KTM 450 SX ATV Owner's Manual
  1. Manuals
  2. Brands
  3. KTM Manuals
  4. Offroad Vehicle
  5. 450 SX ATV
  6. Owner's manual

KTM 450 SX ATV Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
OWNER'S MANUAL
2010
450 SX ATV
505 SX ATV
Art. no. 3211488en

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 450 SX ATV and is the answer not in the manual?

Questions and answers

Related Manuals for KTM 450 SX ATV

Summary of Contents for KTM 450 SX ATV

  • Page 1 OWNER'S MANUAL 2010 450 SX ATV 505 SX ATV Art. no. 3211488en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous DEAR KTM CUSTOMER pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    Opening filler cap ............. 22 Important maintenance work to be carried out by an Closing filler cap .............. 23 authorized KTM workshop (as an additional order) ....47 Fuel tap................24 Important checks and maintenance work to be carried out Choke................
  • Page 6 TABLE OF CONTENTS Front shock absorber - Adjusting the low-speed Adjusting chain tension............. 85 compression damping ............52 Greasing the rear wheel eccentric element ......87 Front shock absorber - adjusting the rebound damping..54 Checking brake discs ............87 Front shock absorber - adjusting the cross over....
  • Page 7 TABLE OF CONTENTS Changing the ignition curve ..........118 Changing the engine oil and oil filter, cleaning the oil screen ..............145 Removing the seat ............119 Draining the engine oil ..........145 Mounting the seat ............119 Removing the radiator spoiler .......... 120 Cleaning the oil screen ..........
  • Page 8 TABLE OF CONTENTS INDEX ................183...

  • Page 9: 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 at an authorized KTM workshop! There, your vehicle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 10: Important Information

    IMPORTANT INFORMATION Use definition KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid regulations and categories of the top international motorsport organizations. Warning Danger of accidents Incorrect assessment of riding situations.
  • Page 11 Spare parts, accessories For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 12 If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the first time. A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you. Notes/warnings Pay close attention to the notes/warnings.
  • Page 13 IMPORTANT INFORMATION Grades of risks Danger Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken. Warning Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken. Note Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 301769-10...
  • Page 15 VIEW OF VEHICLE Hand brake lever Fuse box Shock absorber compression adjustment Front shock absorber Shock absorber rebound adjustment Heel protector Shift lever Kill switch/emergency OFF switch with rip cord Clutch lever Hot start lever...

  • Page 16: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 301770-10...
  • Page 17 VIEW OF VEHICLE Filler cap Main silencer Seat release Shock absorber rebound adjustment Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Handlebar bridge Throttle lever Handlebar cushion...

  • Page 18: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper  control arm. 301771-10 Type label The type label is located on the frame tube on the right and left in front of the radiator. ...

  • Page 19: Engine Number

    LOCATION OF SERIAL NUMBERS Engine number The engine number is stamped on the left side of the engine under the engine sprocket.  301772-10 Shock absorber part number, front The shock absorber part number is stamped on the upper part of the shock absorber. ...

  • Page 20: Shock Absorber Part Number, Rear

    LOCATION OF SERIAL NUMBERS Shock absorber part number, rear The shock absorber part number is stamped on the upper part of the shock absorber.  301831-10...

  • Page 21: Controls

    CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar.  Possible states Clutch lever in neutral position – In this position, the engine is force-locked with the • gear and the starting circuit is interrupted. The electric starter does not turn over when the electric starter button is pressed.

  • Page 22: Hand Brake Lever, Parking Brake

    CONTROLS Hand brake lever, parking brake The hand brake lever is located on the right side of the handlebar and operates the front  brakes. The hand brake lever is combined with the parking brake, which blocks the front wheels to prevent the vehicle from rolling away.

  • Page 23: Throttle Lever

    CONTROLS Throttle lever The throttle lever is fitted on the right side of the handlebar.  The throttle lever is used to control the engine speed. 301773-10 Electric starter button Electric starter button is fitted on the left side of the handlebar. ...

  • Page 24: Kill Switch/Emergency Off Switch With Rip Cord

    CONTROLS Kill switch/emergency OFF switch with rip cord The kill switch/emergency OFF switch is mounted on the left in front of the fuel tank.  Kill switch is used to switch off the engine under normal circumstances.  The emergency OFF switch shuts the engine off if the rider falls off the vehicle. A rip cord is attached to clip .

  • Page 25: Closing Filler Cap

    CONTROLS Closing filler cap – Replace the filler cap and turn clockwise until the release button locks in place.  – Check the fuel tank breather to ensure it is properly seated.  » If the fuel tank breather is at an angle or loose: –...

  • Page 26: Fuel Tap

    CONTROLS Fuel tap The fuel tap is located on the right side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the carbure-  tor. Possible states Fuel supply closed OFF – No fuel can flow from the tank to the carburetor. •...

