KTM 450 Rally Factory Replica 2014 Owner's Manual
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KTM 450 Rally Factory Replica 2014 Owner's Manual

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OWNER'S MANUAL
2014
450 Rally Factory Replica
Art. no. 3213038en

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Summary of Contents for KTM 450 Rally Factory Replica 2014

  • Page 1 OWNER'S MANUAL 2014 450 Rally Factory Replica Art. no. 3213038en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as misprints and other errors.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS 7.11 Display mode SPEED/LAP (lap time)....21 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 7.12 Display mode SPEED/ODO (odometer) ....21 Symbols used ........... 4 7.13 Display mode SPEED/TR1 (trip master 1)..21 Formats used............ 4 7.14 Display mode SPEED/TR2 (trip master 2)..
  • Page 5 TABLE OF CONTENTS 12.12 Adjusting the play of the steering head 15.5 Changing fuses of individual power bearing ............. 47 consumers............75 15.6 Checking the headlight setting ......75 12.13 Greasing the steering head bearing ....48 15.7 Adjusting the headlight range......76 12.14 Removing the seat ..........

  • Page 6: 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 by an authorized KTM workshop. There, your motorcycle will be opti- mally cared for by specially trained experts using the specialist tools required.

  • Page 7: Safety Advice

    SAFETY ADVICE Use definition - intended use KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations.

  • Page 8: Safe Operation

    Keep the Owner's Manual in an accessible place to enable you to refer to it as needed. If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.

  • Page 9: Important Notes

    Guarantee, warranty The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's Service & Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be consid- ered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left 601285-10 Choke ( p. 15) Kill switch ( p. 12) Light switch ( p. 12) Turn signal switch ( p. 13) Horn button ( p. 13) Clutch lever ( p. 12) Steering lock ( p.

  • Page 11: View Of Vehicle, Rear Right

    VIEW OF VEHICLE View of vehicle, rear right 601286-10 Ignition switch ( p. 13) Speedometer overview ( p. 18) Throttle grip ( p. 12) Fuel tap ( p. 14) Foot brake lever ( p. 15) Hand brake lever ( p. 12)

  • Page 12: Serial Numbers

    SERIAL NUMBERS Chassis number Chassis number is embossed in the steering head at the right. 601287-10 Type label Type label is fixed to the right of the steering head. 601287-11 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 13: Shock Absorber Part Number

    SERIAL NUMBERS Shock absorber part number Shock absorber part number is attached to the lower part of the shock absorber at the rear, opposite to the direction of travel. 601327-10...

  • Page 14: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 601290-10 Hand brake lever The hand brake lever is fitted on the right side of the handlebar. The hand brake lever operates the front brake. 601291-10 Throttle grip The throttle grip...

  • Page 15: Turn Signal Switch

    CONTROLS Turn signal switch The turn signal switch is fitted on the left side of the handlebar. Possible states Turn signal off – Turn signal switch is in the central position. Turn signal, left, on – Turn signal switch turned to the left. Turn signal, right, on –...

  • Page 16: Fuel Tank

    CONTROLS 6.11 Fuel tank This model has three separate fuel tanks controlled by a fuel tap. Two fuel tanks are located in front of the seat and one fuel tank is located beneath the seat. The right fuel tank is filled via filler cap and the left fuel tank is filled via filler 601303-10 The rear fuel tank is filled via filler cap...

  • Page 17: Choke

    CONTROLS R REAR – If tap handle • of the fuel tap points up, fuel is taken from the rear fuel tank. Only the rear fuel tank empties out completely. L01354-10 6.13 Choke The choke lever is fitted on the left side of the handlebar. Activating the choke function frees an opening through which the engine can draw extra fuel.

  • Page 18: Side Stand

    CONTROLS 6.16 Side stand The side stand is on the left side of the vehicle. 601699-10 The side stand is used to park the motorcycle. Info When you are riding, the side stand must be folded up and secured with the rubber band 601700-10 6.17...

  • Page 19: Unlocking The Steering

    CONTROLS 6.19 Unlocking the steering – Insert the key in the steering lock, turn it to the left, pull it out, and turn it to the right. Remove the key. You can now steer the bike again. Info Never leave the key in the steering lock. 400731-01...

