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

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OWNER'S MANUAL
2012
450 Rally Factory Replica
Art. no. 3211726en

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Summary of Contents for KTM 450 Rally Replica

  • Page 1 OWNER'S MANUAL 2012 450 Rally Factory Replica Art. no. 3211726en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will DEAR KTM CUSTOMER give you enormous pleasure if you service and maintain it accordingly. We wish you a lot of enjoyment in riding this vehicle.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SERVICE SCHEDULE............28 TABLE OF CONTENTS IMPORTANT INFORMATION ..........4 Service schedule ............28 VIEW OF VEHICLE............... 6 Service work (as additional order)........29 View of vehicle, front left..........6 TUNING THE CHASSIS............30 View of vehicle, rear right ..........7 Checking the basic chassis setting with the rider's SERIAL NUMBERS..............
  • Page 5 TABLE OF CONTENTS TECHNICAL DATA - CARBURETOR........88 Changing the hydraulic clutch fluid ......53 BRAKES ................54 TECHNICAL DATA - CHASSIS ..........89 Lighting equipment ............89 Checking the free travel on the hand brake lever....54 Tires ................90 Adjusting the free travel of the hand brake lever ....

  • Page 6: Important Information

    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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be granted for damage resulting from manipulations and/or alterations to the vehicle.
  • Page 7 IMPORTANT INFORMATION Environment Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob- lems and conflicts do not have to occur.

  • Page 8: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left 601285-10 Choke ( p. 19) Kill switch ( p. 10) Light switch ( p. 10) Turn signal switch ( p. 11) Horn button ( p. 11) Clutch lever ( p. 10) Steering lock ( p.

  • Page 9: View Of Vehicle, Rear Right

    VIEW OF VEHICLE View of vehicle, rear right 601286-10 Ignition switch ( p. 11) Speedometer ( p. 12) Throttle grip ( p. 10) Fuel tap ( p. 18) Foot brake lever ( p. 20) Hand brake lever ( p. 10)

  • Page 10: 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 ...

  • Page 11: 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 12: 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. ...

  • Page 13: 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 14: Speedometer

    CONTROLS Speedometer 4.11 – 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 15: Setting The Clock

    CONTROLS – 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 16: Querying Lap Time

    CONTROLS Info If no button is pressed for 20 seconds, or if a pulse arrives from the wheel speed sensor, the settings are stored automatically and the Setup menu is closed. Querying lap time 4.17 Info This function can be called up only if lap times are measured. Condition The motorcycle is stationary.

  • Page 17: Display Mode Speed/Clk (Clock)

    CONTROLS Display mode SPEED/CLK (clock) 4.20 – Press the button briefly and repeatedly until CLK appears at the bottom right of the display. The time is displayed in CLK display mode. Press the button . No function Press the button .

  • Page 18: Display Mode Speed/Tr2 (Trip Master 2)

    CONTROLS Display mode SPEED/TR2 (trip master 2) 4.24 – 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 19: Display Mode Speed/S1 (Stop Watch 1)

    CONTROLS Display mode SPEED/S1 (stop watch 1) 4.27 – 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 20: Fuel Tank

    CONTROLS Table of conditions and menu activation Display The motorcycle is Menu can be acti- stationary. vated Display mode SPEED/LAP (lap time) • Display mode SPEED/TR1 (trip master 1) • Display mode SPEED/TR2 (trip master 2) • Display mode SPEED/A1 (average speed 1) •...

  • Page 21: Choke

    CONTROLS F FRONT – If the tap handle • of the fuel tap points toward the rear, fuel is taken  from the two front fuel tanks. Only the front fuel tanks empty out completely. 601307-10 R REAR – If tap handle •...

  • Page 22: Foot Brake Lever

    CONTROLS Foot brake lever 4.33 Foot brake lever is located in front of the right footrest.  The rear brake is engaged with the foot brake lever. 601309-10 Side stand 4.34 The side stand is on the left side of the vehicle. ...

  • Page 23: Unlocking The Steering

    CONTROLS Unlocking the steering 4.37 – 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 24: 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 25: 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 26: 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 27: 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 28: Stop, Park

    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. Change down one or two gears, but do not overstress the engine. In this way, you have to brake far less and the brakes do not overheat.
  • Page 29 RIDING INSTRUCTIONS – Fill the fuel tank with fuel up to measurement  Guideline Measurement of 45 mm (1.77 in)  Fuel tank capacity Fuel tank half, 9.0 l Super unleaded (ROZ 95/RON 95/PON front left, (2.38 US gal) 91) ( p.

