KTM 450 SXS-F Owner's Manual
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KTM 450 SXS-F Owner's Manual

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OWNER'S MANUAL
2008
450 SXS-F
ART. NO. 3211253en

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Summary of Contents for KTM 450 SXS-F

  • Page 1 OWNER'S MANUAL 2008 450 SXS-F ART. NO. 3211253en...
  • 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

    Checking brake discs ............. 40 Important maintenance work to be carried out by an Checking free play of hand brake lever......41 authorized KTM workshop. (as additional order)....19 Adjusting basic position of handbrake lever...... 41 Important checks and maintenance work to be carried Checking the front brake fluid level .........
  • Page 5 CONTENTS AUXILIARY SUBSTANCES..........84 Removing the battery ..........52 STANDARDS..............86 Installing the battery ..........52 INDEX ................87 Recharging the battery ..........53 Removing a fuse............54 Replacing the fuse............54 Ignition curve plug connection ........55 Changing the ignition curve ..........55 Removing the seat ............

  • 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

    You should use the fuels, oils and greases according to specifications as listed in the owner's manual. Spare parts, accessories For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 8 IMPORTANT NOTES Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death. Warning Danger that will probably lead to severe and permanent injury or death. Note Danger of serious damage to machine or material. Warning Risk of environmental damage.

  • Page 9: View Of Vehicle

    VIEW OF VEHICLE View of vehicle, front left side 200393-10 Hand brake lever Start number plate Front fender Front wheel Fork part number Oil filter cover Plug-in stand Shift lever Choke button Air filter Filler cap Clutch lever...

  • Page 10: View Of Vehicle, Rear Right Side

    VIEW OF VEHICLE View of vehicle, rear right side 200394-10 Main silencer Shock absorber Brake caliper of rear brake Rear wheel Foot brake pedal Manifold 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 sprocket.

  • Page 12: Operating Elements

    OPERATING ELEMENTS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. 400195-10 Hot start lever The hot start lever is fitted on the left side of the handlebar. If you pull the hot start lever to the handlebar during the start procedure, a bore is opened in the carburetor through which the engine can draw in extra air.

  • Page 13: Fuel Tap

    OPERATING ELEMENTS 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

    OPERATING ELEMENTS Shift lever 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. 400204-10 Foot brake pedal The foot brake pedal is located in front of the right footrest and operates the rear wheel brake.

  • Page 15: Tips 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

    TIPS ON PUTTING INTO OPERATION If you carry any baggage, make sure it is fixed firmly as close as possible to the center of the vehicle and ensure even weight dis- tribution between the front and rear wheels. Info Motorcycles react sensitively to any changes of weight distribution. Do not exceed the overall maximum permitted weight and the axle loads.

  • 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. ( P.

  • 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: Stopping, Parking

    RIDING INSTRUCTIONS Stopping, parking Warning Danger of burns Some vehicle components get very hot when the machine is driven. Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these compo- nents to cool down before starting work on them. Note Danger of damage Danger of damage by the vehicle running away or falling over.

  • Page 20: Greasing And Service Table

    GREASING AND SERVICE TABLE 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. 65) • • • Replace spark plug. •...

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

    GREASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) S10A S20N S40N Carry out a complete fork service. • • Carry out a complete shock absorber service. • • •...
  • Page 22 GREASING AND SERVICE TABLE NB1A Check the coolant level. ( P. 58) • Empty the carburetor float chamber. P. 64) • Check that all operating elements for smooth operation. • Check braking. • Check all screws, nuts and hose clamps regularly for tightness. •...

  • Page 23: Maintenance 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 ON CHASSIS AND ENGINE Turn back counterclockwise the number of turns corresponding to the shock absorber type. Specification Compression damping, high-speed Comfort 23 turns Standard 20 turns Sport 20 turns Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.

  • Page 25: Measuring Rear Wheel Sag Unloaded

    MAINTENANCE ON CHASSIS AND ENGINE Turn back counterclockwise the number of clicks corresponding to the shock absorber type. Specification Rebound damping Comfort 26 clicks Standard 24 clicks Sport 22 clicks Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.

  • Page 26: Checking Riding Sag Of Shock Absorber

    MAINTENANCE ON CHASSIS AND ENGINE Checking riding sag of shock absorber Measure distance of rear wheel unloaded. ( P. 23) With another person holding the motorcycle, sit on the saddle with full protective clothing in a normal sitting position (feet on footrests) and bounce up and down a few times until the rear suspension levels out.

