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KTM 450 XC 2008 Repair Manual

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REPAIR MANUAL
2008
450 XC ATV
525 XC ATV
ART. NO. 3206058en

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Summary of Contents for KTM 450 XC 2008

  • Page 1 REPAIR MANUAL 2008 450 XC ATV 525 XC ATV ART. NO. 3206058en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of delivery.

  • Page 4: Table Of Contents

    CONTENTS 05/EXHAUST ..............48 CONTENTS MEANS OF REPRESENTATION ..........5 Removing the main silencer..........48 IMPORTANT NOTES ............6 Installing the main silencer ..........48 Overview of warning labels..........8 Removing the manifold ..........48 VIEW OF VEHICLE............. 10 Installing the manifold ........... 49 Vehicle view, front left ...........
  • Page 5 CONTENTS Checking the brake fluid level of the front brake ....75 Work on the left section of the engine case ....102 Adding brake fluid for the front brake ......75 Changing the crankshaft seal ring in the clutch cover..102 Checking the front brake linings........
  • Page 6 Installing the carburetor ..........156 Important maintenance work to be carried out by an Carburetor - adjusting idle ..........157 authorized KTM workshop. (as additional order)....198 Checking the throttle valve sensor position..... 158 Important checks and maintenance work to be carried Emptying the carburetor float chamber ......

  • Page 7: Means Of Representation

    MEANS OF REPRESENTATION 1 M EANS OF REPRESENTATION Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). Identifies a page reference (more information is provided on the specified page).

  • Page 8: Important Notes

    You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories Only use spare parts and accessory products that have been released by KTM. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 9 IMPORTANT NOTES...

  • Page 10: Overview Of Warning Labels

    IMPORTANT NOTES Overview of warning labels 100106-10...
  • Page 11 Read this repair manual carefully and in its entirety before beginning work. It contains a lot of information and tips to help you repair and maintain the vehicle. – It is assumed that the necessary KTM special tools and workshop equipment are available to you.

  • Page 12: View Of Vehicle

    VIEW OF VEHICLE 3 V IEW OF VEHICLE Vehicle view, front left 600148-10 Hand brake lever Fuse box Headlight Front shock absorber Right-hand brake caliper Steering damper holder (steering damper is optional) Front left shock absorber Outside brake disk guard Shift lever Left footrest Heel protector...

  • Page 13: View Of Vehicle, Rear Right

    VIEW OF VEHICLE View of vehicle, rear right 600149-10 Light switch, electric starter button, ENG. STOP switch Filler cap Main silencer Rear shock absorber Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Compensating tank for coolant Manifold Top A-arm Front right fender Throttle lever...

  • Page 14: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS 4 L OCATION OF 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 15: Setting Number, Rear Shock Absorber

    LOCATION OF SERIAL NUMBERS Setting number, rear shock absorber The setting number  is stamped into the top of the shock absorber.  100032-10...

  • Page 16: Vehicle

    VEHICLE 5 V EHICLE Jacking up the vehicle 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. – Jack up the vehicle on the frame underneath the engine. The wheels must no longer touch the ground.

  • Page 17: 02/Handlebar, Controls

    02/HANDLEBAR, CONTROLS 6 0 2/HANDLEBAR, CONTROLS Adjusting handlebar position – 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. 100100-10 –...

  • Page 18: Checking Play In Gas Bowden Cable

    02/HANDLEBAR, CONTROLS Checking play in gas Bowden cable – Move the handlebar to the straight-ahead position. Move the throttle lever back and forth slightly to ascertain the play in the gas Bowden cable   Specification Play in gas Bowden cable 3…...

  • Page 19: Detaching The Reverse Gear Bowden Cable

    02/HANDLEBAR, CONTROLS Detaching the reverse gear Bowden cable – Loosen nut   – Detach the Bowden cable from abutment plate  and locking shaft lever    600181-10 Attaching the reverse gear Bowden cable – Attach the Bowden cable to locking shaft lever  and abutment plate ...

  • Page 20: 03/Frame

    03/FRAME 7 0 3/FRAME Removing the engine guard – Remove screws  and  . Remove the engine guard.   600133-10 Installing the engine guard – Check parts for damage and wear. Replace damaged or worn parts. – Position the engine guard on the frame bearer. Mount and tighten screws  ...

  • Page 21: 04/Shock Absorber, Swingarm

    04/SHOCK ABSORBER, SWINGARM 8 0 4/SHOCK ABSORBER, SWINGARM Front shock absorber - adjusting the compression damping Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers. – Only make adjustments within the recommended range. Info The compression damping setting has an impact on the compression of the shock absorber.

  • Page 22: Front Shock Absorber - Adjusting The Cross Over

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - adjusting the cross over Info The cross over setting is used to adjust the suspension travel of the short (soft) spring. Greater cross over makes the suspension at the front softer and the front of the vehicle lies lower. The suspension travel and the progressive part of the long (hard) spring are not fully utilized.

  • Page 23: Removing The Front Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Press together the spring pack, position the securing clip in the corresponding groove and release the spring pack. Specification 0 0 A Clip position, spring preload Standard 7 th position from top Corresponds to a spring preload of 5 mm (0.2 in) Info The spring preload ...

  • Page 24: Installing The Front Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Installing the front shock absorber Info The operations are the same on the left and right sides. – Position the front shock absorber with the reservoir toward the rear. Mount and tighten screw   Specification Screw, front shock absorber 45 Nm (33.2 lbf ft) 600475-11...

  • Page 25: Front Shock Absorber - Installing The Spring

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - installing the spring Alternative 1 – Measure the overall spring length when not under tension. Info 0 0 A The spring preload  is the difference in length between the spring  pack when it is unloaded and when it is installed. –...

  • Page 26: Front Shock Absorber - Disassembling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - disassembling the shock absorber – Remove the spring of the front shock absorber. ( P. 22) – Note down the current state of the rebound and compression damping. – Fully open the adjusting elements of the rebound and compression damping. –...

  • Page 27: Front Shock Absorber - Assembling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Push in seal ring holder  . Remove lock ring    Info Do not scratch the inner surface. 200285-10 – Remove the piston rod. Drain the oil. 200286-10 – Remove the floating piston of the reservoir using the special tool. Disassembly/assembly tool (83019050005) ( P.
  • Page 28 04/SHOCK ABSORBER, SWINGARM – Mount the floating piston using the special tool and slide it all the way into the reservoir. Disassembly/assembly tool (83019050005) ( P. 213) 200301-10 – Measure and note down the distance from the upper rim of the reservoir to the upper edge of the floating piston.
  • Page 29 04/SHOCK ABSORBER, SWINGARM – Mount locking cap  of the shock absorber tube.  200304-10 – Grease the O-ring of the locking cap of the reservoir. Lubricant (T158) ( P. 205) – Mount the locking cap of the reservoir using the special tool. Disassembly/assembly tool (83019050004) ( P.

  • Page 30: Bleeding And Filling Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Bleeding and filling shock absorber 8.11 Info Before working with the vacuum pump, read the operating manual provided for the vacuum pump carefully. Fully open the adjusting wheel of the rebound and compression damping. Leave the needle of the special tool inserted in the membrane to ensure that the floating piston is able to move freely during the filling process.
  • Page 31 04/SHOCK ABSORBER, SWINGARM – As soon as the pressure gauge has reached the specified value, set control lever Damper  to Vacuum.  Specification 3 bar The pressure gauge drops to the specified value. 0 bar 200269-10 – As soon as the pressure gauge has reached the specified value, set control lever Oil reservoir ...
  • Page 32 04/SHOCK ABSORBER, SWINGARM – Remove the needle of the special tool. Filling adapter (83019050016) – Press in locking cap  of the reservoir and remove lock ring    Info Do not scratch the inner surface. 200237-11 – Remove the locking cap of the reservoir using the special tool. Disassembly/assembly tool (83019050004) 200238-10 –...

