KTM 400 Owner's Handbook Manual
2000
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Also See for 400:
- Owner's handbook manual (46 pages) ,
- Owner's handbook manual (42 pages) ,
- Owner's manual (50 pages)
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Summary of Contents for KTM 400
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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... - 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.
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Page 5: Table Of Contents
Changing the spring preloading of the shock absorber ...18 Lubricate rear suspension linkage ........18 TECHNICAL SPECIFICATIONS - CHASSIS......37 Checking chain tension...........18 WIRING DIAGRAMME ..........APPENDIX Correct chain tension............19 Chain maintenance............19 Chain wear..............19 General informations about KTM disc brakes....20 Adjusting of free travel at the hand brake lever ....20... -
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 relevant area on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket. -
Page 7: Indicator Lamps
Indicator lamp 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 Some models are equipped with a digital speedometer KMH = Speed, max. -
Page 8: Flasher Switch
Flasher switch The flasher switch is a separate unit and is mounted on the left portion of the handlebar. The wire harness is designed in a way that whenever you want to use your bike on cross-country, off-road terrain you can dismount the entire turn indicator system without affecting the function of the remaining electrical system. -
Page 9: Choke
Choke In these models the choke operating element is located on the engine. Pull the knob and turn it (approx. 90°) to open a bore in the carburetor through which the engine can take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. -
Page 10: Handlebar Lock
Handlebar lock The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw. CAUTION EVER LEAVE THE KEY INSERTED IN THE LOCK F YOU TURN THE STEERING TO THE LEFT THE KEY COULD GET DAMAGED Compression damping of fork... -
Page 11: Driving Instructions
Arrange for the braking system to be checked – Motorcycle ready for operation and tank full by a KTM specialist, as complete failure of the braking – Luggage system can be avoided. -
Page 12: Starting Off
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 Go to the left of your motorbike. DO NOT open the throttle, and briskly kick the kickstarter ALL THE WAY. -
Page 13: Stopping And Parking
By shifting down, use the brakes if necessary and close throttle WARNING at the same time. Pull clutch lever and shift down to the next – N EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE gear. Let clutch lever go slowely and open throttle or shift ENGINE IS RUNNING down again. -
Page 14: Periodic Maintenance-Schedule
PERIODIC MAINTENANCE SCHEDULE rider dealer 2.99 620 SX 400/540 SXC 400/620 SC IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE... -
Page 15: Maintenance Work On Chassis And Engine
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER CAUTION – W HEN CLEANING THE MOTORCYCLE... -
Page 16: Breather Plugs 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 17: How To Change The Handlebar Position
Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. - Page 18 1. use the right button to select 2. push the left button until the right TOTAL MILEAGE „DST“ the position to be changed figure is showed in the display after changing battery 1 sec 5. push the button on the back with a sharp object approx.
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Page 19: Check/Set Distance Of The Magnetic Sensor
WHEEL CIRCUMFERENCE „WS“ 1. make sure that the indication "TRP" is 2. use the right button to select the 5 sec active and push the button on the position to be changed back approx. seconds ("WS" appears) 1 sec 5. push the button on the back 3. -
Page 20: Changing The Spring Preloading Of The Shock Absorber
Changing the spring preloading of the shock absorber KTM sets the shock absorber for a driver only, weighing approximately 75 kg (165 lb). If you want to take a passenger with you, of if you weigh considerably more or less than 75 kg (165 lb), you should change the spring preloading accordingly. -
Page 21: Correct Chain Tension
Correct chain tension – Loosen collar nut , loosen lock nuts , and turn right and left adjusting screws equally far. Tighten lock nuts – Before tightening the collar nut, verify that the chain adjusters sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. -
Page 22: 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 23: Refilling The Front Brake Fluid Reservoir
Refilling the front brake fluid reservoir * When the brake fluid falls to the middle of the inspection glass, new brake fluid has to be added. Loosen screws and remove lid and membrane Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm (0,2 in) below the rim with clean brake fluid DOT 5.1 (Shell Advance Brake DOT 5.1). -
Page 24: Changing The Basic Position Of The Brake Pedal
Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller . Using the push rod , the free play on the foot brake pedal must be set. -
Page 25: Replacing The Rear Brake Pads
Replacing the rear brake pads* Press brake caliper in direction of chain wheel for the brake piston to reach its basic position. Remove safety device , knock out the guide pin from the brake caliper with a drift towards the chain wheel and remove brake pads. -
Page 26: Dismounting And Mounting The Rear Wheel
– Tire pressure should be checked regularly on a “cold” tire. Proper pres- sure ensures optimum driving comfort and extends the life of your tires. WARNING – D KTM. O O NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY THER TIRES TIRES - AIR PRESSURE COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES –... -
Page 27: Checking Spoke Tension
(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 28: 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 29: Cleaning Of Air Filter
To replace the rear glass fiber yarn pack, drill the rivets open and remove the rear cap NOTE: Always renew the O-rings Glass fiber yarn packs are available in your KTM store. WARNING HE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUNNING AVOID BURNS... -
Page 30: Carburetor - Adjust Idling
CARBURETOR – Adjust idling * 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. Idling is controlled by the throttle stop screw and the mixture control screw... -
Page 31: Adjusting The Throttle Cable
Adjusting the throttle cable There must always be a 3-5 mm (0,12-0,20 in) play in the throttle cable. To 3-5 mm check this, move back the protective cover on the twist grip. You must be able to lift the outer covering of the cable 3-5 mm from the adjustment screw , until resistance is felt. -
Page 32: Engine Oil
Engine oil API: SF, SG, SH Only use high-quality oils (Shell Advance Ultra 4) meeting or surpassing the quality requirements of API classes SF, SG, or SH (for specifications see TEMPERATUR containers). You may use either mineral oils or synthetic oils fulfilling the above criteria. -
Page 33: Changing And Bleeding The Microfilter
Changing and bleeding the microfilter * Replace the microfilter while changing the engine oil. To do so, remove hexagon screws and take off the microfilter cover . Remove the micro- filter, clean its parts and check the O-ring on the microfilter lid for signs of damage. -
Page 34: 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 35 TROUBLE CAUSE REMEDY Engine will not reach full Valve gap to small Adjust valve gap power Loss of compression because hand Check setting of the hand decompression cable decompressor has no play Electronical ignition timing faulty Have ignition system checked Engine stops or splutters in Insuffient fuel Clean and check fuel system and carburetor...
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Page 36: 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 37: Technical Specifications - Engine
TECHNICAL SPECIFICATIONS – ENGINE 400/620 SC, Supermoto 2000 Engine 400 LC4 620 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft Displacement 398 ccm 609 ccm Bore / Stroke 89 / 64 mm 101 / 76 mm Ratio 10,8 : 1... - Page 38 ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play ..........0.03 - 0.12 mm (0.001-0.005 in) run out of crank stud........max. 0.04 mm (0.002 in) Conrod bearing radial play ..........max. 0.05 mm (0.002 in) axial play............max. 1.00 mm (0.04 in) Piston forged assembly clearance ........max.
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Page 39: Technical Specifications - Chassis
TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SC, Supermoto 2000 400/620 SC 620 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 295 / 320 mm (11.6 / 12.6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing... - Page 41 320577...