KTM 450 SMR Owner's Manual
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KTM 450 SMR Owner's Manual

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OWNER'S MANUAL
2009
450 SMR
ART. NO. 3211363en

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Summary of Contents for KTM 450 SMR

  • Page 1 OWNER'S MANUAL 2009 450 SMR ART. NO. 3211363en...
  • Page 3 KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors.

  • Page 4: Table Of Contents

    Adding front brake fluid ..........39 Important maintenance work to be carried out by an Checking the front brake linings........40 authorized KTM workshop. (as additional order)....19 Removing front brake linings ........40 Important checks and maintenance work to be carried Installing the front brake linings .........
  • Page 5 CONTENTS Removing a fuse............52 AUXILIARY SUBSTANCES..........84 Installing the fuse ............52 STANDARDS..............86 Ignition curve plug connection ........52 INDEX ................87 Changing the ignition curve ..........52 Removing the seat ............53 Mounting the seat ............53 Removing the fuel tank ..........

  • 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 done in an authorized KTM workshop! There, your motorcycle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 7: Important Notes

    Warranty The work prescribed in the service schedule must be carried out in an authorized KTM workshop and confirmed in the customer's ser- vice record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
  • Page 8 IMPORTANT NOTES Environment Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a poten- tial problem for the environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such problems and conflicts do not have to occur.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side 500257-10 Hand brake lever Fork compression adjustment Fork part number Fork rebound adjustment Oil filter cover Plug-in stand Shift lever Choke button Air filter Filler cap Clutch lever Hot start lever...

  • Page 10: View Of Vehicle, Rear Right Side

    VIEW OF VEHICLE View of vehicle, rear right side 500258-10 Short circuit button Shock absorber compression adjustment Shock absorber rebound adjustment Foot brake pedal Chassis number/type label Throttle grip...

  • Page 11: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the steering head on the right.  400193-10 Type label The type label is fixed to the front of the steering head.  400284-10 Engine number The engine number is stamped on the left side of the engine under the engine ...

  • 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. 500259-10 Hot start lever The hot start lever is fitted on the left side of the handlebar. ...

  • Page 13: Fuel Tap

    CONTROLS Fuel tap With the tap handle on the fuel tap, you can open or close the supply of fuel to the  carburetor. Possible states Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. •...

  • Page 14: Shift Lever

    CONTROLS Shift lever 5.10 The shift lever is mounted on the left side of the engine.  400204-12 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 400204-11 Foot brake pedal 5.11 Foot brake pedal...

  • Page 15: General Tips And Hints On Putting Into Operation

    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 16: Running In The Engine

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – Run the engine in. Running in the engine – During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline Maximum engine speed During the first 3 service hours 7,000 rpm Maximum engine performance ≤...

  • Page 17: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level.

  • Page 18: Starting Up

    Do not change into a low gear at high engine speed. The engine races and the rear wheel can block. 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 19: Refueling

    RIDING INSTRUCTIONS Note Fire hazard Some vehicle components get very hot when the machine is driven. – Do not place the vehicle where there are flammable or explosive substances. Do not place objects over the vehicle while it is still warm from being run. Always let the vehicle cool first. –...

  • Page 20: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. S10A S30A Engine • • • Change the engine oil and oil filter, and clean the oil screen. p. 64) Replace spark plug. • Check and adjust valve clearance.

  • Page 21: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) S10A S20A S40A • • Carry out a complete fork service. Carry out a complete shock absorber service. • Grease the steering head bearing.
  • Page 22 SERVICE SCHEDULE NB1A Checking the tire air pressure. ( p. 49) • Check the tire condition. ( p. 49) • Check the coolant level. ( p. 55) • Empty the carburetor float chamber. p. 63) • Check that all operating elements for smooth operation. •...

  • Page 23: Maintenance Work On Chassis And Engine

    For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swing arm and frame, the basic settings of the suspension components must match your body weight. As delivered, KTM motorcycles are adjusted for a standard rider weight (with full protective clothing). Standard rider weight 75…...