  • Page 33: Front Shock Absorber - Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM Front shock absorber - disassembling the piston rod 8.12 – Disassemble the front shock absorber. ( P. 24) – Clamp the piston rod with the heim joint in a vise. – Remove nut   200288-10 – Remove washer  and rebound shim set ...

  • Page 34: Front Shock Absorber - Assembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Remove the locking cap and bump rubber. 200294-10 Front shock absorber - assembling the piston rod 8.13 – Clamp the piston rod with the heim joint in a vise. – Mount the bump rubber and locking cap. 200294-10 –...

  • Page 35: Front Shock Absorber - Removing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM – Smooth the piston on both sides using 1200-grit sandpaper on a straightening plate. – Clean the piston. – Mount the piston. Info The side of the piston with partitions  must face down and the side with ...

  • Page 36: Front Shock Absorber - Installing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM – Place special tool  underneath and press out the heim joint using special tool    Press drift (83019050015) ( P. 214) Mounting sleeve (83019050013) ( P. 214) 200297-10 Front shock absorber - installing the heim joint 8.15 Info The operations are the same on the upper and lower heim joint.

  • Page 37: Rear Shock Absorber - Adjusting The Rebound Damping

    04/SHOCK ABSORBER, SWINGARM – Turn the adjusting wheel  clockwise until it stops.  – Turn it back counterclockwise by the number of clicks corresponding to the shock absorber type. Specification Compression damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value 100080-10 Experience has shown that settings outside of this range are detrimental to...

  • Page 38: Removing The Rear Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Loosen lock nut  . Hold adjusting ring  while doing so. Use special tool     Hook wrench (83019002000) ( P. 210) Info Do not loosen lock nut  at the top of the shock absorber.  –...

  • Page 39: Installing The Rear Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Installing the rear shock absorber 8.20 – Check parts for damage and wear. Replace damaged or worn parts. – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw  ...

  • Page 40: Rear Shock Absorber - Disassembling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM Alternative 1 – Measure the overall spring length when not under tension. 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 the specified measurement. Specification Spring preload Standard...
  • Page 41 04/SHOCK ABSORBER, SWINGARM – Pierce the membrane using needle  of the special tool.  Filling adapter (83019050016) The nitrogen pressure is relieved. 200236-10 – Push in locking cap  of the reservoir. Remove lock ring    Info Do not scratch the inner surface. 200237-10 –...

  • Page 42: Rear Shock Absorber - Assembling The Shock Absorber

    04/SHOCK ABSORBER, SWINGARM – Remove the floating piston of the reservoir using the special tool. Disassembly/assembly tool (83019050005) 200242-10 Rear shock absorber - assembling the shock absorber 8.24 – Fill the reservoir all the way to the rim. Shock absorber oil Öhlins ®...
  • Page 43 04/SHOCK ABSORBER, SWINGARM – Fill the shock absorber tube about half way. Shock absorber oil Öhlins ® – Carefully mount the piston rod. – Remove the special tool. Disassembly/assembly tool (83019050005) 200266-10 – Grease the O-ring of the seal ring holder. Lubricant (T158) ( P.

  • Page 44: Rear Shock Absorber - Disassembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Pierce the membrane using needle  of the special tool.  Filling adapter (83019050016) Info Leave the needle of the special tool inserted in the membrane to ensure that the floating piston is able to move freely during the filling process. –...
  • Page 45 04/SHOCK ABSORBER, SWINGARM – Remove washer  and the upper rebound shim set  together with the upper pis-   ton   200245-10 – Remove the upper compression damping shim set  with the supporting plate.  200246-10 – Remove piston rod adapter  ...

  • Page 46: Rear Shock Absorber - Assembling The Piston Rod

    04/SHOCK ABSORBER, SWINGARM – Remove seal ring holder   200251-10 – Remove the locking cap and bump rubber. 200252-10 Rear shock absorber - assembling the piston rod 8.26 – Clamp the piston rod with the heim joint in a vise. –...
  • Page 47 04/SHOCK ABSORBER, SWINGARM – Smooth the lower piston on both sides using 1200-grit sandpaper on a straighten- ing plate. – Clean the piston. – Mount the lower piston. Info The side of the piston with rectangular surfaces  must face down and the ...

  • Page 48: Rear Shock Absorber - Removing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM – Ensure that the triangular plates precisely cover the single drill holes. 200261-10 – Mount the upper rebound shim set  with washer    Info Mount triangular plates  of the upper rebound damping shim set  facing  ...

  • Page 49: Rear Shock Absorber - Installing The Heim Joint

    04/SHOCK ABSORBER, SWINGARM – Remove seal rings  on both sides.  200254-10 – Place special tool  underneath and press out the heim joint using special tool    Press drift (83019050014) Mounting sleeve (83019050007) ( P. 214) 200255-10 Rear shock absorber - installing the heim joint 8.28 Info The operations are the same on the upper and lower heim joint.

  • Page 50: 05/Exhaust

    05/EXHAUST 9 0 5/EXHAUST Removing the main silencer – Remove spring   Spring hooks (50305017000) ( P. 207) 600153-10 – Remove screws  and  and take off the main silencer.   600154-10 Installing the main silencer – Insert the main silencer and position and tighten screws  and ...

  • Page 51: Installing The Manifold

    05/EXHAUST – Remove screws  and    600156-10 – Remove screws  and take off heel guard    – Remove manifold   600157-10 Installing the manifold – Position manifold  and mount springs    Spring hooks (50305017000) ( P. 207) 600155-11 –...

  • Page 52: 06/Air Filter

    06/AIR FILTER 06/AIR FILTER Removing the air filter 10.1 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 53: Removing The Air Filter Box Lid With The Carburetor Connection Boot

    06/AIR FILTER – Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( P. 205) – Clean the air filter box. – Check carburetor connection boot for damage and tightness. – Install the air filter ( P.

  • Page 54: 07/Fuel Tank, Seat, Trim

    07/FUEL TANK, SEAT, TRIM 07/FUEL TANK, SEAT, TRIM Removing the seat 11.1 – Pull the release hook  back. Lift up the seat at the rear, pull it back and then  remove from above. 100041-10 Mounting the seat 11.2 – Check parts for damage and wear.

  • Page 55: Installing The Radiator Spoiler

    07/FUEL TANK, SEAT, TRIM Installing the radiator spoiler 11.4 Info The operations are the same on the left and right. – Check parts for damage and wear. Replace damaged or worn parts. – Hook the catch  of the radiator spoiler into the holder  of the fuel tank and ...

  • Page 56: Installing The Fuel Tank

    07/FUEL TANK, SEAT, TRIM – Remove screw  and take off the fuel tank.  600151-10 Installing the fuel tank 11.6 Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 57: Fuel Tap

    07/FUEL TANK, SEAT, TRIM Fuel tap 11.7 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  carburetor. Possible states Fuel supply off OFF – No fuel can flow from the tank to the carburetor.

  • Page 58: 08/Mask, Fender

    08/MASK, FENDER 08/MASK, FENDER Removing the front cover 12.1 – Remove screw   – Slide the front cover up and remove it. 100053-10 Installing the front cover 12.2 – Check parts for damage and wear. Replace damaged or worn parts. –...

  • Page 59: Installing The Front Trim

    08/MASK, FENDER Installing the front trim 12.4 – Check parts for damage and wear. Replace damaged or worn parts. – Connect the plug-in connectors of the head light and the emergency OFF switch with the rip cord and position the front trim. –...

