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

KTM 450 SMR Owner's Manual

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OWNER'S MANUAL
2013
450 SMR
Art. no. 3211866en

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Summary of Contents for KTM 450 SMR

  • Page 1 OWNER'S MANUAL 2013 450 SMR Art. no. 3211866en...
  • 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

    TABLE OF CONTENTS 10.2 Compression damping of the shock absorber..23 TABLE OF CONTENTS MEANS OF REPRESENTATION ........4 10.3 Adjusting the low-speed compression damping Symbols used ........... 4 of the shock absorber ........23 Formats used............ 4 10.4 Adjusting the high-speed compression SAFETY ADVICE............
  • Page 5 TABLE OF CONTENTS 18 CLEANING, CARE ............79 11.40 Checking the swingarm ....... 49 18.1 Cleaning the motorcycle ........79 11.41 Checking the throttle cable routing ....49 11.42 Checking the rubber grip ......... 49 19 STORAGE ..............80 11.43 Additionally securing the rubber grip....50 19.1 Storage ............

  • 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: Protective Clothing

    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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.

  • Page 10: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left (example) L00097-10 Hand brake lever ( p. 11) Clutch lever ( p. 11) Filler cap Plug-in stand ( p. 14) Air filter box lid Engine number ( p. 10) Shift lever ( p.

  • Page 11: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE View of vehicle, rear right (example) L00098-10 Kill switch ( p. 11) Electric starter button ( p. 11) Fork compression adjustment Fork rebound adjustment Foot brake lever ( p. 14) Level viewer, engine oil Shock absorber compression adjustment Level viewer for brake fluid, rear Shock absorber rebound adjustment...

  • Page 12: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the steering head. L00099-10 Type label The type label is fixed to the front of the steering head. L00099-11 Engine number The engine number is stamped on the left side of the engine under the engine sprocket.

  • Page 13: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. L00162-10 Hand brake lever Hand brake lever is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. L00163-10 Throttle grip The throttle grip...

  • Page 14: Overview Of Indicator Lamps

    CONTROLS Overview of indicator lamps Possible states FI warning lamp (MIL) lights up/flashes orange – The OBD (on-board diagnosis) has detected an emission- or safety-critical error. L00105-10 Opening the filler cap 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 15: Cold Start Button

    CONTROLS Cold start button The cold start button is fitted on the left on the throttle valve body. The injection system extends the injection time if the engine is cold and the outside temperature is low. The engine can only burn the increased fuel quantity if it receives more air.

  • Page 16: Foot Brake Lever

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 601839-10 6.12 Foot brake lever Foot brake lever is located in front of the right footrest. The foot brake lever is used to activate the rear brake. 601840-10 6.13 Plug-in stand...

  • Page 17: 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 18: Running In The Engine

    PREPARING FOR USE Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load 145 kg (320 lb.) Maximum permissible rear axle load 190 kg (419 lb.) – Run in the engine. ( p. 16) Running in the engine –...

  • Page 19: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance work when preparing for use Info Before riding the vehicle, always check its condition and operating safety. The vehicle must be in perfect technical condition when used. – Check the engine oil level. ( p. 75) –...

  • Page 20: 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 21: Transport

    – In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.) – Only refuel with clean fuel that meets the specified standards.
  • Page 22 RIDING INSTRUCTIONS – Switch off the engine. – Open the filler cap. ( p. 12) – Fill the fuel tank with fuel up to measurement Guideline Measurement of 35 mm (1.38 in) Total fuel tank 7.5 l Super unleaded (ROZ 95/RON 95/PON capacity, approx.

  • Page 23: Service Schedule

    • • • • • • Read out the fault memory using the KTM diagnostics tool after a test ride. Make the service entry in KTM DEALER.NET and in the service record. • • • • S1N: Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal) S10A: Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race...

  • Page 24: Service Work (As Additional Order)

    SERVICE SCHEDULE Service work (as additional order) S20N S40A S50A S100A Change the front brake fluid. • Change the rear brake fluid. • Change the hydraulic clutch fluid. p. 50) • Grease the steering head bearing. p. 36) • Service the shock absorber. •...

  • Page 25: 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 low-speed setting can be seen during the slow to normal compression of the shock absorber.

  • Page 26: Adjusting The High-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 high-speed setting can be seen during the fast compression of the shock absorber.