  • Page 20: Speedometer

    SPEEDOMETER Speedometer overview – Press the button to change the display mode or change to one of the Setup menus. – Press the button to control different functions. – Press the button to control different functions. Info When the vehicle is delivered, only the SPEED/H and SPEED/ODO display modes are activated.

  • Page 21: Setting The Clock

    SPEEDOMETER – Press the button for 3 - 5 seconds. The settings are stored and the Setup menu is closed. Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

  • Page 22: Querying Lap Time

    SPEEDOMETER Info If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed. Querying lap time Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary.

  • Page 23: Display Mode Speed/Clk (Time)

    SPEEDOMETER 7.10 Display mode SPEED/CLK (time) – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is shown in display mode CLK. Press the button . No function Press the button .

  • Page 24: Display Mode Speed/Tr2 (Trip Master 2)

    SPEEDOMETER 7.14 Display mode SPEED/TR2 (trip master 2) – Press the button briefly and repeatedly until TR2 appears at the top right of the display. TR2 (trip master 2) runs constantly and counts up to 999.9. The displayed value can be set manually with the button and the button .

  • Page 25: Display Mode Speed/S1 (Stop Watch 1)

    SPEEDOMETER 7.17 Display mode SPEED/S1 (stop watch 1) – Press the button briefly and repeatedly until S1 appears at the top right of the display. S1 (stop watch 1) displays the journey time on the basis of TR1 and continues when an impulse is received from the wheel speed sensor.

  • Page 26: Table Of Conditions And Menu Activation

    SPEEDOMETER 7.20 Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/H (service hours) • Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) •...

  • Page 27: Preparing For Use

    When using your motorcycle, 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 28: Running In The Engine

    PREPARING FOR USE Info Motorcycles react sensitively to any changes of weight distribution. – Do not exceed the overall maximum permitted weight and the axle loads. Guideline Maximum permissible overall weight 400 kg (882 lb.) Maximum permissible front axle load 190 kg (419 lb.) Maximum permissible rear axle load 250 kg (551 lb.)

  • Page 29: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p.

  • Page 30: Starting Off

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up. Info If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop. First gear is used for starting off or for steep inclines.

  • Page 31: Stopping, Parking

    RIDING INSTRUCTIONS – On sandy, wet or slippery surfaces, use the rear brake. – Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed. – On long downhill stretches, use the braking effect of the engine. To do so, shift back one or two gears, but do not overrev the engine.

  • Page 32: Refueling

    RIDING INSTRUCTIONS Refueling 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. Clean up spilt fuel immediately. –...

  • Page 33: Service Schedule

    ○ ● ● ● Check the idle. ○ ● ● ● Final check: Check the vehicle for safe operation and take a test ride. ○ ● ● ● Make the service entry in KTM DEALER.NET and in the service record.

  • Page 34: Service Work (As Additional Order)

    SERVICE SCHEDULE ○ One-time interval ● Periodic interval 10.2 Service work (as additional order) Annually Every 80 operating hours Every 40 operating hours Once after 20 operating hours / Every 20 operating hours ● ● ● Change the front brake fluid. ●...

  • Page 35: Tuning The Chassis

    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 high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 36: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    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 low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 37: Checking The Static Sag Of The Shock Absorber

    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 Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.

  • Page 38: Adjusting The Riding Sag

    TUNING THE CHASSIS – After removing the shock absorber, clean it thoroughly. Main work – Loosen screw 0 0 1 0 0 2 – Turn adjusting ring until the spring is no longer under tension. Combination wrench (50329080000) Hook wrench (T106S) –...

  • Page 39: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 11.12 Adjusting the compression damping of the fork Info The hydraulic compression damping determines the fork suspension behavior. – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the top end of the fork legs. Make the same adjustment on both fork legs.