  • Page 60: Installing The Rear Fender

    08/MASK, FENDER Installing the rear fender 12.6 – Check parts for damage and wear. Replace damaged or worn parts. – 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.

  • Page 61: 09/Front Wheel

    Tire condition checking 13.2 Info Fit only tires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the vehicle.

  • Page 62: Mounting Wheel/Wheels

    Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop. – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 63: 10/Rear Wheel

    10/REAR WHEEL 10/REAR WHEEL Checking chain dirt 14.1 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( P. 61) Cleaning the chain 14.2 Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 64: Checking The Chain Tension

    10/REAR WHEEL Checking the chain tension 14.5 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel eccentric element) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.

  • Page 65: Adjusting The Toe Width Of Rear Axle

    10/REAR WHEEL – Loosen the screws  by four turns.  Alternative 1 – Insert the tool  from the tool set into the hole  of the rear wheel eccentric   element. Alternative 2 – Use a special tool on the rear wheel eccentric. Hook wrench (83019011000) ( P.

  • Page 66: Removing The Rear Axle

    10/REAR WHEEL Setting a wide toe width: – Mount the spacing sleeve  with the cone facing inward.  0 0 2 0 0 3 – Mount the conical ring  with the cone facing outward.  – Mount the wheel hub  ...

  • Page 67: Installing The Rear Axle

    10/REAR WHEEL – Take brake disc  off the rear axle with the holder.  – Remove the O-ring. 600412-10 – Push the rear axle slightly to the left. Using a plastic hammer, lightly strike against the chain sprocket carrier  to release the chain sprocket carrier from the lock ...
  • Page 68 10/REAR WHEEL – Position O-ring  . Attach brake disc holder  with the thread facing outward.   – Carefully insert sealing area  on the brake disc carrier into the shaft seal ring of  the rear wheel eccentric by lightly turning and tilting the rear axle. Info Do not damage the sealing lip of the shaft seal ring.

  • Page 69: Changing The Rear Axle Bearing

    10/REAR WHEEL – Place the chain on the sprocket. Mount chain joint   Info When installing the chain joint, always make sure that the closed side of the joint is facing forward (direction of travel). 600409-11 Setting a narrow toe width: –...
  • Page 70 10/REAR WHEEL – Take out shaft seal rings  on both sides and remove inner bearing races    600417-10 – Remove old grease and clean the rear wheel eccentric. – Heat the rear wheel eccentric. Specification 100 °C (212 °F) – Remove outer bearing races  on both sides.

  • Page 71: 11/Wiring Harness, Battery

    11/WIRING HARNESS, BATTERY 11/WIRING HARNESS, BATTERY Ignition curve plug connection 15.1 The plug-in connector  is located under the trim at the front on the frame tube.  Possible states Soft – The plug-in connector is connected for better driveability. • Performance – The plug-in connector is disconnected for better performance. •...

  • Page 72: Recharging The Battery

    11/WIRING HARNESS, BATTERY Recharging the battery 15.5 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 73: Changing The Main Fuse

    11/WIRING HARNESS, BATTERY Changing the main fuse 15.6 – Switch off all power-consuming components and switch off the engine. – Main fuse  is located in starter relay  in front of the battery.   – Remove protection covers   – Remove the faulty main fuse.

  • Page 74: Checking The Battery Voltage

    11/WIRING HARNESS, BATTERY Warning Fire hazard The electrical system can be overloaded by the use of incorrect fuses. – Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Insert a new fuse of the appropriate strength. Fuse (58011109110) Fuse (58011109115) The replacement fuses should always be present in the fuse box to make sure they are available when needed.

  • Page 75: Checking The Starter Relay

    11/WIRING HARNESS, BATTERY – Disconnect the negative (minus) cable of the battery. – Connect the multimeter between the negative cable and the negative terminal of the battery. Check the closed-circuit current. Maximum closed-circuit current < 1 mA » If the measured value is higher than the specified value: –...

  • Page 76: 13/Brake System

    13/BRAKE SYSTEM 13/BRAKE SYSTEM Handbrake lever, parking brake 16.1 The hand brake lever  is located on the right side of the handlebar and operates the  front wheel brakes. The parking brake is combined with the handbrake lever so that the front wheels can be blocked to prevent the vehicle from rolling.

  • Page 77: Checking The Brake Fluid Level Of The Front Brake

    13/BRAKE SYSTEM Checking the brake fluid level of the front brake 16.4 – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Check the brake fluid level in the viewer   » When the brake fluid level has dropped to the bottom of the viewer: –...

  • Page 78: Checking The Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 79: Changing The Front Brake Linings

    13/BRAKE SYSTEM – Mount the locking split pins   – Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Mount the wheel/wheels. ( P. 60) 100073-10 Changing the front brake linings 16.9 Warning Skin irritations Brake fluid can cause skin irritation on contact.

  • Page 80: Adjusting Basic Position Of Footbrake Lever

    13/BRAKE SYSTEM – Disconnect spring   – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play   Specification Free play at foot brake lever 3… 5 mm (0.12… 0.2 in) »...

  • Page 81: Adding Brake Fluid For The Rear Brake

    13/BRAKE SYSTEM Adding brake fluid for the rear brake 16.13 Warning Skin irritations Brake fluid can cause skin irritation on contact. – Avoid contact with skin and eyes, and keep out of the reach of children. – If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 82: Removing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construc- tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the origi- nal license.

  • Page 83: Changing The Rear Brake Linings

    13/BRAKE SYSTEM – Grease the bearing bolt  and insert the brake caliper with the bearing bolt into  the brake caliper support   100068-10 – Swing the brake caliper downwards. Mount and tighten screw . Specification Screw, rear brake caliper 10 Nm Loctite ®...

  • Page 84: 30/Engine

    30/ENGINE 30/ENGINE Removing the engine 17.1 – Remove the engine guard. ( P. 18) – Drain the coolant. ( P. 163) – Remove the rear shock absorber. ( P. 36) – Remove the manifold. ( P. 48) – Remove the carburetor. ( P.
  • Page 85 30/ENGINE – Release hose clamps  and take off the radiator hoses and hose clamps.  – Push back the clamp on engine breather hose   – Pull the engine breather hose off of the engine case. – Pull off the spark plug connector. 600170-10 –...

  • Page 86: Installing The Engine

    30/ENGINE – Remove screws  and take off the engine bearer.  600179-10 – Remove screw  and take the engine out of the frame toward the front right.  Info Having an assistant is helpful in this step. 600177-10 Installing the engine 17.2 –...
  • Page 87 30/ENGINE – Mount and tighten nut   Specification Nut, swingarm pivot M16x1,5 100 Nm (73.8 lbf ft) – Tighten all previously mounted screws. Specification Engine carrying screw 60 Nm (44.3 lbf ft) 600173-11 Engine bracket screw 60 Nm (44.3 lbf ft) – If the vehicle is to be raised, secure the swingarm to the subframe with a tension belt ...
  • Page 88 30/ENGINE – Fix the cable with cable clamps  and sleeves    600167-11 – Position the slave cylinder of clutch  . Mount and tighten screws    Specification Slave cylinder of the clutch on engine 10 Nm (7.4 lbf ft) case – Connect the negative (minus) cable of the battery. –...

  • Page 89: 30/Disassembling The Engine

    30/DISASSEMBLING THE ENGINE 30/DISASSEMBLING THE ENGINE Preparations 18.1 – Thoroughly clean the outside of the engine and attach it to the universal mounting rack using the special tool. Engine holder (83112001050) ( P. 215) Universal mounting rack (56012001000) ( P. 207) –...

