Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for KTM 400 SX RACING 2000
Summary of Contents for KTM 400 SX RACING 2000
-
Page 3: Frame Number
(b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM S PORTMOTORCYCLE RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT TECHNICAL SPECIFICATIONS... - Page 4 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this opportunity to thank you for putting your trust in us; we will not let you down. You are now owner of a sporty and modern motorcycle which you are bound to have a great time with provided you care for it properly.
-
Page 5: Table Of Contents
Chain wear ........17 General informations about KTM disc brakes ..18 HEAD WORD INDEX . -
Page 6: Serial Number Locations
SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. -
Page 7: Digital Speedometer, Indicator Lamps (Exc)
Digital speedometer, indicator lamps (EXC) The green control lamp flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp lights up when the high beam is on. Speedometer – digital (EXC) Some models are equipped with a digital speedometer KMH = Speed, max. -
Page 8: Combination Switch (Exc)
Combination switch (EXC) The light switch has 2, respetively 3 switch positions. = Light off (this function is not available in all models) = Low beam on = High beam on You may use button to actuate the horn. The red short circuit button serves to switch off the engine. -
Page 9: Filler Cap
Filler cap To open filler cap: Turn the filler cap counter-clockwise. To close filler cap: ut filler cap on and tighten it by turning it clockwise. Install tank breather hose without kinks. Fuel The LC4 engine needs premium gasoline with an octane number of 95 or higher. -
Page 10: Choke
Choke If you pull the choke button out as far as possible, a bore in the carbure- tor will be unblocked through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. -
Page 11: Rebound Damping Of Fork
Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding. STANDARD ADJUSTMENT –... -
Page 12: Driving Instructions
Arrange for the braking system to be checked Never exceed the maximum permissible laden weight and by a KTM specialist, as complete failure of the braking the axle weights. The maximum permissible laden weight is system can be avoided. - Page 13 Starting when the engine is cold 1 Open the fuel tap 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke 5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter.
-
Page 14: Stopping And Parking
Only give as much gas as the engine can handle. Through WARNING quick and high reving of throttle, the fuel usage increases. – I N CASE OF RAIN AFTER WASHING THE MOTORCYCLE AFTER RIDES By shifting down, use the brakes if necessary and close throttle THROUGH WATER AND IN CASE OF RIDES ON WET OFF ROAD TRACKS at the same time. - Page 15 PERIODIC MAINTENANCE SCHEDULE rider dealer 11.99 400/520 SX RACING 400/520 EXC RACING IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 15 HOUR SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RACE Check engine oil level Change engine oil Clean short and long oil screens and magnet of the drain plug whenever you exchange the engine oil Change short and long oil filter unit...
-
Page 16: Maintenance Work On Chassis And Engine
MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF. -
Page 17: Breather Plug Front Fork
Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. -
Page 18: Changing The Spring Preload Of Shock Absorber
Changing the spring preloading of the shock absorber The spring preload can be changed by turning the adjusting ring . For this purpose, you should dismount the shock absorber and clean it thoroughly. NOTE: – Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring. -
Page 19: Correct Chain Tension
Correct chain tension Loosen collar nut , loosen lock nuts , and turn right and left adjusting screws equally far. Tighten lock nuts. To ensure the correct alignment of the rear wheel, the marks at the left and right chain adjusters must be positioned identically in relation to the reference marks . -
Page 20: General Informations About Ktm Disc Brakes
In this case, consult an authorized KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 21: Checking Of Brake Fluid Level - Front Brake
Checking of brake fluid level - front brake The brake fluid reservoir is linked with the hand brake cylinder at the hand- lebar and the reservoir is provided with an inspection glass. With the reser- voir in a horizontal position, the brake fluid level should not drop below the middle of the glass. -
Page 22: Changing The Basic Position Of The Brake Pedal
Mount the right brake pad and fix it with the bolt. Mount the left brake pad and insert the bolt until it stops. Mount the clips. When mounting the brake pads, be sure to check for correct fit of the sliding metal-sheet in the caliper support and of the leaf spring WARNING... -
Page 23: Checking The Rear Brake Pads