  • Page 40: Setting The Fork Offset

    TUNING THE CHASSIS If marking 1 is not visible in drilled hole (as delivered), you will obtain better riding stability on fast stretches. Fork offset No mark 22 mm (0.87 in) If marking 1 is visible in drilled hole , you obtain better handling in curves. Fork offset Marking 1 is visible 20 mm (0.79 in)

  • Page 41: Handlebar Position

    TUNING THE CHASSIS 11.16 Handlebar position On the upper triple clamp, there are 2 holes at a distance to each other. Distance between holes 15 mm (0.59 in) The holes on the handlebar support are placed at a distance of from the center.
  • Page 42 TUNING THE CHASSIS – Insert lower shells – Position the handlebar. Info Make sure cables and wiring are positioned correctly. – Position handlebar clamps with rubber washers and elastomers Elastomer kit green - soft quality (SXS05125203) Elastomer kit yellow - medium quality (standard) (SXS05125204) Elastomer kit red - hard quality (SXS05125205) Info The elastomers are available in different versions.

  • Page 43: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 12.1 Raising the motorcycle with the lift stand Note Danger of damage The parked vehicle may roll away or fall over. – Always place the vehicle on a firm and even surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (54829055000) The wheels must no longer touch the ground.

  • Page 44: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 12.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 41) – Dismount the front fender. ( p. 42) Main work – Push dust boots of both fork legs downward.

  • Page 45: Removing The Fork Legs

    SERVICE WORK ON THE CHASSIS 12.7 Removing the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 41) – Remove the front wheel. p. 67) – Dismount the front fender. ( p. 42) Main work –...

  • Page 46: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with the lift stand. ( p. 41) – Remove the front wheel. p. 67) – Dismount the front fender. ( p. 42) – Remove the fork legs.

  • Page 47: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 12.10 Installing the lower triple clamp Main work – Clean the bearing and sealing elements, check for damage, and grease. High viscosity grease ( p. 118) – Insert the lower triple clamp with the steering stem. Mount the upper steering head bearing.

  • Page 48: Checking The Steering Head Bearing Play

    Danger of accidents Unstable vehicle handling from incorrect steering head bearing play. – Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.) Info If the bike is ridden with play in the steering head bearing, the bearing and the bearing seats in the frame can become dam-...

  • Page 49: Adjusting The Play Of The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Preparatory work – Raise the motorcycle with the lift stand. ( p. 41) Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing.

  • Page 50: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS – Position steering damper . Mount and tighten screws Guideline Screw, steering damper 15 Nm (11.1 lbf ft) – Remove the cable binders and place the handlebar onto the handlebar clamp base. – Mount the holding plate with the handlebar clamps and position the handlebar. Mount and tighten screws Guideline 601337-10...

  • Page 51: Mounting The Seat

    SERVICE WORK ON THE CHASSIS 12.15 Mounting the seat – Let the locking pin of the seat engage in lock housing – Lock the seat at the front with quick release – Make sure that the seat is correctly locked in. 601348-10 12.16 Removing the air filter...

  • Page 52: Removing The Main Silencer

    SERVICE WORK ON THE CHASSIS 12.18 Removing the main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven. – Allow the exhaust system to cool down. Do not touch hot components. – Detach springs –...

  • Page 53: Removing The Fuel Tank Toward The Front

    SERVICE WORK ON THE CHASSIS 12.21 Removing the fuel tank toward the front 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 54: Checking The Chain For Dirt Accumulation

    SERVICE WORK ON THE CHASSIS – Mount the trim. ( p. 58) 12.23 Checking the chain for dirt accumulation – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 52) 400678-01 12.24 Cleaning the chain...

  • Page 55: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS Main work – Push the chain upward at the end of the chain sliding guard to measure chain ten- sion Info The upper chain section must be taut. Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 56: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS 12.27 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with the lift stand. ( p. 41) Main work – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...

  • Page 57: Checking The Frame

    If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 601609-01...

  • Page 58: Checking The Swingarm

    If the swingarm shows signs of damage, cracking, or deformation: – Change the swingarm. Info A damaged swingarm must always be changed. Repair of the swingarm is not authorized by KTM. 601608-01 12.30 Checking the rubber grip – Check the rubber grips on the handlebar for damage, wear, and looseness.