  • Page 90: Removing The Shift Lever

    30/DISASSEMBLING THE ENGINE Removing the shift lever 18.5 – Remove screw  . Take off shift lever    600182-10 Removing the clutch cover 18.6 – Remove screws  . Remove the spring holder. Take off the clutch cover.  600187-10 – Remove centering pin ...

  • Page 91: Removing The Outer Clutch Hub

    30/DISASSEMBLING THE ENGINE Removing the outer clutch hub 18.8 – Bend open lock washer   600193-10 – Apply counterpressure against the inner clutch hub using special tool  . Loosen  nut   Clutch holder (59029003100) ( P. 208) – Remove nut  with lock washer ...

  • Page 92: Removing The Starter Idler Gear/Torque Limiter

    30/DISASSEMBLING THE ENGINE Removing the starter idler gear/torque limiter 18.9 – Remove lock ring   Circlip pliers reverse (51012011000) ( P. 207) – Take off disk  and starter idler gear    – Remove torque limiter  with bearing bolt  and both needle bearings. ...

  • Page 93: Removing The Primary Gear With The Free-Wheel-Gear

    30/DISASSEMBLING THE ENGINE Removing the primary gear with the free-wheel-gear 18.14 – Remove primary gear  and free-wheel-gear using the special tool.  Extractor (59029033000) ( P. 209) Info Make sure that the washer spring remains in place. 600204-10 Removing the spark plug 18.15 –...

  • Page 94: Removing The Ignition Pulse Generator

    30/DISASSEMBLING THE ENGINE – Remove screw   600209-11 – Screw in special tool  until the crankshaft is blocked.  Crankshaft locking bolt (113080802) ( P. 207) Info With perceptible resistance, move the flywheel back and forth so that the special tool can engage in the recess of the crankshaft. 600210-10 Removing the ignition pulse generator 18.18...

  • Page 95: Removing The Oil Pumps

    30/DISASSEMBLING THE ENGINE Removing the oil pumps 18.20 – Remove screws   – Remove oil pump cover   600214-10 – Remove oil pump shaft  together with pin  , internal rotor  and external    rotor   600215-10 – Remove screws  ...

  • Page 96: Removing The Timing Chain Tensioner

    30/DISASSEMBLING THE ENGINE Removing the timing chain tensioner 18.22 – Remove screw  with the sealing disc.  Info Screw  is spring loaded!  600221-10 – Pull out spring   – Remove screws  and pull out timing chain tensioner    600222-10 Removing the water pump cover 18.23...

  • Page 97: Removing The Cylinder Head

    30/DISASSEMBLING THE ENGINE – Prevent the timing chain from falling down using cable ties   – Remove the camshaft with camshaft gear   600224-10 Removing the cylinder head 18.26 – Remove screws   600225-10 – Remove screws  in crisscross pattern. Remove the screws and washers. ...

  • Page 98: Removing The Piston

    30/DISASSEMBLING THE ENGINE Removing the piston 18.28 – Remove piston pin retainer   – Remove piston pin   – Remove piston   600228-10 Removing the timing chain 18.29 – Remove screws  . Remove timing chain guide rail  and timing chain tensioning ...

  • Page 99: Removing The Gear Sensor

    30/DISASSEMBLING THE ENGINE Removing the gear sensor 18.32 – Remove screws  with abutment plate  . Remove gear sensor     600233-10 – Remove contact bolts  with the springs behind them.  600234-10 Taking off the left section of the engine case 18.33 600235-10 –...

  • Page 100: Remove The Shift Rails And Forks

    30/DISASSEMBLING THE ENGINE – Swing the left section of the engine case upward. – Remove nut and screw   600236-10 – Take off the left section of the engine case   Info The bosses on the engine case can be used for lightly striking with the plas- tic hammer.

  • Page 101: Removing The Transmission Shaft

    30/DISASSEMBLING THE ENGINE Removing the transmission shaft 18.36 – Take off O-ring  with inner bearing race    600241-10 – Pull main shaft  and countershaft  out of the bearing seats together with the   axle  for the reverse gear. ...

  • Page 102: 30/Engine - Work On Individual Parts

    30/ENGINE - WORK ON INDIVIDUAL PARTS 30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the right section of the engine case 19.1 – Remove oil jet   – Remove bearing retainers   – Remove the shaft seal ring of crankshaft  ...

  • Page 103: Removing The Oil Pressure Regulator Valve

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Blow though all oil holes with compressed air and check that they are clear. 600249-01 Removing the oil pressure regulator valve 19.2 – Remove plug  with seal rings    – Remove pressure spring  and piston valve ...

  • Page 104: Work On The Left Section Of The Engine Case

    30/ENGINE - WORK ON INDIVIDUAL PARTS Work on the left section of the engine case 19.5 – Remove all dowels. – Remove the shaft seal ring of countershaft  , shift rail with locking lever    shift shaft   – Remove any sealing compound remnants and clean the engine case section thor- oughly.

  • Page 105: Disassembling The Autodecompressor

    30/ENGINE - WORK ON INDIVIDUAL PARTS Disassembling the autodecompressor 19.7 – Remove lock ring   Circlip pliers reverse (51012011000) ( P. 207) – Pull off water pump wheel   600261-10 – Remove pin  . Pull seal holder  from the camshaft. ...

  • Page 106: Assembling The Autodecompressor

    30/ENGINE - WORK ON INDIVIDUAL PARTS Assembling the autodecompressor 19.8 – Check parts for damage and wear. Replace damaged or worn parts. – Position autodecompression spring  and insert autodecompression shaft    Preload the autodecompression spring by approx. ½ turn in the direction of the arrow and slide onto the autodecompression shaft.

  • Page 107: Changing The Camshaft Bearing

    30/ENGINE - WORK ON INDIVIDUAL PARTS Changing the camshaft bearing 19.9 – Remove lock ring   Circlip pliers reverse (51012011000) ( P. 207) – Pull off water pump wheel   600261-10 – Remove pin  . Pull seal holder  from the camshaft. ...

  • Page 108: Checking The Rocker Arms And Rocker Arm Shafts

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Mount pin   600262-12 – Position water pump wheel  and mount lock ring    600261-12 – Remove camshaft bearing  using special tool    Extractor (59029033000) ( P. 209) 600321-10 – Mount the new camshaft bearing  ...

  • Page 109: Removing The Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check rocker arm shafts  for damage and wear.  » If there is damage or wear: – Change the rocker arm shafts. – Check the contact surface of adjusting screws  for damage and wear. ...

  • Page 110: Checking The Valves

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the valves 19.12 Info The valve stem is chrome-hardened, and wear normally takes place in the valve guide. – Check for valve retainer run-out. Valves ≤ 0.05 mm (≤ 0.002 in) Run-out on valve plate » If the measured value does not equal the specified value: –...

  • Page 111: Checking The Cylinder Head

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the cylinder head 19.15 – Check the valve guides using special tool   Limit plug gauge (59029026006) ( P. 209) » If the special tool is easy to insert into the valve guide: –...

  • Page 112: Checking The Timing Assembly

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Tension the valve springs with a special tool. Valve spring mounter (59029019000) ( P. 208) – Mount the valve keys. Info When mounting the valve keys, check that they are seated correctly; prefer- ably, fix the valve keys to the valve with a little grease.

  • Page 113: Checking The Crankshaft Run-Out On The Bearing Pin

    30/ENGINE - WORK ON INDIVIDUAL PARTS 600455-01 – Position the new crank pin and press it into the first crank web. The oil hole in the crank web is aligned with the oil hole in the crank pin. Info If the oil holes are not correctly aligned, the conrod bearing will not be provided with oil. –...