  • Page 24: Adjusting The Low-Speed Compression Damping Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Standard 1.5 turns Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping. Adjusting the low-speed compression damping of the shock absorber Danger Danger of accidents The shock absorber is under high pressure.

  • Page 25: Measuring Rear Wheel Sag Unloaded

    MAINTENANCE WORK ON CHASSIS AND ENGINE Measuring rear wheel sag unloaded – Jack up the motorcycle. ( p. 21) – Measure the distance – as vertical as possible – between the rear axle and a fixed point, for example, a mark on the side cover. –...

  • Page 26: Adjusting The Spring Preload Of The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the spring preload of the shock absorber 9.11 Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself.

  • Page 27: Removing The Shock Absorber

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the shock absorber 9.13 – Jack up the motorcycle. ( p. 21) – Remove screw and lower the rear wheel with the swing arm as far as possible  without blocking the rear wheel. Fix the rear wheel in this position. –...

  • Page 28: Adjusting The Rebound Damping Of The Fork

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Turn adjusting screws clockwise until they stop.  Info The adjusting screws are located at the top end of the fork legs.  Make the same adjustment on both fork legs. – Turn back counterclockwise by the number of clicks corresponding to the fork type. Guideline Compression damping 500262-10...

  • Page 29: Cleaning Dust Boots Of Fork Legs

    Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play. – The steering head bearing play should be adjusted immediately in an authorized KTM workshop. Info If the bike is driven for a longer time with play in the steering head bearing, the bearing and the bearing seats in the frame can be damaged after time.

  • Page 30: Adjusting Play Of Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE – 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. » If there is noticeable play present: –...

  • Page 31: Adjusting The Fork Offset

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the fork offset 9.25 – Remove the lower triple clamp. p. 30) – Remove screw . Remove the steering stem.  – Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten screw ...

  • Page 32: Removing The Lower Triple Clamp

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the brake line. Put the clamp on, and mount and tighten screws  – Install the front wheel. p. 47) 500200-13 Removing the lower triple clamp 9.28 – Remove the fork legs. p.

  • Page 33: Greasing The Steering Head Bearing

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the upper triple clamp with the steering. – Mount and tighten screw  Guideline Screw, top steering head M20x1.5 10 Nm (7.4 lbf ft) – Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws ...

  • Page 34: Dismount The Start Number Plate

    MAINTENANCE WORK ON CHASSIS AND ENGINE Dismount the start number plate 9.33 – Remove screw and take off clamp.  – Remove screw . Remove the start number plate.  500191-10 Installing the start number plate 9.34 – Position the start number plate. Mount and tighten screw ...

  • Page 35: Checking Gas Bowden Cable Route

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Position the handlebar clamp. Fit and evenly tighten the four screws  Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Checking gas Bowden cable route 9.37 – The two gas Bowden cables must run parallel behind the handlebar down to the frame.

  • Page 36: Checking For Chain Dirt Accumulation

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking for chain dirt accumulation 9.40 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 34) 400549-10 Cleaning the chain 9.41 Warning Danger of accidents Oil or grease on the tires reduces their grip.

  • Page 37: Checking The Chain Tension When Fitting Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension when fitting rear wheel 9.43 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 38: Adjusting The Chain Tension

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain tension 9.46 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 39: Adjusting Chain Tension - After Checking

    MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting chain tension - after checking 9.47 – Loosen nut  – Loosen nuts  – Adjust the chain tension by turning the adjusting screws left and right.  Guideline Chain tension 8… 10 mm (0.31… 0.39 in) Turn the adjusting screws left and right so that the markings on the left and ...

  • Page 40: Adjusting Chain Guide

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

  • Page 41: Adjusting The Basic Position Of The Handbrake Lever

    Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 42: Checking The Front Brake Linings

    Change the front brake linings. p. 42) 500202-10 Removing front brake linings 9.56 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Remove locking split pins  500203-11...

  • Page 43: Installing The Front Brake Linings

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

  • Page 44: Changing The Front Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 45: Adjusting Basic Position Of Footbrake Lever

    Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop.