  • Page 30: Service Schedule

    • 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. • • • • S1N: Once after 1 operating hour...

  • Page 31: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S20N S20A S40A S80A • • • Change the front brake fluid. Change the rear brake fluid. • • • Change the hydraulic clutch fluid. p. 53) • • Grease the steering head bearing. p.

  • Page 32: 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 33: 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 34: 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 35: Adjusting The Riding Sag

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

  • Page 36: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS Adjusting the compression damping of the fork 8.12 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. ...

  • Page 37: Setting The Fork Offset

    TUNING THE CHASSIS When mark 1 is visible in drill hole (as delivered), you will achieve better handling in  bends. Fork offset Mark 1 visible 20 mm (0.79 in) If mark 1 is not visible in drill hole , you will achieve better riding stability on fast ...

  • Page 38: Adjusting The Handlebar Position

    TUNING THE CHASSIS Adjusting the handlebar position 8.17 Warning Danger of accidents Handlebar breakage. – If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handle- bar. – Remove the four screws .

  • Page 39: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 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 40: Dismounting The Front Fender

    SERVICE WORK ON THE CHASSIS 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. – Clean and oil the dust boots and inner fork tube of both fork legs.

  • Page 41: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS Installing the fork legs – Position the fork legs. Info The upper triple clamp must be flush with the upper edge of the fork legs. Position bleeder screws toward the front.  601334-10 – Tighten screws ...

  • Page 42: Installing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS – Fix handlebar onto the instrument support with cable binders   601344-10 – Loosen screws   – Remove screw and secure against falling out under triple clamp   601343-10 – Remove O-ring .
  • Page 43 SERVICE WORK ON THE CHASSIS – Position the fork legs. Info The fork legs must be flush with the upper edge of the upper triple clamp. Position bleeder screws toward the front.  601384-10 – Tighten screws  Guideline Screw, top triple clamp 17 Nm (12.5 lbf ft) –...

  • Page 44: 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- aged over time.

  • Page 45: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS – Fix handlebar onto the instrument support with cable binders   – Loosen screws   601336-10 – Loosen nut and screw   – Retighten nut  Guideline Nut, upper steering head M20x1 12 Nm (8.9 lbf ft) –...

  • Page 46: Removing The Seat

    SERVICE WORK ON THE CHASSIS Removing the seat 9.14 – Lift and turn quick release bracket  – Pull on loop . At the same time, lift the seat at the rear and take it off.  601347-10 Mounting the seat 9.15 –...

  • Page 47: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 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. –...

  • Page 48: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS Changing the glass fiber yarn filling of the main silencer 9.20 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. Info Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out".

  • Page 49: Removing The Fuel Tank Toward The Front

    SERVICE WORK ON THE CHASSIS – Position the trim and attach it with quick releases  601352-11 Removing the fuel tank toward the front 9.23 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 50: Installing The Fuel Tank At The Front

    SERVICE WORK ON THE CHASSIS Installing the fuel tank at the front 9.24 – Position the fuel tank. Mount and tighten screws  Guideline Screw, front fuel tank 8 Nm (5.9 lbf ft) – Clean quick releases of fuel line and connect them.

  • Page 51: Checking The Chain Tension

    SERVICE WORK ON THE CHASSIS Checking the chain tension 9.27 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) are under additional load.

  • Page 52: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    SERVICE WORK ON THE CHASSIS Checking the chain, rear sprocket, engine sprocket, and chain guide 9.29 – Raise the motorcycle with the lift stand. ( p. 37) – Shift gear to neutral. – Check the rear sprocket and engine sprocket for wear. »...

  • Page 53: 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 Checking the swingarm 9.31 –...

  • Page 54: Checking The Rubber Grip

    SERVICE WORK ON THE CHASSIS Checking the rubber grip 9.32 – Check the rubber grips on the handlebar for damage, wear, and looseness. » If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip. Rubber grip adhesive (00062030051) ( p.

  • Page 55: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS Changing the hydraulic clutch fluid 9.36 Warning Environmental hazard Hazardous substances cause environmental damage. – Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 56: Brakes

    Danger of accidents Reduced braking efficiency due to worn brake disc(s). – Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.) – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement ...

  • Page 57: Checking The Front Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 58: Checking The Front Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 59 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 60: Checking The Free Travel Of The Foot Brake Lever

    BRAKES – 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 61: Checking The Rear Brake Fluid Level

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Stand the vehicle upright.