  • Page 114: Measuring The Axial Clearance Of The Crankshaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Measuring the axial clearance of the crankshaft 19.21 – Clamp the right section of the engine case into the engine work stand. Universal mounting rack (56012001000) ( P. 207) – Install crankshaft   600244-10 –...

  • Page 115: Cylinder - Nikasil Coating

    30/ENGINE - WORK ON INDIVIDUAL PARTS ® cylinder - Nikasil coating 19.23 ® Nikasil is a surface protection layer for a coating procedure developed by the Mahle company. The name is derived from the two materials used in this procedure - a layer of nickel into which is embedded the particularly hard silicone carbide.

  • Page 116: Checking/Measuring The Piston

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking/measuring the piston 19.25 – Check the piston bearing surface for damage. » If the piston sliding surface is damaged: – Change the piston and, if necessary, the cylinder. – Check that the piston rings can move easily in the piston ring grooves. »...

  • Page 117: Checking The Piston/Cylinder Mounting Clearance

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the piston/cylinder mounting clearance 19.27 – Check/measure the cylinder. ( P. 113) – Check/measure the piston. ( P. 114) – The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diam- eter.

  • Page 118: Checking The Shift Mechanism

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the shift mechanism 19.29 600287-01 – Check sliding plate  in contact areas  for wear.   » If the sliding plate is worn: – Change the sliding plate. – Check that guide pin  is firmly seated and check it for wear.

  • Page 119: Disassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check springs  of the shift rails for damage and wear.  » If the spring is broken or worn: – Change the spring of the shift rail. – On a flat surface, check shift rail  for run-out.

  • Page 120: Preassembling The Shift Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Preassembling the shift shaft 19.31 – Fix the short end of the shift shaft in a vise. 0 0 5 Specification Use soft jaws. 0 0 1 – Mount sliding plate  with the guide pin facing downward and attach the guide pin ...

  • Page 121: Disassembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check inner clutch hub  for damage and wear.  » If there is damage or wear: – Change the inner clutch hub. – Check pressure piece  for damage and wear.  » If there is damage or wear: –...

  • Page 122: Checking The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the main shaft 19.34 0 0 1 0 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 5 0 0 4 0 0 3 0 0 2 0 0 6 0 0 7 600295-01...

  • Page 123: Assembling The Main Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Assembling the main shaft 19.35 Info Use new lock rings in every repair job. – Oil all parts carefully before assembling. – Check the countershaft. ( P. 123) 0 0 1 0 0 3 0 0 2 0 0 4 0 0 5...

  • Page 124: Disassembling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Disassembling the countershaft 19.36 0 0 3 0 0 2 0 0 6 0 0 4 0 0 5 0 0 9 0 0 7 0 0 8 0 0 b k 0 0 b l 0 0 b m 0 0 b n 0 0 b o...

  • Page 125: Checking The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking the countershaft 19.37 0 0 2 0 0 8 0 0 7 0 0 2 0 0 3 0 0 8 0 0 5 0 0 4 0 0 3 0 0 4 0 0 6 0 0 2 0 0 6...

  • Page 126: Assembling The Countershaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS – Check stop disk  for damage and wear.  » If there is damage or wear: – Change the stop disk. Assembling the countershaft 19.38 Info Use new lock rings in every repair job. –...

  • Page 127: Checking/Premounting The Reverse Gear Shaft

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking/premounting the reverse gear shaft 19.39 0 0 1 0 0 5 0 0 3 0 0 4 0 0 6 0 0 7 600319-01 – Check the pivot points of reverse gear shaft  for damage and wear.

  • Page 128: Checking Electric Starter Operation

    30/ENGINE - WORK ON INDIVIDUAL PARTS Checking electric starter operation 19.40 0 0 2 0 0 1 0 0 3 0 0 4 0 0 5 0 0 6 0 0 7 0 0 A 600323-01 – Check the toothing of starter motor  for damage and wear.

  • Page 129: Removing The Free-Wheel

    30/ENGINE - WORK ON INDIVIDUAL PARTS Removing the free-wheel 19.41 – Press together spreader ring  with suitable pliers and take it off.  600435-10 – Take free-wheel  out of the primary pinion.  600436-11 Checking the free-wheel 19.42 – Place free-wheel-gear  in primary pinion ...

  • Page 130: 30/Assembling The Engine

    30/ASSEMBLING THE ENGINE 30/ASSEMBLING THE ENGINE Installing the crankshaft 20.1 – Clamp the right section of the engine case into the engine work stand. Universal mounting rack (56012001000) ( P. 207) Engine holder (83112001050) ( P. 215) – Slide crankshaft  all the way into the bearing seat of the right section of the ...

  • Page 131: Installing The Shift Forks

    30/ASSEMBLING THE ENGINE Installing the shift forks 20.4 – Oil all parts well. – For all shift forks, secure shift rollers  with a small amount of grease.  600329-10 – Mount the short shift fork  with the long side of the guide facing downward. ...
  • Page 132 30/ASSEMBLING THE ENGINE – Insert dowels   – Grease the sealing areas. Apply sealing compound to the left section of the engine case.  5910 Loctite ® – Mount the left section of the engine case. If necessary, tap it lightly with a rubber hammer and turn the transmission shaft.

  • Page 133: Installing The Timing Chain Sprocket

    30/ASSEMBLING THE ENGINE – Remove the special tool. Mounting sleeve (59029005010) ( P. 208) – Position O-ring  and mount spacing sleeve  with the phase facing downward.   600336-10 – Using a dial gauge, check the axial clearance of the crankshaft. Specification Crankshaft - axial clearance 0.25…...

  • Page 134: Installing The Cylinder

    30/ASSEMBLING THE ENGINE – Mount piston  on connecting rod  and insert piston pin     Info Note the orientation of the piston when installing it. The arrow on the piston must point in the direction of travel. 600228-11 – Position the new piston pin retainer ...

  • Page 135: Installing The Camshaft

    30/ASSEMBLING THE ENGINE – Mount the cylinder head. Mount screws  and tighten in a crisscross pattern.  Specification Screw, cylinder head Step 1 40 Nm (29.5 lbf ft) Step 2 50 Nm (36.9 lbf ft) 600342-10 – Mount and tighten screws   Specification Screw, cylinder head 10 Nm (7.4 lbf ft) 600343-10 Installing the camshaft...

  • Page 136: Installing The Cylinder Head Top Section

    30/ASSEMBLING THE ENGINE – Reconfigure the special tool. Rivet the rivet link until the edges of the pins are visi- bly flattened. Timing chain separating and riveting tool (59029020000) ( P. 209) 600349-10 Installing the cylinder head top section 20.14 –...

  • Page 137: Installing The Timing Chain Tensioner

    30/ASSEMBLING THE ENGINE Installing the timing chain tensioner 20.15 – With timing chain tensioner  in the installation position, install it with a new seal.  Mount and tighten screws   Specification Screw, timing-chain tensioner 10 Nm (7.4 lbf ft) – Mount and tighten spring  with seal ring ...

  • Page 138: Adjusting The Valve Clearance

    30/ASSEMBLING THE ENGINE Adjusting the valve clearance 20.18 – Set the valve clearance by turning adjusting screw  between the valve and rocker  arm using special tool   Specification Valve clearance, cold, intake 0.10… 0.15 mm (0.0039… 0.0059 in) Valve clearance, cold, exhaust 0.10…...

  • Page 139: Installing The Primary Gear With The Free-Wheel-Gear

    30/ASSEMBLING THE ENGINE Installing the primary gear with the free-wheel-gear 20.23 – Ensure that spring washer  is seated properly.  600357-10 – Oil the free-wheel in the primary gear. – Slide the primary gear with the free-wheel onto free-wheel-gear  and mount them ...