  • Page 27: Choke

    CONTROLS Choke 5.10 The choke is fitted on the left side of the carburetor.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 28: Foot Brake Pedal

    CONTROLS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 301784-10 Foot brake pedal 5.12 The foot brake pedal is located in front of the right footrest and operates the rear wheel ...

  • Page 29: General Tips And Hints On Putting Into Operation

    – A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you. Warning Risk of injury Missing or poor protective clothing present an increased safety risk.
  • Page 30 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Warning Danger of accidents Accident risk caused by presence of a passenger. – Your vehicle is not designed to carry passengers. Do not ride with a passenger. Warning Danger of accidents Brake system failure. –...

  • Page 31: Running In The Engine

    GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION – 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. – Before your first trip, read the entire owner's manual thoroughly.
  • Page 32 GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION Guideline Maximum engine speed During the first 3 service hours 7,000 rpm Maximum engine performance ≤ 50 % During the first 3 service hours ≤ 75 % During the next 12 service hours –...

  • Page 33: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the vehicle is roadworthy 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 34: Starting

    RIDING INSTRUCTIONS – Check that all controls are correctly adjusted and free to move. Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.

  • Page 35: Starting Up

    RIDING INSTRUCTIONS Condition The engine is cold – Pull choke lever out as far as possible. Condition The engine is hot – Pull the hot start lever all the way out. – Pull the clutch lever. – Press the electric starter button. Info When the clutch lever is not pulled, the starting circuit is not closed.

  • Page 36: Shifting

    Adapt your braking to the traffic situation and the road conditions. Warning Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake. – Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 37: Riding

    Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. If the vehicle goes out of control and you fall off the vehicle, the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing.

  • Page 38: Riding In Bends

    RIDING INSTRUCTIONS Guideline ≥ 2 min – Avoid slipping the clutch frequently and for prolonged periods. This heats the engine oil, the engine and the cooling system. – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch. Riding in bends Info When riding in bends, the outer wheels cover a greater distance than the inner wheels.

  • Page 39: Riding Downhill

    RIDING INSTRUCTIONS Riding downhill Warning Danger of accidents Danger of accidents when riding on slopes. – Always check the terrain before riding onto a slope. – Never ride on a slope with an inclination of more than 25°. – Never ride on a slope that exceeds your driving skills. –...

  • Page 40: Riding Uphill

    RIDING INSTRUCTIONS Riding uphill Warning Danger of accidents Danger of accidents when riding on slopes. – Always check the terrain before riding onto a slope. – Never ride on a slope with an inclination of more than 25°. – Never ride on a slope that exceeds your driving skills. –...

  • Page 41: Riding Perpendicular To The Slope

    RIDING INSTRUCTIONS Riding perpendicular to the slope 7.10 Warning Danger of accidents When riding perpendicular to a slope, the vehicle can tip easily and roll over. – Avoid riding perpendicular to the slope if possible. – Ride slowly and shift you weight toward the slope. –...
  • Page 42 RIDING INSTRUCTIONS – If you come to a stop on a slope with your vehicle, dismount from the vehicle and turn – Switch off the engine and activate the parking brake. – Dismount from the vehicle on the uphill side. –...

  • Page 43: Riding Through Water

    After riding through water, dry the brakes by lightly activating both brakes until normal braking power is available again. – If the vehicle became submerged, an authorized KTM workshop must perform a thor- ough check and comprehensive service. Do not start the engine. Switching off the engine 7.13...

  • Page 44: Stopping, Parking

    RIDING INSTRUCTIONS Alternative 1 Switch off the engine using the kill switch. – Press kill switch at engine idle speed until the engine stops. (Figure 301777-10 p. 22)  Alternative 2 Switch off the engine using the emergency OFF switch with a rip cord. –...

  • Page 45: Refueling

    RIDING INSTRUCTIONS – Stop the vehicle and park it on a surface that is as horizontal as possible. – Shift gear to neutral. – Switch off the engine. ( p. 41) – Remove the ignition key and the clip from the emergency OFF switch. –...
  • Page 46 RIDING INSTRUCTIONS Warning Environmental hazard Improper handling of fuel is a danger to the environment. – Do not allow fuel to get into the ground water, the ground, or the sewage system. – Switch off the engine. – Open the filler cap. ( p.

  • Page 47: 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, clean the oil screen. p. 145) Replace spark plug. • Check the valve clearance and adjust if necessary.
  • Page 48 SERVICE SCHEDULE S10A S30A Brakes Check the free travel of the hand brake lever. ( p. 88) • • • Check the free travel of the foot brake lever. ( p. 97) • • • Check the brake system. • •...

  • Page 49: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop (As An Additional Order)

    S10A: Every 10 service hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel (55.5 US gal) Important maintenance work to be carried out by an authorized KTM workshop (as an additional order) S10A...