  • Page 59: Checking The Fluid Level Of The Hydraulic Clutch

    SERVICE WORK ON THE CHASSIS 12.33 Checking the fluid level of the hydraulic clutch Info The fluid level rises with increased wear of the clutch lining discs. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 60: Removing The Trim

    SERVICE WORK ON THE CHASSIS 12.35 Removing the trim – Detach the plug-in connectors on the turn signal cables. – Open quick releases – Remove the trim toward the front. 601352-10 12.36 Mounting the trim – Attach the trim to guides Info When positioning the trim, exercise caution with counterpieces of the...

  • Page 61: Brake System

    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...

  • Page 62: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to 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 63: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to 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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 64 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 65: Checking The Free Travel Of The Foot Brake Lever

    BRAKE SYSTEM – Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. – Add brake fluid to level Guideline Measurement of 5 mm (0.2 in) Brake fluid DOT 4 / DOT 5.1 ( p.

  • Page 66: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to 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.) – Stand the vehicle upright.

  • Page 67: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to 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 Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 68 BRAKE SYSTEM – Stand the vehicle upright. – Remove screw cap with the washer and membrane – Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Ensure that brake fluid does not overflow from the brake fluid reser- voir, using suction to remove it if it does.

  • Page 69: Wheels, Tires

    WHEELS, TIRES 14.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 41) Main work – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons.

  • Page 70: Removing The Rear Wheel

    WHEELS, TIRES – Activate the hand brake lever multiple times until the brake linings are in contact with the brake disc. – Remove the motorcycle from the lift stand. ( p. 41) – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten.

  • Page 71: Installing The Rear Wheel

    WHEELS, TIRES 14.4 Installing the rear wheel Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. – Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Main work –...

  • Page 72: Checking The Rear Hub Rubber Dampers X

    Checking the tire condition Info Only mount tires approved and/or recommended 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 motorcycle.

  • Page 73: Checking The Tire Air Pressure

    Danger of accidents Instable handling due to incorrect spoke tension. – Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.) Info A loose spoke causes wheel imbalance and rapidly leads to more loose spokes.
  • Page 74 WHEELS, TIRES Torque wrench with various accessories in set (58429094000)

  • Page 75: Electrical System

    – Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries. Info Even when there is no load on the battery, it still loses power steadily.

  • Page 76: Changing The Main Fuse

    ELECTRICAL SYSTEM – Disconnect the negative cable of the battery to avoid damage to the onboard elec- tronics. Main work – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test the open-circuit voltage and starting voltage of the battery, and to test the alternator.

  • Page 77: Changing Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM 15.5 Changing fuses of individual power consumers Info The fuse box containing the fuses of individual power consumers is located under the seat. Preparatory work – Switch off all power consumers and switch off the engine. – Remove the seat. ( p.

  • Page 78: Adjusting The Headlight Range

    ELECTRICAL SYSTEM » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 76) 15.7 Adjusting the headlight range Preparatory work – Check the headlight setting. ( p. 75) – Remove the trim. ( p.

  • Page 79: Cooling System

    COOLING SYSTEM 16.1 Cooling system Water pump in the engine circulates the coolant. The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap . This ensures that operating the vehicle at the specified coolant tem- perature will not result in a risk of malfunctions.

  • Page 80: Draining The Coolant

    COOLING SYSTEM Condition The engine is cold. – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – 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: –...
  • Page 81 COOLING SYSTEM – Mount the radiator cap. – Take a short test ride. – Check the coolant level. ( p. 77)

  • Page 82: Tuning The Engine

    TUNING THE ENGINE 17.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Move the throttle grip back- wards and forwards to ascertain the play in the throttle cable. Play in throttle cable 3…...

  • Page 83: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE The idle mixture is adjusted with the idle adjusting screw 601378-10 The idle speed is adjusted with adjusting screw 601379-10 17.4 Carburetor - adjusting the idle speed – Screw in idle adjusting screw until it stops and then to the prescribed basic set- ting.

  • Page 84: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motorcyclist will set the mixture about ¼ of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use.

  • Page 85: Checking The Basic Position Of The Shift Lever

    TUNING THE ENGINE 17.6 Checking the basic position of the shift lever – Sit on the vehicle in the riding position and determine distance between the upper edge of your boot and the shift lever. Distance between shift lever and upper 10…...