  • Page 140: Installing The Ignition Pulse Generator

    30/ASSEMBLING THE ENGINE – Position oil pump gear  and washer  . Mount shaft retainer     600362-10 – Mount external rotor  and internal rotor  with marking  facing inward.    The marking should not be visible after installation. –...

  • Page 141: Installing The Gear Sensor

    30/ASSEMBLING THE ENGINE – Mount the generator cover seal. – Position generator cover  . Mount and tighten screws    Specification Screw, generator cover 10 Nm (7.4 lbf ft) 600366-10 Installing the gear sensor 20.27 – Insert contact bolts  with the springs.  600369-10 –...

  • Page 142: Installing The Shift Drum Locating

    30/ASSEMBLING THE ENGINE Installing the shift drum locating 20.30 – Push locking lever  away from the shift drum locating and position shift drum  locating   Info The flat surfaces of the shift drum locating are not symmetric. – Release the locking lever. –...

  • Page 143: Installing The Outer Clutch Hub And Clutch Discs

    30/ASSEMBLING THE ENGINE Installing the outer clutch hub and clutch discs 20.34 – Mount washer  and both needle bearings    600376-10 – Mount outer clutch hub  and insert the two half washers  into the main shaft   with grease. 600377-10 –...

  • Page 144: Installing The Clutch Cover

    30/ASSEMBLING THE ENGINE – Insert pressure piece   600381-10 – Mount the pressure cap. Mount screws  with washers and springs. Tighten all  screws in a crisscross pattern. Specification Screw, clutch spring 8 Nm Loctite ® 243™ (5.9 lbf ft) 600382-10 Installing the clutch cover 20.35 –...

  • Page 145: Installing The Starter Motor

    30/ASSEMBLING THE ENGINE Installing the starter motor 20.36 – Grease the O-ring. Mount starter motor   Long-life grease ( P. 205) – Mount and tighten screw   Specification Screw, starter engine 10 Nm (7.4 lbf ft) 600388-10 Installing the oil drain plug 20.37 –...

  • Page 146: Filling Up With Engine Oil

    30/ASSEMBLING THE ENGINE – Oil the O-rings of oil filter covers  and mount them with the oil filter covers.  – Mount and tighten screws   Specification Screw, oil filter cover 6 Nm (4.4 lbf ft) 600390-10 Filling up with engine oil 20.40 –...

  • Page 147: 31/Carburetor

    31/CARBURETOR 31/CARBURETOR Choke 21.1 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 148: Disassembling The Carburetor

    31/CARBURETOR – Undo hose clip   600160-10 – Take carburetor  out of the frame toward the rear and set it on the frame.  600161-10 – Remove screws  . Remove carburetor cover    600162-10 – Loosen nut  . Detach the gas Bowden cable and hang it to one side. ...
  • Page 149 31/CARBURETOR – Remove screw  with the spring and washer.  – Pull the jet needle out of the throttle slide. – Remove screw   600444-10 – Pull up throttle slide arm  . Take throttle slide  out of the carburetor along with ...
  • Page 150 31/CARBURETOR – Screws  should not be removed.  700046-11 – Remove screw  . Pull the hose connector out of the carburetor.  700047-12 – Remove screw  . Take off throttle valve sensor    Info Only remove the throttle valve sensor if necessary. If screw  is loosened, ...

  • Page 151: Checking/Adjusting The Carburetor Components

    31/CARBURETOR Checking/adjusting the carburetor components 21.5 600397-02 – Disassemble the carburetor. ( P. 146) – Check/adjust the accelerator pump. ( P. 149) – Check the hot start slide. ( P. 150) – Check the choke slide. ( P. 150) – Check the jet needle.

  • Page 152: Checking The Hot Start Slide

    31/CARBURETOR – Check/adjust the throttle slide opening. ( P. 153) Info Adjusting the play of the accelerator pump changes the time at which injec- tion starts and does not influence the injection rate or the intensity of the accelerator pump. –...

  • Page 153: Checking The Throttle Slide

    31/CARBURETOR Checking the throttle slide 21.10 – Check the throttle slide rollers for damage and wear. » If the throttle slide rollers do not turn easily, are worn or have flat areas: – Change the throttle slide. – Except for throttle slide roller  (removable), all rollers must rest flush against the ...

  • Page 154: Checking The Throttle Valve Sensor Tps

    31/CARBURETOR Checking the throttle valve sensor TPS 21.13 Info The value in the figure is an example only! – Remove the carburetor. ( P. 145) – Check the throttle slide. ( P. 151) Condition Component temperature: 20 °C (68 °F) – Connect the positive wire of the multimeter to the blue (bu) cable and the ground wire to the black (bl) cable of the connector of throttle valve sensor TPS.

  • Page 155: Checking/Adjusting The Throttle Slide Opening

    31/CARBURETOR – Connect the positive wire of the multimeter to the yellow (ye) cable and the ground wire to the black (bl) cable of the connector of throttle valve sensor TPS. – Measure the variable resistance R of the throttle valve sensor. Info The throttle slide must be in the neutral position. –...
  • Page 156 31/CARBURETOR – Mount and tighten the choke slide and hot start slide   Specification Choke slide 2.5 Nm (1.84 lbf ft) – Position throttle valve sensor  . Mount screw  with the spring ring and washer   but do not tighten yet. Info When installing the throttle valve sensor, ensure that the flat area of the 600398-10 inner clutch hub engages in the recess of the throttle valve sensor.
  • Page 157 31/CARBURETOR – Position the float chamber and adjustment screw. – Mount screws  but do not tighten them yet.  700067-10 – Insert throttle slide  with throttle slide roller  and the throttle slide plate into   throttle slide arm  and position them in the carburetor. ...

  • Page 158: Installing The Carburetor

    31/CARBURETOR – Position the accelerator pump cover. Mount and tighten screws   Specification Other screws, carburetor 2 Nm (1.5 lbf ft) 700038-12 – Position and mount the vent hoses. – Position the hose holder. Mount the screws  and tighten all screws in a crisscross ...

  • Page 159: Carburetor - Adjusting Idle

    31/CARBURETOR – Attach engine breather hose  to the carburetor.  Info Ensure that the engine breather hose has been laid correctly. 600159-11 – Attach connector  of throttle valve sensor TPS    600158-11 – Lay the engine breather hose toward the bottom and secure with a retaining bracket.

  • Page 160: Checking The Throttle Valve Sensor Position

    31/CARBURETOR – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above 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.

  • Page 161: Emptying The Carburetor Float Chamber

    31/CARBURETOR Emptying the carburetor float chamber 21.21 Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 162: 32/Clutch

    32/CLUTCH 32/CLUTCH Checking fluid level of hydraulic clutch 22.1 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 163: 33/Transmission

    33/TRANSMISSION 33/TRANSMISSION Removing the engine sprocket 23.1 – Remove screws  and  . Take off engine sprocket cover     600164-10 – Press the rear brake and remove screw  with spring washer    – Pull engine sprocket  with chain  off of the countershaft.

  • Page 164: 35/Water Pump, Cooling System

    35/WATER PUMP, COOLING SYSTEM 35/WATER PUMP, COOLING SYSTEM Checking antifreeze and coolant level 24.1 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is driven. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 165: Draining Coolant

    35/WATER PUMP, COOLING SYSTEM Condition The radiator must be completely full. – The coolant level  must be between MIN and MAX.  » If the level of the cooling liquid does not meet specifications: – Open the compensating tank cover  and correct the coolant level. ...

