ignition system defective Check the spark plug connector. – Check the ignition coil. – Check the ignition pulse generator. – Check the alternator. – Check the CDI controller. – Engine has no idle.
Page 191 TROUBLESHOOTING Faults Possible cause Action – Engine overheats. Radiator fins excessively dirty Clean radiator fins. – Foam formation in cooling system Drain the coolant. p. 161) – Fill coolant/bleed cooling system. p. 163) – Bent radiator hose Change the radiator hose. –...
Page 192 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Engine oil too thin (low viscosity) Change the engine oil and oil filter, clean the oil screens. p. 174) – Piston or cylinder worn Check the piston/cylinder mounting clearance. – Parts of the electrical system are not Fault in the electrical system Change the fuses of individual power consumers.
Page 193: Technical Data - Engine
TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine with balancer, water-cooled Displacement 510 cm³ (31.12 cu in) Stroke 72 mm (2.83 in) Bore 95 mm (3.74 in) Compression ratio 11:1 Idle speed 1,500… 1,600 rpm Control 4 valves controlled via rocker arm and overhead camshaft, camshaft drive via simplex chain Valve diameter, intake 35 mm (1.38 in)
Page 194: Capacity - Engine Oil
TECHNICAL DATA - ENGINE 5th gear 23:26 Alternator 12 V, 200 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK DCPR 8 E Spark plug electrode gap 0.6 mm (0.024 in) Cooling Water cooling, permanent circulation of coolant by water pump Starting aid Electric starter Capacity - engine oil...
Page 195: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in alternator cover 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, gear sensor 6 Nm (4.4 lbf ft) Loctite 243™...
Page 196 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, engine case M6x65 10 Nm (7.4 lbf ft) – Screw, engine case M6x75 10 Nm (7.4 lbf ft) ® Screw, exhaust flange 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™...
Page 197 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Nut, rotor M12x1 60 Nm (44.3 lbf ft) – Spark plug M12x1.25 17 Nm (12.5 lbf ft) ® Bleeder flange, engine case M12x1.5 Loctite 243™ – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –...
Page 198: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 39 Carburetor 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 Jet needle OBDVT Idling jet Main air jet Idle air jet Cold start jet...
Page 199: Technical Data - Chassis
TECHNICAL DATA - CHASSIS Frame Double cradle of chromium molybdenum steel tubes, powder- coated Wheel suspension Front Single wheel suspension with double transverse control arm Rear Rigid axle Suspension travel Front 275 mm (10.83 in) Rear 272 mm (10.71 in) Fork offset Front 46 mm (1.81 in)
Page 200 TECHNICAL DATA - CHASSIS Maximum allowable axle load Front 160 kg (353 lb.) Rear 190 kg (419 lb.) Maximum permissible overall weight 335 kg (739 lb.) Vehicle length 1,810 mm (71.26 in) Vehicle width 1,148 mm (45.2 in) Vehicle height 1,125 mm (44.29 in) Brake system Front...
Page 201: Lighting Equipment
12 V 10 W Brake / tail light License plate lamp W5W/socket W2.1x9.5d 12 V Tires 23.2 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: Capacity - Fuel
TECHNICAL DATA - CHASSIS Capacity - fuel 23.3 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: Technical Data - Front Shock Absorber
TECHNICAL DATA - FRONT SHOCK ABSORBER Option: KT 770... 24.1 Shock absorber type 36PRC Setting number KT 770... Compression damping Standard 14 clicks −5… 5 clicks Maximum deviation from standard value Rebound damping Standard 20 clicks −5… 5 clicks Maximum deviation from standard value Cross over 17±1.5 mm (0.67±0.059 in) Clip position, spring preload...
Page 204 TECHNICAL DATA - FRONT SHOCK ABSORBER Standard 15 clicks −5… 5 clicks Maximum deviation from standard value Rebound damping Standard 20 clicks −5… 5 clicks Maximum deviation from standard value 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...
Page 205: Technical Data - Rear Shock Absorber
TECHNICAL DATA - REAR SHOCK ABSORBER Option: KT 771... 25.1 Shock absorber type 46PRCQ Setting number KT 771... Compression damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value Rebound damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value Spring preload Standard 3 mm (0.12 in)
Page 206 TECHNICAL DATA - REAR SHOCK ABSORBER 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: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw on fuel tank 6 Nm (4.4 lbf ft) – Screw, clamping nut, rear axle 10 Nm (7.4 lbf ft) ®...
Page 208 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) – Screw, footrest 45 Nm (33.2 lbf ft) – Screw, front shock absorber 45 Nm (33.2 lbf ft) – Screw, steering column at bottom of 25 Nm (18.4 lbf ft) steering lever –...
Page 209: Substances
– Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
Page 210 SAE ( p. 213) (SAE 10W/50) 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 ® Motorex –...
Page 211 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
Page 212: Auxiliary Substances
AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Chain lube for road use Guideline –...
Page 213 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Bike Grease 2000 Lubricant (T625) Guideline – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Motorcycle cleaner Guideline – ® KTM recommends Motorex products.
Page 214 AUXILIARY SUBSTANCES Paint cleaner and 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.
Page 215: Standards
STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
Page 216: Index
INDEX Brake linings of front brake INDEX changing ........132 Accessories .
Page 217 INDEX refilling ........179 Choke ........43 Clutch Engine oil level fluid level, checking .
Page 218 INDEX spring preload, adjusting ......74 Front trim Ignition switch ........24 installing .
Page 219 INDEX downhill ........57 Play in throttle cable adjusting .
Page 220 INDEX Steering Turn signal switch ....... . 23 locking ........46 Type label .
Page 221 *3211604en* 3211604en 06/2010 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

KTM 545 XC ATV EU 2011 Owner's Manual

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