Checking the rear brake pads min. The brake pads can be inspected from the rear. The thickness of the linings 1 mm may not be less than 1 mm (0.04 in). WARNING T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN OTHERWISE THEY COULD LEAD TO BRAKE FAILURE OR YOUR OWN SAFETY ’... -
Page 24: Dismounting And Mounting The Rear Wheel
The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer. Mount the collar nut , turn the speedometer drive such that the speedo- meter shaft is directed upward parallel to the fork leg (see photo), and tigh- ten the collar nut to 40 Nm (30 ft.lb). -
Page 25: Tires-Air Pressure
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. WARNING... -
Page 26: Adjusting Digital Speedometer
1. use the right button to 2. push the left button until TOTAL MILEAGE „DST“ select the position to be the right figure is showed changed in the display AFTER CHANGING BATTERY 1 sec 5. push the button on the back with a sharp object approx. -
Page 27: Check/Set Distance Of Magnetic Sensor
WHEEL CIRCUMFERENCE „WS“ 1. make sure that the indication 2. use the right button to select the position 5 sec "TRP" is active and push the but- to be changed ton on the back approx. 5 seconds ("WS" appears) 1 sec 5. -
Page 28: Battery (Exc)
Battery (EXC) The battery is mounted under the seat. The battery has a closed system and therefore requires no maintenance. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. -
Page 29: Fuse (Exc)
Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere. -
Page 30: Cooling System
Cooling system Coolant is circulated by a water pump located in the engine. When the engine is cold the coolant circulates only through the cylinder and the cylin- der head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat opens and the coolant is also pumped through both aluminum radiators. -
Page 31: Cleaning The Air Filter
Then, drill open the rivets and remove the end cap. NOTE! In every exhaust repair procedure, the O-rings must be replaced by new ones. Glass fiber yarn packings are available at your licensed KTM mechanic. WARNING... -
Page 32: Checking Adjustment Of The Hand Decompression Release Cable
SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased at your KTM dealer. CAUTION... -
Page 33: Carburetor Adjust Idling
CARBURETOR – Adjust idling (MX-FCR39) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel and the mixture control screw... -
Page 34: Draining Of Float Chamber Of The Carburetor
Draining of float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carbure- tor should be drained in order to remove any water that may have penetra- ted into it. Water in the float chamber causes malfunction. Perform this task on a cold engine. -
Page 35: Engine Oil
Engine oil Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or sur- API: SG, SH passing the quality requirements of API classes SG or SH (see specifications on the container). TEMPERATURE CAUTION – 0°C NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE 32°F 10W 40 15W 40... - Page 36 CHANGING THE OIL FILTERS Remove the screw and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws and dismount the two oil filter covers. Using circlip pliers, you may now pull the oil-filter inserts out of the housing.
-
Page 37: Trouble Shooting
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. - Page 38 Dismount left side paneling and filter box cover, replace fuse E-starter do not work The battery is discharged The battery isn’t charged by the Remove seat and fuel tank and check voltage regulator generator because connections; voltage regulator and generator should be checked by a KTM dealer.
-
Page 39: Cleaning
CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION EVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH... -
Page 40: Technical Specifications - Engine
TECHNICAL DATA – ENGINE 400/520 SX, EXC RACING 2000 Type 400 SX RACING 400 EXC RACING 520 SX RACING 520 EXC RACING Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 ccm 510 ccm Bore/Stroke 89 / 64 mm 95 / 72 mm Ratio 11 : 1... -
Page 41: Tightening Torques
TIGHTENING TORQUES Hexagon collar screw engine case, clutch cover, ignition cover 8 Nm (6 ft.lb) Oil drain plug M12x1,5 20 Nm (15 ft.lb) Allan head plug oil screen short M16x1,5 10 Nm (7 ft.lb) Hexagon plug oil screen long M20x1,5 15 Nm (11 ft.lb) Plug pressure valve... -
Page 42: Technical Specifications - Chassis
TECHNICAL DATA – CHASSIS 400/520 SX, EXC RACING 2000 400 SX RACING 520 SX RACING 400/520 EXC RACING 400/520 EXC RACING USA Frame Central chrom-moly-steel frame Fork White Power – Up Side Down 43 MA Wheel travel front/rear 295/320 mm Rear suspension WP Progressive Damping System shock absorber, aluminium swingarm Front brake... -
Page 43: Head Word Index
Fuel tap ................7 Changing the engine oil............33 Fuse (EXC) ................27 Changing the original position of the clutch lever ....14 General informations about KTM disc brakes ......18 Changing the spring preload of shock absorber ....16 Hand brake lever ..............4 Charging battery..............26 Hand decompression lever ............4...