  • Page 166: Filling Coolant / Bleeding Cooling System

    35/WATER PUMP, COOLING SYSTEM – Open the plug of the compensation tank   – Remove the screws  and empty the compensating tank    – Check parts for damage and wear. Replace damaged or worn parts. – Position the compensating tank  .
  • Page 167 35/WATER PUMP, COOLING SYSTEM – Completely fill the radiator and close the radiator cap   600123-10 – Top up the compensating tank to level  . Mount the cap    – Install the front trim. ( P. 57) – Make a short test ride. –...

  • Page 168: 38/Lubrication System

    38/LUBRICATION SYSTEM 38/LUBRICATION SYSTEM Changing engine oil and oil filter, cleaning oil screens 25.1 – Drain engine oil, clean oil screens. ( P. 166) – Remove the oil filter. ( P. 167) – Mount the oil filter. ( P. 168) –...

  • Page 169: Removing The Oil Filter

    38/LUBRICATION SYSTEM – Check parts for damage and wear. Replace damaged or worn parts. – Thoroughly clean parts and sealing area. – Oil the O-rings  , mount them on the oil screen and using a long hexagon key   insert them until the O-ring is seated in the housing with the oil screen.

  • Page 170: Mounting Oil Filter

    38/LUBRICATION SYSTEM – Pull the oil filters  and  out of the engine housing.   Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean parts and sealing area. 600138-10 Mounting oil filter 25.4 – Check parts for damage and wear. Replace damaged or worn parts. –...

  • Page 171: Checking Engine Oil Level

    38/LUBRICATION SYSTEM Checking engine oil level 25.6 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. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.

  • Page 172: 39/Ignition System

    39/IGNITION SYSTEM 39/IGNITION SYSTEM Checking the generator 26.1 – Remove the fuel tank. ( P. 53) – Disconnect the electric plug-in connector  of the stator coil.  600408-10 – Using a multimeter, measure the stator coil on connector   Stator coil - resistance black - black 0.0…...

  • Page 173: Checking The Spark Plug Connector

    39/IGNITION SYSTEM – Use a multimeter to measure the secondary coil value. Secondary coil ignition coil - ignition coil input at: 5.0… 7.5 kΩ 20 °C (68 °F) » If the measured value differs from the nominal value: – Change the ignition coil. 600434-01 –...

  • Page 174: 61/Atv Front Section

    61/ATV FRONT SECTION 61/ATV FRONT SECTION Toe, checking 27.1 – Park the vehicle on a horizontal surface. – Check the tire condition. ( P. 59) – Checking the tire air pressure. ( P. 59) – Check the chassis parts for damage, play and wear. –...

  • Page 175: Adjusting The Toe

    61/ATV FRONT SECTION Adjusting the toe 27.2 – Park the vehicle on a horizontal surface. – Check the tire condition. ( P. 59) – Checking the tire air pressure. ( P. 59) – Check the chassis parts for damage, play and wear. Replace damaged or worn parts.

  • Page 176: Checking/Adjusting Camber

    61/ATV FRONT SECTION Checking/adjusting camber 27.3 Info The left and right camber should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( P. 14) – Loosen nuts   600128-10 –...

  • Page 177: Adjusting The Fork Offset

    61/ATV FRONT SECTION Adjusting the fork offset 27.4 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( P. 14) – Remove screws  with bushings ...
  • Page 178 61/ATV FRONT SECTION – Unthread the brake caliper. – Hang the brake caliper and the brake line loosely to one side. 400401-10 – Remove nut  and take the tie rod out of the wheel carrier.  600447-10 – Remove nuts  ...

  • Page 179: Installing The Wheel Carrier

    61/ATV FRONT SECTION Installing the wheel carrier 27.6 Info The operations are the same on the left and right sides. – Insert the wheel carrier between the A-arms. Mount and tighten nuts   Specification Nut, ball head, A-arm bottom M12x1,5 40 Nm (29.5 lbf ft) Nut, ball head, A-arm top...

  • Page 180: Removing The A-Arms

    61/ATV FRONT SECTION – Position brake line guide  and secure it with cable clamp    Info Note the holding lug of the brake line guide. – Mount brake disc guard   – Mount the wheel/wheels. ( P. 60) – Check the toe.

  • Page 181: A-Arm Top - Changing The Bearing

    61/ATV FRONT SECTION – Position upper A-arm  with bushings  . Mount and tighten screws     Specification Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) Info The fork offset is set using the bushings   600453-11 – When the nuts on the heim joint have been released, align the heim joint at right angles to the screws and tighten nut ...

  • Page 182: A-Arm Bottom - Changing The Bearing

    61/ATV FRONT SECTION – Mount lock ring   Circlip pliers reverse (51012011000) Info When mounting the lock ring, do not damage the rubber boot. 600467-10 – Loosen nuts  . Remove heim joint  . Screw the nuts off of the heim joints. ...
  • Page 183 61/ATV FRONT SECTION 600457-01 – Remove flange adapters  and bearing sleeves    – Remove shaft seal rings   – Remove spacing washers   Info The spacing washers are only installed at the front pivot point. – Press out needle bearing  using the thin long side of the special tool.
  • Page 184 61/ATV FRONT SECTION – Remove lock ring   Circlip pliers reverse (51012011000) 600464-10 – Press out ball head  using the special tool.  Disassembly/assembly holder (83019020150) ( P. 212) 600465-10 – Press in the ball head using the special tool. Press mandrel (83019020130) ( P.

  • Page 185: Technical Data - Engine

    TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine with balancer, water-cooled Displacement (450 XC ATV) 448 cm³ (27.34 cu in) Displacement (525 XC ATV) 510 cm³ (31.12 cu in) Stroke 72 mm (2.83 in) Bore (450 XC ATV) 89 mm (3.5 in) Bore (525 XC ATV) 95 mm (3.74 in) Compression ratio 11:1...

  • Page 186: Capacity - Coolant

    TECHNICAL DATA - ENGINE Capacity - coolant 28.2 Coolant With compensating tank 1.50 l (1.59 qt.) Coolant ( P. 204) Coolant (mixed ready to use) ( P. 204) Without compensating tank 1.30 l (1.37 qt.) Coolant ( P. 204) Coolant (mixed ready to use) ( P.

  • Page 187: Technical Data - Tolerance, Wear Limits Of Engine

    TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE TECHNICAL DATA - TOLERANCE, WEAR LIMITS OF ENGINE Rocker arm - axial clearance 0.02… 0.10 mm (0.0008… 0.0039 in) Valves Sealing seat width, intake 1.50 mm (0.0591 in) Sealing seat width, exhaust 2.00 mm (0.0787 in) ≤ 0.05 mm (≤ 0.002 in) Run-out on valve plate Valve springs Minimum length of outside spring...

  • Page 188: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover Loctite 243™ – Oil jet for conrod lubrication 2 Nm (1.5 lbf ft) ® Screw, timing chain securing guide 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite...
  • Page 189 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Ignition rotor nut 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) – Plug, oil pressure regulator valve M12x1.5 20 Nm (14.8 lbf ft) Locking screw, oil sieve, short...

  • Page 190: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR TECHNICAL DATA - CARBURETOR 450/525 XC ATV 31.1 Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3925H Needle position (450 XC ATV) 2nd position from top Needle position (525 XC ATV) 3rd position from top Idle mixture adjusting screw Open 1.0 turn Pump membrane stop...

  • Page 191: Technical Data - Carburetor Tightening Torques

    TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES TECHNICAL DATA - CARBURETOR TIGHTENING TORQUES ® Screw, throttle slide arm 2 Nm (1.5 lbf ft) Loctite 243™ ® Screw, hose connection 2 Nm (1.5 lbf ft) Loctite 243™ – Other screws, carburetor 2 Nm (1.5 lbf ft) – Idle air jet M4,5x0.75 2 Nm (1.5 lbf ft) –...