  • Page 27: Measuring Rear Wheel Sag Unloaded

    TUNING THE CHASSIS 10.6 Measuring rear wheel sag unloaded Preparatory work – Raise the motorcycle with the lift stand. ( p. 30) Main work – Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover.

  • Page 28: Adjusting The Spring Preload 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 29: Checking The Basic Setting Of The Fork

    TUNING THE CHASSIS Info The spring rate is shown on the outside of the spring. Finishing work – Install the shock absorber. p. 38) – Install the main silencer. ( p. 41) – Check the static sag of the shock absorber. ( p.

  • Page 30: Adjusting The Rebound Damping Of The Fork

    TUNING THE CHASSIS 10.13 Adjusting the rebound damping of the fork Info The hydraulic rebound damping determines the fork suspension behavior. – Remove protection caps – Turn adjusting screws clockwise all the way. Info Adjusting screws are located at the bottom end of the fork legs. Make the same adjustment on both fork legs.
  • Page 31 TUNING THE CHASSIS – Position the handlebar clamps. Fit and evenly tighten the four screws Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft)

  • Page 32: Service Work On The Chassis

    SERVICE WORK ON THE CHASSIS 11.1 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. The wheels must no longer touch the ground.

  • Page 33: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with the lift stand. ( p. 30) – Remove the fork protector. ( p. 32) Main work – Push dust boots of both fork legs downward.

  • Page 34: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11.6 Installing the fork legs Main work – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 35: Removing The Lower Triple Clamp

    SERVICE WORK ON THE CHASSIS 11.9 Removing the lower triple clamp Preparatory work – Raise the motorcycle with the lift stand. ( p. 30) – Remove the front wheel. p. 60) – Remove the fork legs. p. 31) – Remove the start number plate. ( p.
  • Page 36 SERVICE WORK ON THE CHASSIS – Position the fork legs. Info Grooves are milled into the side of the upper end of the fork legs. The sec- ond milled groove (from the top) must be flush with the top edge of the upper triple clamp.

  • Page 37: 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 38: Greasing The Steering Head Bearing

    SERVICE WORK ON THE CHASSIS Finishing work – Mount the handlebar cushion. – Remove the motorcycle from the lift stand. ( p. 30) 11.13 Greasing the steering head bearing – Remove the lower triple clamp. p. 33) – Install the lower triple clamp. p.

  • Page 39: Installing The Front Fender

    SERVICE WORK ON THE CHASSIS 11.17 Installing the front fender – Ensure that the spacers are mounted in the fender. – Position the front fender. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Make sure the holding lugs engage in the start number plate. L00123-10 11.18 Removing the shock absorber...

  • Page 40: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11.19 Installing the shock absorber Main work – Insert the shock absorber from above. – Turn the shock absorber toward the rear and position the manifold. – Position the shock absorber. – Mount and tighten screw Guideline Screw, top shock absorber 60 Nm...

  • Page 41: Removing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS 11.22 Removing the air filter box lid Condition The air filter box lid is secured. – Remove screws L00132-10 – Pull off the air filter box lid in area sideways and remove it toward the front. L00132-11 11.23 Installing the air filter box lid...

  • Page 42: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS Main work – Detach air filter holder at the bottom and swing it to one side. Remove the air filter with the air filter support. – Remove the air filter from the air filter support. L00133-10 11.25 Installing the air filter...

  • Page 43: Securing The Air Filter Box Lid

    SERVICE WORK ON THE CHASSIS – Clean the intake flange and check it for damage and tightness. Finishing work – Install the air filter. p. 40) – Install the air filter box lid. ( p. 39) 11.27 Securing the air filter box lid Preparatory work –...

  • Page 44: Changing The Glass Fiber Yarn Filling Of The Main Silencer

    SERVICE WORK ON THE CHASSIS 11.30 Changing the glass fiber yarn filling of 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. Info Over time, the fibers of the glass fiber yarn escape and the damper "burns"...

  • Page 45: Installing The Fuel Tank

    SERVICE WORK ON THE CHASSIS Main work – Disconnect electric plug-in connection of the fuel pump. – Thoroughly clean the plug-in connection of the fuel line using compressed air. Info Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve.

  • Page 46: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately.

  • Page 47: Cleaning The Chain

    SERVICE WORK ON THE CHASSIS 11.34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip. – Remove oil and grease with a suitable cleaning material. Warning Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs. –...