  • Page 62: Checking The Rear Brake Linings

    Warning Danger of accidents Reduced braking effect caused by old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
  • Page 63 BRAKES – 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 64: Wheels, Tires

    WHEELS, TIRES Removing the front wheel 11.1 – Raise the motorcycle with the lift stand. ( p. 37) – Press the brake caliper by hand on to the brake disc in order to press back the brake pistons. Info Make sure when pushing back the brake pistons that you do not press the brake caliper against the spokes.

  • Page 65: 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. 37) – Pull the front brake and compress the fork powerfully a few times. The fork legs straighten.

  • Page 66: Installing The Rear Wheel

    WHEELS, TIRES Installing the rear wheel 11.4 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. –...

  • Page 67: Checking The Tire Condition

    DOT code. The first two digits indicate the week of manufacture and the last two digits the year of manu- facture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. »...

  • Page 68: 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 69: Electrical System

    – Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner. Give the battery to your KTM dealer or to a recycling center that accepts used batteries. Info Even when there is no load on the battery, it still loses power steadily.

  • Page 70: Changing The Main Fuse

    ELECTRICAL SYSTEM – 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. With this device, you cannot over- charge the battery.

  • Page 71: Changing Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM Changing fuses of individual power consumers 12.5 Info The fuse box containing the fuses of individual power consumers is located under the seat. – Switch off all power consumers and switch off the engine. – Remove the seat. ( p.

  • Page 72: Adjusting The Headlight Range

    ELECTRICAL SYSTEM » If the boundary between light and dark does not meet specifications: – Adjust the headlight range. ( p. 70) Adjusting the headlight range 12.7 – Check the headlight setting. ( p. 69) – Remove the trim. ( p.

  • Page 73: Cooling System

    COOLING SYSTEM Cooling system 13.1 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- ...

  • Page 74: Draining The Coolant

    COOLING SYSTEM – 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 75 COOLING SYSTEM – Take a short test ride. – Check the coolant level. ( p. 71)

  • Page 76: Tuning The Engine

    TUNING THE ENGINE Checking the play in the throttle cable 14.1 – 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 77: Carburetor - Adjusting The Idle Speed

    TUNING THE ENGINE The idle speed is adjusted with adjusting screw  601379-10 Carburetor - adjusting the idle speed 14.4 – Screw in idle adjusting screw until it stops and then to the prescribed basic set-  ting. Guideline Idle mixture adjusting screw Open 1.5 turns –...

  • Page 78: Emptying The Carburetor Float Chamber

    TUNING THE ENGINE Info Following extreme air temperature or altitude changes, adjust the idle speed again. Emptying the carburetor float chamber 14.5 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 79 TUNING THE ENGINE – Clean gear teeth of the shift lever and shift shaft.  – Mount the shift lever on the shift shaft in the required position and engage the gearing. Info The range of adjustment is limited. The shift lever must not come into contact with any other vehicle compo- nents during the shift procedure.

  • Page 80: Service Work On The Engine

    SERVICE WORK ON THE ENGINE Checking the engine oil level 15.1 Info The engine oil level can be checked when the engine is cold or warm. – The motorcycle is positioned on a horizontal surface. Condition The engine is cold. –...
  • Page 81 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.

  • Page 82: 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. 114) Engine oil (SAE 10W/50) ( p. 114) 601324-10 – Position the upper oil filter cover. Mount and tighten screws ...
  • Page 83 SERVICE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventila- tion, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.

  • Page 84: Cleaning, Care

    CLEANING, CARE Cleaning motorcycle 16.1 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, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 85: Checks And Maintenance Steps For Winter Operation

    CLEANING, CARE Checks and maintenance steps for winter operation 16.2 Info If you use the motorcycle in winter, you must 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 86: 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. 37) – Cover the vehicle with an air-permeable cover or blanket.

  • Page 87: Technical Data - Engine

    TECHNICAL DATA - 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 88: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Jet, engine case breather On block Loctite 243™ ® Oil jet, cam lever lubrication 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling 4 Nm (3 lbf ft) Loctite 243™ ®...
  • Page 89 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Nut, cylinder head M10x1.25 Tightening sequence: Lubricated with engine oil Tighten in diagonal sequence. Tightening stage 1 10 Nm (7.4 lbf ft) Tightening stage 2 30 Nm (22.1 lbf ft) Tightening stage 3 50° –...