  • Page 86: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 18.1 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – The motorcycle is positioned on a horizontal surface. Condition The engine is cold. –...
  • Page 87 SERVICE WORK ON THE ENGINE – Mount and tighten oil drain plug with the seal ring. Guideline Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) 601320-10 – Remove screws . Remove the lower oil filter cover with the O-ring. 601322-10 –...

  • Page 88: Adding Engine Oil

    SERVICE WORK ON THE ENGINE – Fill the oil filter housing with oil and wait until air bubbles stop rising. Engine oil (SAE 10W/60) (00062010035) ( p. 116) Engine oil (SAE 10W/50) ( p. 116) 601324-10 – Position the upper oil filter cover. Mount and tighten screws Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft)
  • Page 89 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 90: Cleaning, Care

    CLEANING, CARE 19.1 Cleaning motorcycle Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – When cleaning the vehicle with a pressure cleaner, do not point the water jet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts.

  • Page 91: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE 19.2 Checks and maintenance steps for winter operation Info If you use the motorcycle in winter, you can expect salt on the roads. Precautions need to be taken against the aggressive road salt. If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

  • Page 92: Storage

    50… 75 % – Place the vehicle on a dry storage place that is not subject to large temperature variations. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 41) – Cover the vehicle with an air-permeable cover or blanket.

  • Page 93: Technical Data

    TECHNICAL DATA 21.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 60.8 mm (2.394 in) Bore 97 mm (3.82 in) Compression ratio 12.5:1 Idle speed 1,550… 1,650 rpm Control DOHC, four valves controlled via cam lever, drive via helical gear pair and tooth-wheel chain Valve diameter, intake 40.4 mm (1.591 in)
  • Page 94 TECHNICAL DATA ® Screw, timing train axle retaining 6 Nm (4.4 lbf ft) Loctite 243™ bracket Nut, cylinder head 10 Nm (7.4 lbf ft) Lubricated with engine oil ® Nut, water-pump wheel 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, timing chain tensioner 6 Nm (4.4 lbf ft) Loctite...

  • Page 95: Capacities

    TECHNICAL DATA ® Nut, primary gear M27x1 80 Nm (59 lbf ft) Loctite 243™ Plug, oil screen M32x1.5 30 Nm (22.1 lbf ft) Lubricated with engine oil 21.3 Capacities 21.3.1 Engine oil Engine oil Oil change 1.20 l (1.27 qt.) Engine oil (SAE 10W/60) (00062010035) ( p.

  • Page 96: Electrical System

    Rear tires 90/90 - 21 54S TT 130/80 - 18 66S TT Michelin T63 Michelin T63 Additional information is available in the Service section under: http://www.ktm.com 21.7 Fork Fork part number 14.18.7M.40 Fork WP Suspension Up Side Down 4860 MXMA CC...

  • Page 97: Shock Absorber

    TECHNICAL DATA 21.8 Shock absorber Shock absorber part number 12.18.7M.51 Shock absorber WP Suspension 5018 DACC Compression damping, low-speed Standard 10 clicks Compression damping, high-speed Standard 1.5 turns Rebound damping Standard 18 clicks Spring preload Standard 17 mm Spring rate Weight of rider:: 75…...
  • Page 98 TECHNICAL DATA ® Screw, chain sliding guard 6 Nm (4.4 lbf ft) Loctite 243™ – Screw, engine guard bracket on engine 15 Nm (11.1 lbf ft) bearer ® Screw, front brake disc 14 Nm (10.3 lbf ft) Loctite 243™ ® Screw, rear brake disc 14 Nm (10.3 lbf ft) Loctite...

  • Page 99: Carburetor With Carburetor Configuration (Carburetor Sheets)

    TECHNICAL DATA 21.10 Carburetor with carburetor configuration (carburetor sheets) Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4100D Needle position 3 th position from top Idle mixture adjusting screw Open 1.5 turns Main jet Jet needle OBDVT (OBDTQ) Idling jet Idle air jet Cold start jet...

  • Page 100: Wiring Diagram

    WIRING DIAGRAM 22.1 Page 1 of 9 ye-rd wh-rd ye-rd ye-rd EY/3 EZ/3 gn-rd ye-rd ye-rd ye-rd L01360-01...
  • Page 101 WIRING DIAGRAM Components: CDI controller Fuse Fuse Battery Alternator Starter relay with main fuse Starter motor Voltage regulator Ignition switch...