  • Page 46: Adding Brake Fluid For The Rear Brake

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 47: Removing Rear Brake Linings

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

  • Page 48: Changing The Rear Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 49: Installing The Front Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Always lay the wheel down in such a way that the brake disc is not dam- aged.

  • Page 50: Removing Rear Wheel

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. – Remove the motorcycle from the work stand. ( p. 21) – Pull the front wheel brake and push down hard on the fork several times to align the fork legs.

  • Page 51: Checking The Tire Condition

    9.71 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 52: Checking Spoke Tension

    Danger of accidents Unstable riding behavior due to loose spokes. – If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose spokes in a short time.

  • Page 53: Recharging The Battery

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Mount the seat. ( p. 53) Recharging the battery 9.76 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. –...

  • Page 54: Removing A Fuse

     Replace a burned-out fuse only by an equivalent fuse.  If the new fuse burns out, contact an authorized KTM workshop. – Replace the protection cover. 400273-10 – Install the air filter box lid. ( p.

  • Page 55: Removing The Seat

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat 9.81 – Remove screw . Lift up the seat at the rear, pull it back and then remove from  above. 500080-10 Mounting the seat 9.82 – Hook in the front of the seat at the collar sleeve of the fuel tank, lower it at the rear and simultaneously push it forward.

  • Page 56: Installing The Fuel Tank

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull both spoilers to the side of the radiator bracket and lift the fuel tank off.  500220-10 Installing the fuel tank 9.84 Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.

  • Page 57: Cooling System

    MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system 9.85 The water pump in the engine forces the coolant to flow.  The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap .

  • Page 58: Draining The Coolant

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Stand the motorcycle upright on a horizontal surface. – Remove the radiator cap. – Check the coolant level in the radiator. Coolant level above radiator fins. 10 mm (0.39 in)  » If the level of the cooling liquid does not meet specifications: –...

  • Page 59: Removing Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Removing main silencer 9.90 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. – Disconnect spring ...

  • Page 60: Installing The Glass Fiber Yarn Filling Of The Main Silencer

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the glass fiber yarn filling of the main silencer 9.94 – Attach the glass fiber yarn filling to inner tube . Mount the inner tube in outer  tube  – Mount connecting cap .

  • Page 61: Installing The Air Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter 9.99 – Mount a clean air filter. Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. – Position and tighten hose clamp ...

  • Page 62: Antihopping Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE Antihopping clutch 9.102 The antihopping system reduces the force required to activate the clutch and improves clutch handling; in addition, it increases riding stability by reducing slippage of the rear wheel by means of engine braking action during downshifting. 500276-01 The antihopping system uses a two-part inner clutch hub that is connected to a helical gear.

  • Page 63: Checking The Fluid Level Of Hydraulic Clutch

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Remove screw together with the spring retainer and the clutch spring.  Info Do not remove all screws at once! – Remove or add the desired washer. Mount and tighten screw together with the ...

  • Page 64: Changing The Hydraulic Clutch Fluid

    MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the hydraulic clutch fluid 9.105 Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 65: Emptying The Carburetor Float Chamber

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Adjust the idle speed with the adjusting screw  Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 11) Idle speed 1,600… 1,650 rpm – Turn the idle adjusting screw slowly until the idle speed begins to fall.

  • Page 66: Checking Engine Oil Level

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from ...

  • Page 67: Cleaning The Oil Screen

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Place a suitable container under the engine. – Remove oil drain plug with the seal ring.  – Completely drain the engine oil. – Thoroughly clean the oil drain plug with the magnet. –...

  • Page 68: Installing The Oil Filter

    MAINTENANCE WORK ON CHASSIS AND ENGINE – Pull the oil filter insert out of the oil filter casing.  Circlip pliers reverse (51012011000) – Completely drain the engine oil. – Thoroughly clean parts and sealing area. 400263-10 Installing the oil filter 9.114 –...