  • Page 90: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR 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 91: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Lattice frame of chromium-molybdenum steel tubes, powder- coated Suspension travel Front 300 mm (11.81 in) Rear 310 mm (12.2 in) Fork offset Mark 1 visible 20 mm (0.79 in) No mark 22 mm (0.87 in) Brake system Disc brakes, brake calipers on floating bearings Brake discs - diameter...

  • Page 92: 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 Capacity - fuel 21.3 Fuel tank capacity Fuel tank half, front left, 9.0 l (2.38 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 93: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7K.51 Fork WP Suspension Up Side Down 4860 MXMA CC Compression damping Standard 10 clicks Rebound damping Standard 20 clicks Spring length with preload spacer(s) 492 mm (19.37 in) Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 4.6 N/mm (26.3 lb/in) Weight of rider (standard): 75…...

  • Page 94: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7K.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 95: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Screw, license plate holder, bottom EJOT 3 Nm (2.2 lbf ft) – Screw, license plate lamp EJOT PT K50x18 T20 1.5 Nm (1.11 lbf ft) – Screw, tail light EJOT PT K60x20 2 Nm (1.5 lbf ft) –...
  • Page 96 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Screw, front fuel tank 8 Nm (5.9 lbf ft) – Screw, fuel tank bracket 15 Nm (11.1 lbf ft) – Screw, handlebar clamp 16 Nm (11.8 lbf ft) – Screw, license plate holder, top 20 Nm (14.8 lbf ft) –...

  • Page 98: Wiring Diagram

    WIRING DIAGRAM Page 1 of 9 25.1 ye-rd wh-rd ye-rd ye-rd ye-rd EM/3 EN/3 gn-rd ye-rd ye-rd ye-rd 601401-01...
  • Page 99 WIRING DIAGRAM Components: CDI controller Fuse Fuse Battery Alternator Starter relay with main fuse Starter motor Voltage regulator Ignition switch...

  • Page 100: Page 2 Of

    WIRING DIAGRAM Page 2 of 9 25.2 bl-rd bl-rd bl-rd bl-rd bl-rd gn-rd gn-rd gn-rd wh-bl wh-bl 601402-01...
  • Page 101 WIRING DIAGRAM Components: Radiator fan temperature switch Fuse Fuse Radiator fan...

  • Page 102: 100

    WIRING DIAGRAM Page 3 of 9 25.3 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 103 WIRING DIAGRAM Components: CDI controller Low beam Fuse Low beam relay Horn Light switch, horn button, kill switch...

  • Page 104: 102

    WIRING DIAGRAM Page 4 of 9 25.4 rd-bu rd-bu bu-or bu-or bu-rd 601404-01...
  • Page 105 WIRING DIAGRAM Components: High beam High beam relay High beam indicator light...

  • Page 106: 104

    WIRING DIAGRAM Page 5 of 9 25.5 DA/4 DB/4 CX/2 CW/2 601405-01...
  • Page 107 WIRING DIAGRAM Components: Wheel speed sensor, front Speedometer Parking light Tripmaster switch...

  • Page 108: 106

    WIRING DIAGRAM Page 6 of 9 25.6 ye-bu ye-bu ye-bu bl-gn ye-bu bl-gn 601406-01...
  • Page 109 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 110: 108

    WIRING DIAGRAM Page 7 of 9 25.7 gn-gr gn-gr gn-gr gn-gr bl-ye bl-ye bl-ye bl-ye bl-ye bl-ye 601407-01...
  • Page 111 WIRING DIAGRAM Components: Oil pressure sensor Temperature switch indicator lamp Temperature warning lamp Oil pressure warning lamp...

  • Page 112: 110

    WIRING DIAGRAM Page 8 of 9 25.8 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 113 WIRING DIAGRAM Components: Front brake light switch Rear brake light switch License plate lamp Fuse Fuse Brake/tail light...

  • Page 114: 112

    WIRING DIAGRAM Page 9 of 9 25.9 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 115 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 116: Substances

    – 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 – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 117 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1)

  • Page 118: 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 119 AUXILIARY SUBSTANCES Universal oil spray Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Synthetic...

  • Page 120: 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 121: Index

    INDEX Coolant INDEX draining ....... . . 72 Accessories ........4 refilling .
  • Page 122 INDEX Headlight Riding sag headlight range, adjusting ..... 70 adjusting ....... . . 33 Headlight setting Rubber grip checking .
  • Page 123 INDEX Transport ........4 Trim mounting .
  • Page 124 *3211726en* 3211726en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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