  • Page 102: 100

    WIRING DIAGRAM 22.2 Page 2 of 9 bl-rd bl-rd bl-rd bl-rd bl-rd gn-rd gn-rd gn-rd wh-bl wh-bl 601402-01...
  • Page 103 WIRING DIAGRAM Components: Radiator fan temperature switch Fuse Fuse Radiator fan...

  • Page 104: 102

    WIRING DIAGRAM 22.3 Page 3 of 9 bl-ye bl-ye bl-ye bl-ye bu-rd gn-or gn-or gn-or gn-or gn-or gn-or 601403-01...
  • Page 105 WIRING DIAGRAM Components: CDI controller Low beam Fuse Low beam relay Horn Light switch, horn button, kill switch...

  • Page 106: 104

    WIRING DIAGRAM 22.4 Page 4 of 9 rd-bu rd-bu bu-or bu-or bu-rd 601404-01...
  • Page 107 WIRING DIAGRAM Components: High beam High beam relay High beam indicator light...

  • Page 108: 106

    WIRING DIAGRAM 22.5 Page 5 of 9 DA/4 DB/4 CX/2 CW/2 601405-01...
  • Page 109 WIRING DIAGRAM Components: Wheel speed sensor, front Speedometer Parking light Tripmaster switch...

  • Page 110: 108

    WIRING DIAGRAM 22.6 Page 6 of 9 ye-bu ye-bu ye-bu bl-gn ye-bu bl-gn 601406-01...
  • Page 111 WIRING DIAGRAM Components: Turn signal relay Turn signal indicator light Idling speed indicator lamp Front left turn signal Front right turn signal Rear left turn signal Rear right turn signal Turn signal switch...

  • Page 112: 110

    WIRING DIAGRAM 22.7 Page 7 of 9 gn-gr gn-gr gn-gr gn-gr bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye 601407-01...
  • Page 113 WIRING DIAGRAM Components: Oil pressure sensor Temperature switch indicator lamp Temperature warning lamp Oil pressure warning lamp...

  • Page 114: 112

    WIRING DIAGRAM 22.8 Page 8 of 9 wh-gn ye-bu ye-bu ye-bu ye-bu ye-bu wh-gn wh-gn wh-gn wh-gn wh-gn wh-gn wh-ye wh-ye 601408-01...
  • Page 115 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Fuse Fuse Brake/tail light...

  • Page 116: 114

    WIRING DIAGRAM 22.9 Page 9 of 9 wh-rd wh-rd wh-rd bl-or bl-or bl-or bl-or bl-bu bl-bu bl-br bl-br bl-br bl-br 601409-01...
  • Page 117 WIRING DIAGRAM Components: CDI controller Throttle position sensor circuit A Pulse generator Fuse Ignition coil (cylinder 1) Emergency OFF switch, electric starter button X280 Connector, ignition curve X281 Connector, ignition curve Cable colors: Black Brown Blue Green Gray Light blue Orange Pink Violet...

  • Page 118: Substances

    Brake fluid DOT 4 / DOT 5.1 According to – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corre- sponding properties. KTM recommends Castrol and Motorex ® products. Supplier Castrol –...
  • Page 119 Hydraulic fluid (15) According to – 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 ® –...

  • Page 120: Auxiliary Substances

    AUXILIARY SUBSTANCES Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Protect & Shine...
  • Page 121 AUXILIARY SUBSTANCES Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE Universal oil spray Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Joker 440 Synthetic...

  • Page 122: 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 123: Index

    INDEX Compression damping, high-speed INDEX shock absorber, adjusting ..... 33 Accessories ........7 Compression damping, low-speed shock absorber, adjusting .
  • Page 124 INDEX Rear sprocket checking ....... . . 54 Hand brake lever ......12 Rear wheel free travel, adjusting .
  • Page 125 INDEX chassis ........93 chassis tightening torques ..... 95 electrical system .
  • Page 126 *3213038en* 3213038en 07/2013 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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