  • Page 69: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – The engine cannot be cranked (elec- Operating error Go through the steps of starting the engine. tric starter) p. 15) – Battery discharged Recharge the battery. p. 51) – Check the charging voltage. – Check the closed current.
  • Page 70 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power. Fuel feed interrupted Check the fuel tank breather. – Clean the fuel tap. – Check/set the carburetor components. – Air filter very dirty Clean the air filter. p. 59) –...

  • Page 71: Cleaning

    CLEANING Cleaning motorcycle 11.1 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, plug connectors, Bowden cables and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 72: Storage

    Storage temperature of battery without direct sunlight. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature fluctuations. Info KTM recommends jacking up the motorcycle. – Jack up the motorcycle. ( p. 21) –...

  • Page 73: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cyliner 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 1,600… 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 74: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Engine housing vent jet 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™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 75 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 76: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 41 Carburetor identfication number 4125I Needle position 4th position from top Idle mixture adjusting screw Open 1.5 turns Pump membrane stop 2.15 mm (0.0846 in) Hot start button Diameter of bore in carburetor body 2.5 mm (0.098 in) Main jet Jet needle...

  • Page 77: Technical Data - Chassis

    Nominal capacity: 3 Ah maintenance-free 4Ah battery YTX5L-BS Battery voltage: 12 V Nominal capacity: 4 Ah maintenance-free Front tire Rear tire 125/80 R 420 TL 170/55 R 17 TL Dunlop KR106 Dunlop KR108 Additional information is available in the Service section under: http://www.ktm.com...

  • Page 78: Capacity - Fuel

    TECHNICAL DATA - CHASSIS Capacity - fuel 16.1 Total fuel tank capacity, 8.2 l (2.17 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p. 83) approx.

  • Page 79: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7E.18 Fork WP Suspension 4860 MXMA CC Compression damping Standard 15 clicks Rebound damping Standard 15 clicks Spring length with preload spacer(s) 482 mm (18.98 in) Spring rate Weight of rider: 75… 85 kg (165… 187 lb.) 4.8 N/mm (27.4 lb/in) Weight of rider: 85…...

  • Page 80: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber WP Suspension PDS 5018 DCC Compression damping, low-speed Standard 10 clicks Compression damping, high-speed Standard 1.5 turns Rebound damping Standard 20 clicks Spring preload 11 mm (0.43 in) Spring rate Weight of rider: 75… 85 kg (165… 187 lb.) 80 N/mm (457 lb/in) Spring length 250 mm (9.84 in)

  • Page 81: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Spoke nipple, front wheel M4.5 5 Nm (3.7 lbf ft) – Spoke nipple, rear wheel 5 Nm (3.7 lbf ft) – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) –...

  • Page 82: Wiring Diagram

    WIRING DIAGRAM Wiring diagram 20.1 yellow-black blue-white brown yellow-black green blue blue yellow yellow black black red-white red-white white black-white grey-black grey brown black yellow black yellow red-white red-white black-white 400277-10...
  • Page 83 WIRING DIAGRAM Components Battery Generator Ignition coil Pulse generator Voltage regulator/rectifier Electric starter button Starter relay Starter motor Short circuit button Throttle position sensor Ignition curve plug connection CDI controller Cable colors black Black black-white Black-white brown Brown brown-white Brown-white blue Blue blue-white...

  • Page 84: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (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 85 SUBSTANCES Supplier ® Motorex – Hydraulic Fluid 75 Shock absorber oil (SAE 2.5) (50180342S1) According to – SAE ( p. 86) (SAE 2.5) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
  • Page 86 AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Air filter oil Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Air Filter Oil Spray 655...
  • Page 87 AUXILIARY SUBSTANCES Offroad chain spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Lube 622 Universal oil spray Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Joker 440 Universal...
  • Page 88 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 89 INDEX changing fluid ......62 INDEX checking fluid level ......61 Accessories .
  • Page 90 INDEX Front wheel Putting into operation Installing ....... . . 47 Advice on first use .
  • Page 91 INDEX Transport ........5 Troubleshooting ......67-68 Type label .
  • Page 92 *3211363en* 3211363en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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