  • Page 48: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11.36 Adjusting the chain tension 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 49 SERVICE WORK ON THE CHASSIS – Pull on the upper part of the chain with the specified weight Guideline Weight, chain wear measurement 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the lower chain section. Info Chain wear is not always even, so you should repeat this measurement at different chain positions.

  • Page 50: Adjusting The Chain Guide

    SERVICE WORK ON THE CHASSIS – Check the chain guide for wear. Info Wear is visible on the front of the chain guide. » If the light part of the chain guide is worn: – Change the chain guide. 400985-01 –...

  • Page 51: Checking The Frame

    If the frame exhibits cracking 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. 401519-01 11.40 Checking the swingarm –...

  • Page 52: Additionally Securing The Rubber Grip

    SERVICE WORK ON THE CHASSIS 11.43 Additionally securing the rubber grip Preparatory work – Check the rubber grip. ( p. 49) Main work – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rub- ber grip.
  • Page 53 SERVICE WORK ON THE CHASSIS – Fill bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Brake fluid DOT 4 / DOT 5.1 ( p. 90) – On the clutch slave cylinder, remove bleeder screw and mount bleeding syringe C00163-10 –...

  • Page 54: 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 disk...

  • Page 55: Checking The Brake Fluid Level Of The Front Brake

    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 56: 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 Environmental hazard Hazardous substances cause environmental damage.
  • Page 57 BRAKE SYSTEM – Press the spring hanger of the spring forward and pull out pin – Take off springs . Remove the brake linings. B00867-11 – Remove screws with washers and take off the brake caliper. – Clean the brake caliper. B00866-10 –...

  • Page 58: Checking The Free Travel Of Foot Brake Lever

    BRAKE SYSTEM – Remove the fixation of the hand brake lever. 12.8 Checking the free travel of foot brake lever Warning Danger of accidents Brake system failure. – If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating.

  • Page 59: 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 60: 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 Environmental hazard Hazardous substances cause environmental damage.
  • Page 61 BRAKE SYSTEM – Manually press the brake caliper to the brake disc to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir, extracting it by suction if it does. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 62: Wheels, Tires

    WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with the lift stand. ( p. 30) Main work – Remove screw – Loosen screw L00135-10 – Remove screws with washers and take off the brake caliper. Info Do not pull the hand brake lever when the brake caliper is removed.

  • Page 63: Removing The Rear Wheel

    WHEELS, TIRES – Lift the front wheel into the fork, position it, and insert the wheel spindle. – Mount and tighten screw Guideline Screw, front wheel spindle M24x1.5 45 Nm (33.2 lbf ft) L00135-11 – Position the brake caliper. Mount screws with washers but do not tighten yet.

  • Page 64: Installing The Rear Wheel

    WHEELS, TIRES – Remove spacers L00152-10 13.4 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 65: Checking The Tire Condition

    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 66 WHEELS, TIRES – Briefly strike each spoke with the tip of a screwdriver. Info The tone frequency depends on the length of the spoke and the spoke diam- eter. If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.

  • Page 67: Electrical System

    ELECTRICAL SYSTEM 14.1 Removing the battery 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. – Avoid contact with battery acid and battery gases. –...

  • Page 68: Changing The Main Fuse

    – 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. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 69 ELECTRICAL SYSTEM Main work – Remove screw L00133-12 – Lift rear fairing slightly and pull starter relay out of the holder. 101088-10 – Remove protection caps – Remove the faulty main fuse Info A defective fuse can be identified by the burned-out fuse wire A reserve fuse is located in the starter relay.

  • Page 70: Cooling System

    COOLING SYSTEM 15.1 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 71: 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 radiator fins. 10 mm (0.39 in) » If the coolant level does not meet specifications: –...

  • Page 72: Refilling Coolant

    COOLING SYSTEM 15.5 Refilling coolant Warning Danger of poisoning Coolant is poisonous and a health hazard. – Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immedi- ately.

  • Page 73: Tuning The Engine

    TUNING THE ENGINE 16.1 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 74: Adjusting The Idle Speed

    TUNING THE ENGINE 16.3 Adjusting the idle speed – Run the engine until warm. – Set the desired idle speed by turning the idle speed adjusting screw Guideline Idle speed 2,250… 2,350 rpm Tachometer (45129075000) Info Turn counterclockwise to decrease the idle speed. Turn clockwise to increase the idle speed.