  • Page 192: Technical Data - Chassis

    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 257 mm (10.12 in) Rear 265 mm (10.43 in) Fork offset Front 46 mm (1.81 in)

  • Page 193: Lighting Equipment

    Front tire Rear tire 21 x 7.00 - 10 20 x 11.00 - 9 MAXXIS Razr M‑931 MAXXIS Razr M‑932 For further information, see the Service section under: http://www.ktm.com Capacity - fuel 33.3 Tank capacity 13.4 l (3.54 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 204) Fuel reserve 3 l (3 qt.)

  • Page 194: Technical Data - Front Shock Absorber

    TECHNICAL DATA - FRONT SHOCK ABSORBER TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber type 36PRC Setting number KT 7702 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 195: Technical Data - Rear Shock Absorber

    TECHNICAL DATA - REAR SHOCK ABSORBER TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber type 46PRCQ Setting number KT 7710 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 196: Technical Data - Chassis Tightening Torques

    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, rear brake caliper 10 Nm (7.4 lbf ft) Loctite 243™ ®...

  • Page 197: Cleaning

    CLEANING CLEANING Cleaning the vehicle 37.1 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 electri- cal components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 198: Storage

    STORAGE STORAGE Storage 38.1 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 immedi- ately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, con- tact a doctor immediately.

  • Page 199: Greasing And Service Table

    GREASING AND SERVICE TABLE GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. 39.1 S15A S30A Engine Change the engine oil and oil filter, clean the oil screens. ( P. 166) • •...

  • Page 200: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    S15A: Every 15 service hours - corresponds to about 105 liters of fuel / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) 39.2...
  • Page 201 GREASING AND SERVICE TABLE NB1A Check the chain wear. ( P. 61) • Check rear sprocket / engine sprocket for wear. ( P. 61) • Clean the air filter. ( P. 50) • Checking the tire air pressure. ( P. 59) •...

  • Page 202: Wiring Diagram

    WIRING DIAGRAM WIRING DIAGRAM 450/525 XC ATV 40.1 pos. high C_BC/4 50,48 C_DG/4 C_AK/2 C_AH/2 54,55 C_AU/2 C_BI/2 C_AH/2 C_AK/2 C_AJ/3 C_BG/3 -S10 600146-10...
  • Page 203 WIRING DIAGRAM Components CDI controller ACC1 Socket connector for auxiliary devices (switching on with ignition) ACC2 Socket connector for auxiliary devices (permanent positive) Throttle valve sensor TPS Battery Generator Idling speed indicator lamp Reverse gear indicator lamp Ignition indicator lamp High beam indicator light Brake / tail light Headlight...
  • Page 204 WIRING DIAGRAM yellow blue-red orange brown yellow-green black-yellow orange orange orange brown brown black brown brown brown brown brown brown black-green yellow-green yellow-green brown brown brown brown yellow white yellow white yellow yellow green blue blue white-green white-green white-blue brown white blue-red green...

  • Page 205: Substances

    – NLGI Specification – Use only grease that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Long Therm 2000 Brake fluid DOT 4 / DOT 5.1 according to –...
  • Page 206 – ISO VG (15) Specification – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the ® corresponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Coolant Specification –...

  • Page 207: Auxiliary Substances

    AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Lubricant (T158) Specification – ® KTM recommends Lubcon products. Supplier ® Lubcon – Turmogrease PP 300 Lubricant (T625) Specification – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Air filter cleaner Specification – ® KTM recommends Motorex products.
  • Page 208 AUXILIARY SUBSTANCES Motorcycle cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Cleaning and polishing materials for metal, rubber and plastic Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Protect & Shine 645 High-luster polish for paint Specification –...

  • Page 209: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Crankshaft locking bolt ART. NO.: 113080802 400035-01 Spring hooks ART. NO.: 50305017000 400363-01 Circlip pliers reverse ART. NO.: 51012011000 400059-01 Universal mounting rack ART. NO.: 56012001000 400067-01 Extractor ART. NO.: 58012009000 400073-01...
  • Page 210 SPECIAL TOOLS Assembly ring ART. NO.: 58012015095 Feature 95 mm (3.74 in) 400074-01 Tool for inner bearing race ART. NO.: 58429037037 400082-01 Clutch holder ART. NO.: 59029003100 400098-01 Mounting sleeve ART. NO.: 59029005010 400095-01 Valve spring mounter ART. NO.: 59029019000 400101-01...
  • Page 211 SPECIAL TOOLS Timing chain separating and riveting tool ART. NO.: 59029020000 400102-01 Limit plug gauge ART. NO.: 59029026006 400104-01 Extractor ART. NO.: 59029033000 400105-01 Adjustment tool for mixture control screw ART. NO.: 59029034000 400106-01 Feeler gauge ART. NO.: 59029041100 400110-01...
  • Page 212 SPECIAL TOOLS Spark plug wrench ART. NO.: 75029172000 400170-01 Hook wrench, Öhlins ART. NO.: 83019001000 200224-10 Hook wrench ART. NO.: 83019002000 200225-10 Open-end wrench accessory 46mm ART. NO.: 83019010461 500172-01 Hook wrench ART. NO.: 83019011000 600430-01...
  • Page 213 SPECIAL TOOLS Press mandrel ART. NO.: 83019012000 600421-01 Press mandrel ART. NO.: 83019013000 600476-01 Camber gauge ART. NO.: 83019014000 500229-01 Steering fixing for straight-ahead position ART. NO.: 83019015000 200424-10 Extractor ART. NO.: 83019020000 600477-01...
  • Page 214 SPECIAL TOOLS Mounting sleeve ART. NO.: 83019020100 600461-01 Press mandrel ART. NO.: 83019020130 600462-01 Disassembly/assembly holder ART. NO.: 83019020150 600463-01 Press mandrel ART. NO.: 83019020170 600460-01 Push-out tool ART. NO.: 83019021000 600452-01...
  • Page 215 SPECIAL TOOLS Mounting sleeve ART. NO.: 83019050001 200217-10 Adapter WP vacuum pump ART. NO.: 83019050002 200218-10 Disassembly/assembly tool ART. NO.: 83019050004 200220-10 Disassembly/assembly tool ART. NO.: 83019050005 200221-10 Disassembly fork ART. NO.: 83019050006 200222-10...
  • Page 216 SPECIAL TOOLS Mounting sleeve ART. NO.: 83019050007 200223-10 Mounting sleeve ART. NO.: 83019050012 200228-10 Mounting sleeve ART. NO.: 83019050013 200229-10 Press drift ART. NO.: 83019050014 200230-10 Press drift ART. NO.: 83019050015 200231-10...
  • Page 217 SPECIAL TOOLS Filling adapter ART. NO.: 83019050016 200276-10 Adapter cable ART. NO.: 83029043000 600402-01 Engine holder ART. NO.: 83112001050 600422-01 Vacuum pump ART. NO.: T1240S 200273-10...

  • Page 218: Standards

    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 specifi- cation.

  • Page 219: Index

    INDEX checking the choke slide ..... 150 INDEX checking the float needle valve ....151 A-Arm bottom checking the hot start slide .
  • Page 220 INDEX checking the shift mechanism ....116 installing the timing chain rails ....131 checking the spring length of the oil pressure regulator installing the timing chain sprocket .
  • Page 221 INDEX Engine sprocket Ignition curve installing ....... . 161 changing ....... . . 69 removing .
  • Page 222 INDEX Reverse gear release lever Wheel/wheels adjusting ....... . . 16 installing .
  • Page 223 *3206058en* 3206058en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

525 xc 2008

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