  • Page 27: Adjusting Riding Sag

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting riding sag Remove shock absorber. P. 25) After removing the shock absorber, clean it thoroughly. Choose and fit a suitable spring. Specification Spring rate Weight of rider: 65… 75 kg (143… 165 lb.) 72 N/mm (411 lb/in) Weight of rider: 75…...

  • Page 28: Checking Basic Setting Of Fork

    MAINTENANCE ON CHASSIS AND ENGINE Checking basic setting of fork Info For various reasons, no exact riding sag can be determined for the forks. As with the shock absorber, smaller weight differences can be compensated by the spring preload. However, if your fork is often overloaded (hard end stop on compression), you must fit harder springs to avoid damage to the fork and frame.

  • Page 29: Bleeding Fork Legs

    MAINTENANCE ON CHASSIS AND ENGINE Bleeding fork legs Jack up the motorcycle. ( P. 21) Remove bleeder screws briefly. Any excess pressure escapes from the interior of the fork. Info Do not remove screws Mount and tighten bleeder screws. Remove the motorcycle from the work stand. ( P.

  • Page 30: Checking Play Of Steering Head Bearing

    Warning 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 31: Fork Offset

    MAINTENANCE ON CHASSIS AND ENGINE Fork offset You can see the offset by markings on the upper triple clamp. The fork offset has an impact on the handling of the vehicle. It is calculated from the center of the fork leg to the center of the steering head bearing. The fork offset can optionally be adjusted.

  • Page 32: Removing The Fork Legs

    MAINTENANCE ON CHASSIS AND ENGINE Turn the steering stem with the nut another half turn clockwise. 200388-10 Push the lower triple clamp upwards. Mount and tighten screws Specification ® Screw, steering stem, bot- 20 Nm Loctite 243™ (14.8 lbf ft) Mount and tighten screws Specification Screw, bottom triple clamp...

  • Page 33: Installing The Fork Legs

    MAINTENANCE ON CHASSIS AND ENGINE Loosen screw . Remove the fork leg on the left. Loosen screw . Remove the fork leg on the right. 200369-10 Installing the fork legs Check parts for damage and wear. Replace damaged or worn parts. Position the fork legs.

  • Page 34: Installing The Fork Protector

    MAINTENANCE ON CHASSIS AND ENGINE Installing the fork protector Check parts for damage and wear. Replace damaged or worn parts. Position the fork protection on the left fork leg. Mount and tighten screws Specification Remaining screws, chassis 10 Nm (7.4 lbf ft) Position the fork protection on the right fork leg.

  • Page 35: Greasing The Steering Head Bearing

    MAINTENANCE ON CHASSIS AND ENGINE Position the upper triple clamp with the steering. Mount and tighten nut Specification Nut, upper steering head M20x1 15 Nm (11.1 lbf ft) Hold nut and tighten screw Specification Screw, top steering head M20x1 10 Nm (7.4 lbf ft) 200391-10 Position the clutch line, wiring harness and CDI control unit.

  • Page 36: Dismount The Start Number Plate

    MAINTENANCE ON CHASSIS AND ENGINE Dismount the start number plate Remove screw and take off clamp. Remove screw . Remove the start number plate. 500123-10 Fitting the start number plate Check parts for damage and wear. Replace damaged or worn parts. Position the start number plate.

  • Page 37: Checking Gas Bowden Cable Route

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

  • Page 38: Checking Chain Dirt

    MAINTENANCE ON CHASSIS AND ENGINE Checking chain dirt Check the chain for coarse dirt accumulation. » If the chain is very dirty: Clean the chain. ( P. 36) 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.

  • Page 39: Checking The Chain Tension When Fitting Rear Wheel

    MAINTENANCE ON CHASSIS AND ENGINE Checking the chain tension when fitting rear wheel 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 40: Adjusting The Chain Tension

    MAINTENANCE ON CHASSIS AND ENGINE 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. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.

  • Page 41: Adjusting Chain Tension - After Checking

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting chain tension - after checking Loosen nut Loosen nuts Adjust the chain tension by turning the adjusting screws left and right. Specification 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 right chain adjusters are in the same position relative to the reference marks The rear wheel is then correctly aligned.

  • Page 42: Adjusting Chain Guide

    MINIf the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not ride any further. The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn.

  • Page 43: Checking Free Play Of Hand Brake 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 44: Topping Up The Front Brake Fluid

    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: Removing 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 46: 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 47: Adjusting Basic Position Of Footbrake Lever

    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. Stand the vehicle upright. Check the brake fluid level in the viewer »...