  • Page 75: Antihopping Clutch

    TUNING THE ENGINE 16.6 Antihopping clutch 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. L00160-11 The antihopping system uses a two-part inner clutch hub that is connected to a helical gear.
  • Page 76 TUNING THE ENGINE – Only ever remove one of screws and add or remove the desired washers. Guideline Screw, clutch spring retainer 8 Nm (5.9 lbf ft) Info The spring preload must be the same on all screws. L00164-10 – Position the outer clutch cover.

  • Page 77: Service Work On The Engine

    SERVICE WORK ON THE ENGINE 17.1 Changing the fuel screen 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 78: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screens

    SERVICE WORK ON THE ENGINE 17.3 Changing the engine oil and oil filter, cleaning the oil screens Warning Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden. – Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 79 SERVICE WORK ON THE ENGINE – Push the engine oil screen with the O-rings onto a pin wrench. – Push the pin wrench through the opening into the drill hole of the opposite engine case wall and push the engine oil screen as far as possible into the engine case. C00236-10 –...

  • Page 80: Adding Engine Oil

    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 81: Cleaning, Care

    CLEANING, CARE 18.1 Cleaning the 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 82: Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. Info KTM recommends raising the motorcycle. – Raise the motorcycle with the lift stand. ( p. 30) – Cover the vehicle with a tarp or a cover that is permeable to air.

  • Page 83: Troubleshooting

    – Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool. – Engine does not speed up Defect in fuel injection system Read out the fault memory using the KTM diag- nostics tool.
  • Page 84 TROUBLESHOOTING Faults Possible cause Action – High oil consumption Piston and cylinder worn Piston/cylinder - determine the mounting clear- ance. – Battery is discharged Battery is not charging Check the charging voltage. – Check the stator winding of the alternator. –...

  • Page 85: Blink Code

    BLINK CODE Blink code FI warning lamp (MIL) 02 FI warning lamp (MIL) flashes 2x short Error level condition Crankshaft position sensor - circuit fault Blink code FI warning lamp (MIL) 06 FI warning lamp (MIL) flashes 6x short Error level condition Throttle position sensor circuit A - input signal too low Throttle position sensor circuit A - input signal too high Blink code FI warning lamp (MIL)

  • Page 86: Technical Data

    TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.3 cm³ (27.418 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.6:1 Idle speed 2,250… 2,350 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 87: Capacities

    TECHNICAL DATA ® Screw, bearing bolt for starter idler 10 Nm (7.4 lbf ft) Loctite 243™ gear ® Screw, bearing bolt, torque limiter 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, camshaft support plate 10 Nm (7.4 lbf ft) Loctite 243™...

  • Page 88: Fuel

    TECHNICAL DATA 22.3.3 Fuel Total fuel tank capacity, 7.5 l (1.98 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p. 91) approx. 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP Suspension Up Side Down 4860 MXMA CC Suspension travel Front 280 mm (11.02 in)

  • Page 89: Tires

    165/55 R 17 M/C TT Metzeler Racetec SM 17 125/80 R 17 M/C NHS TL ‑ K1 Metzeler Racetec SM 17 165/55 R 17 M/C NHS TL ‑ K1 Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork part number 14.18.7M.08...

  • Page 90: Chassis Tightening Torques

    TECHNICAL DATA Riding sag 75 mm (2.95 in) Fitted length 479 mm (18.86 in) Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 90) 22.9 Chassis tightening torques – Screw, air filter box lid EJOT PT ® K60x20-Z 3 Nm (2.2 lbf ft) –...
  • Page 91 TECHNICAL DATA – Nut, rear wheel spindle M25x1.5 80 Nm (59 lbf ft)

  • Page 92: 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 93 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 94: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Dirt Bio Remover Chain cleaner Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 95 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – KTM recommends Motorex ® products. Supplier Motorex ® – Twin Air Liquid Bio Power Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – KTM recommends Motorex ®...

  • Page 96: 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 97: Index

    INDEX Clutch ........73 INDEX adjusting .
  • Page 98 INDEX Front fender Preparing for use installing ....... . . 37 advice on first use .
  • Page 99 INDEX Swingarm checking ....... . . 49 Technical data capacities ....... . 85 chassis .
  • Page 100 *3211866en* 3211866en 07/2012 KTM-Sportmotorcycle AG 5230 Mattighofen/Austria Photo: Mitterbauer/KTM http://www.ktm.com...

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