  • Page 48: Adding Rear Brake Fluid

    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: 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 50: 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 51: Fitting Front Wheel

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

  • Page 52: Removing Rear Wheel

    MAINTENANCE ON CHASSIS AND ENGINE Removing rear wheel Jack up the motorcycle. ( P. 21) Press the brake caliper by hand on to the brake disc in order to press back the brake piston. Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes.

  • Page 53: Tire Condition Checking

    Tire condition checking Info Fit only tires approved 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 54: Checking Spoke Tension

    Warning 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 55: Recharging The Battery

    MAINTENANCE ON CHASSIS AND ENGINE Alternative 2 Place the battery in the battery holder. Lithium-ion battery, 4.6Ah (ANR26650M1) ( P. 76) Reconnect the rubber band Attach the plus cable and replace the plus pole cover Attach the minus cable Mount the seat. ( P.

  • Page 56: Removing A Fuse

    Replace a burned-out fuse only by an equivalent fuse. Refit the fuse. Fuse (58011109110) ( P. 76) Info 400273-10 If the new fuse burns out, contact an authorized KTM workshop. Replace the protection cover. Install the air filter box lid. ( P. 61)

  • Page 57: Ignition Curve Plug Connection

    MAINTENANCE ON CHASSIS AND ENGINE Ignition curve plug connection The plug connection is located in front of the fuel tank on the left of the frame. Possible states • Soft If the plug connection is separated, riding is more flexible. •...

  • Page 58: Installing The Fuel Tank

    MAINTENANCE ON CHASSIS AND ENGINE 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, espe- cially on hot vehicle components. Clean up spilt fuel immediately. Fuel in the fuel tank expands when warm and can escape if the tank is overfilled.

  • Page 59: Cooling System

    MAINTENANCE ON CHASSIS AND ENGINE Check parts for damage and wear. Replace damaged or worn parts. Position the fuel tank and fit the two spoilers to the side of the radiator fixing. Make sure that no cables or Bowden cables are trapped or damaged. 500067-01 Mount the fuel tank vent hose.

  • Page 60: Checking The Coolant Level

    MAINTENANCE ON CHASSIS AND ENGINE Stand the motorcycle upright on a horizontal surface. Remove the radiator cap. Check antifreeze of coolant. 25… 45 °C ( 13… 49 °F) » If the antifreeze of the cooling liquid does not meet specifications: Correct antifreeze of coolant.

  • Page 61: Refilling Coolant

    MAINTENANCE ON CHASSIS AND ENGINE Stand the vehicle upright. Place a suitable container under the water pump cover. Remove screw . Remove the radiator cap Completely drain the coolant. Fit screw with a new seal and tighten it. Specification Screw, water pump cover 10 Nm (7.4 lbf ft) 400242-11 Refilling coolant...

  • Page 62: Glass Fiber Yarn Filling Of Main Silencer

    MAINTENANCE ON CHASSIS AND ENGINE Glass fiber yarn filling of main silencer The main silencer is filled with glass fiber yarn. Over a period, the fibers of the insulating material vanish into the air, and the silencer "burns out". Not only is the noise level higher, the performance characteristic changes. Removing glass fiber yarn filling from main silencer Warning Danger of burns The exhaust system gets very hot when the vehicle is driven.

  • Page 63: Installing The Air Filter Box Lid

    MAINTENANCE ON CHASSIS AND ENGINE Installing the air filter box lid Check parts for damage and wear. Replace damaged or worn parts. Insert the air filter box lid into the rear area and clip it into the front area 200381-11 Removing the air filter Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine.

  • Page 64: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE ON CHASSIS AND ENGINE Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( P. 84) Info Only press the air filter to dry it, never wring it out. Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( P.

  • Page 65: Carburetor - Idle

    MAINTENANCE ON CHASSIS AND ENGINE Fill the bleeding syringe with the appropriate hydraulic fluid. Bleed syringe (50329050000) Hydraulic fluid (15) ( P. 82) On the slave cylinder, remove the bleeder screw and fit the bleeding syringe 500224-10 Inject the liquid into the system until it escapes from the bore hole of the mas- ter cylinder without bubbles.

  • Page 66: Emptying The Carburetor Float Chamber

    MAINTENANCE ON CHASSIS AND ENGINE Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extreme sport motocyclist will set the mixture about 1/4 of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use.

  • Page 67: Checking Engine Oil Level

    MAINTENANCE ON CHASSIS AND ENGINE Checking engine oil level Info The engine oil level can be checked on a cold or hot engine. Stand the motorcycle upright on a horizontal surface. Condition The engine is at operating temperature. Check the engine oil level. Info After switching off the engine, wait one minute before checking the level.

  • Page 68: Cleaning The Oil Screen

    MAINTENANCE ON CHASSIS AND ENGINE Cleaning the oil screen Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven. Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 69: Mounting Oil Filter

    MAINTENANCE ON CHASSIS AND ENGINE Mounting oil filter Check parts for damage and wear. Replace damaged or worn parts. Lay the motorcycle on its side and fill the oil filter housing to about full with engine oil. Fill the oil filter with engine oil and place it in the oil filter container. Oil the O-ring of the oil filter cover and assemble it with the oil filter cover Mount and tighten screws.

  • Page 70: Troubleshooting

    Do not touch parts of the ignition system. Have work on the ignition system car- ried out in an authorized KTM workshop. Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.
  • Page 71 TROUBLESHOOTING Faults Possible cause Measure Engine does not speed up. Carburetor running over because float Have carburetor checked. needle dirty or worn Loose carburetor jets Have carburetor checked. Electronic ignition adjustment defective Have ignition system checked. Engine has too little power. Fuel feed interrupted Check the fuel tank breather.

  • Page 72: Cleaning

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

  • Page 73: Storage

    0… 35 °C (32… 95 °F) The storage place should be dry and not subject to large temperature differences. Info KTM recommends jacking up the motorcycle. Jack up the motorcycle. ( P. 21) Cover the motorcycle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 74: 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 4 valves controlled by cam levers ad 2 camshafts, driven by heli- cal gear pair and tooth-wheel chain Valve diameter, intake 40.4 mm (1.591 in)

  • Page 75: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Engine housing vent jet Loctite 243™ ® Oil jet, piston cooling 4 Nm (3 lbf ft) Loctite 243™ ® Oil jet, cam lever lubrication 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, clutch oil supply M5x1 6 Nm (4.4 lbf ft) Loctite...
  • Page 76 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Nut, cylinder head M10x1,25 Tightening sequence: Engine oil (any) 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° Stud, cylinder head M10x1,25 20 Nm (14.8 lbf ft) ®...

  • Page 77: 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 78: Technical Data - Chassis

    80/100 - 21 51 M TT 110/90 - 19 62 M TT Bridgestone M59 Bridgestone M70 For further information, see: http://www.ktm.com Capacity - fuel Tank capacity 8.2 l (2.17 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) (...

  • Page 79: Technical Data - Fork

    TECHNICAL DATA - FORK Fork part number 14.18.7D.16 Fork WP 4860 MXMA CC Compression damping Comfort 18 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort 24 clicks Standard 22 clicks Sport 21 clicks Clip position, spring preload Comfort 2nd groove from top Standard 3rd groove from top...

  • Page 80: Technical Data - Shock Absorber

    TECHNICAL DATA - SHOCK ABSORBER Shock absorber part number 12.18.7D.12 Shock absorber WP PDS 5018 DCC Compression damping, low-speed Comfort 15 clicks Standard 12 clicks Sport 10 clicks Compression damping, high-speed Comfort 23 turns Standard 20 turns Sport 20 turns Rebound damping Comfort 26 clicks...

  • 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) Screw, rear brake disc 14 Nm (10.3 lbf ft) Screw, front brake disc...

  • Page 82: Wiring Diagram

    WIRING DIAGRAM Wiring diagram 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 Starter button Starter relay Starter motor Short circuit button Throttle valve sensor TPS 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

    Brake fluid DOT 5.1 according to Specification Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex Brake Fluid DOT 5.1...
  • Page 85 SUBSTANCES Supplier ® Motorex Racing Fork Oil...
  • Page 86 AUXILIARY SUBSTANCES Universal oil spray Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Joker 440 Universal Long-life grease Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Long Therm 2000 Chain cleaner Specification ® KTM recommends Motorex products.
  • Page 87 AUXILIARY SUBSTANCES High-luster polish for paint Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Moto Polish Contact spray Specification ® KTM recommends Motorex products. Supplier ® Motorex ® Motorex Accu Contact...
  • 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 Clutch lever ........10 adjusting basic position ..... . . 62 Accessories .
  • Page 90 INDEX removing ....... . . 48 Checks before putting into operation ....15 Fuel tank fitting .
  • Page 91 INDEX Wiring diagram ......80-81...
  • Page 92 *3211253en* 3211253en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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