  • Page 50: Important Checks And Maintenance Work To Be Carried Out By The Rider

    SERVICE SCHEDULE S10A S20A S40A S80A Check the crankshaft run-out at the bearing pin. • • • • Change the conrod bearing. • • Check the seating of the piston pin. • • Change the crankshaft main bearing. Fully check the transmission. •...
  • Page 51 SERVICE SCHEDULE NB1A Check and adjust control cables. • Clean the chain. ( p. 82) • Check the chain tension. ( p. 82) • Check the chain wear. ( p. 84) • Check rear sprocket / engine sprocket for wear. ( p.

  • Page 52: Maintenance On Chassis And Engine

    MAINTENANCE ON CHASSIS AND ENGINE Jacking up the vehicle Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. – Jack up the vehicle on the frame underneath the engine. The wheels must no longer touch the ground.

  • Page 53: Compression Damping Of The Shock Absorber

    Danger 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.) Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers.

  • Page 54: Front Shock Absorber - Adjusting The Low-Speed Compression Damping

    Front shock absorber - Adjusting the low-speed compression damping Danger 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.)
  • Page 55 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers. – Only make adjustments within the recommended range. Info The low-speed setting can be seen during the slow to normal compression of the shock absorber. The left and right shock absorbers should have the same settings.

  • Page 56: Front Shock Absorber - Adjusting The Rebound Damping

    Danger 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.) Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers.

  • Page 57: Front Shock Absorber - Adjusting The Cross Over

    Danger 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 cross over setting is used to adjust the suspension travel of the short (soft) spring.

  • Page 58: Front Shock Absorber - Adjusting The Spring Preload

    Danger 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.) Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers.
  • Page 59 MAINTENANCE ON CHASSIS AND ENGINE Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling. Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. –...

  • Page 60: Rear Shock Absorber - Adjusting The High Speed Compression Damping

    Rear shock absorber - adjusting the high speed compression damping 9.10 Danger 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.)
  • Page 61 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers. – Only make adjustments within the recommended range. Info The high-speed setting takes effect during the fast compression of the shock absorber. –...

  • Page 62: Rear Shock Absorber - Adjusting The Low-Speed Compression Damping

    Danger 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.) Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers.

  • Page 63: Rear Shock Absorber - Adjusting The Rebound Damping

    Danger 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.) Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers.

  • Page 64: Rear Shock Absorber - Adjusting The Spring Preload

    Danger 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.) Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers.
  • Page 65 After removing the shock absorber, clean it thoroughly. – Loosen lock ring . Hold adjusting ring while doing so. Suitable tools are available   from an authorized KTM workshop. Hook wrench (83019002000) – Turn the adjusting ring until the spring pack is fully unloaded. 200601-01...

  • Page 66: Removing The Rear Shock Absorber

    MAINTENANCE ON CHASSIS AND ENGINE – Measure the entire spring pack when it is unloaded. Info Spring preload is the difference in length between the spring pack when it is  unloaded and when it is installed. – Tighten the spring pack by turning the adjusting ring to the specified setting. Guideline Spring preload Comfort...
  • Page 67 MAINTENANCE ON CHASSIS AND ENGINE Note Danger of damage The chain sliding piece and frame can be damaged from incorrect handling. – When removing the rear shock absorber, secure the swingarm with a tension belt to prevent it from swinging down further. –...

  • Page 68: Installing The Rear Shock Absorber

    MAINTENANCE ON CHASSIS AND ENGINE Installing the rear shock absorber 9.15 – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw  Guideline Screw, rear top shock absorber 60 Nm (44.3 lbf ft) –...
  • Page 69 MAINTENANCE ON CHASSIS AND ENGINE – Load the vehicle with the specified weight. Guideline Average rider weight 70… 80 kg (154… 176 lb.) – Move the handlebar into the straight-ahead position and fix it. Handlebar fixation for straight-ahead position (83019015100) 300272-10...
  • Page 70 MAINTENANCE ON CHASSIS AND ENGINE 400333-10 – Measure distances   » If distances are not equal:   – Adjust the toe. p. 69) – Measure distances   Guideline Front 0 mm (0 in)

  • Page 71: Adjusting The Toe

    MAINTENANCE ON CHASSIS AND ENGINE Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv-   ing straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. »...
  • Page 72 MAINTENANCE ON CHASSIS AND ENGINE 400333-11 – Loosen nuts   – Adjust the distances to the same value by rotating the tie rods    – Adjust the distances to the specified value by evenly rotating the tie rods ...

  • Page 73: Checking/Adjusting The Camber

    MAINTENANCE ON CHASSIS AND ENGINE Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv-   ing straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange. –...
  • Page 74 MAINTENANCE ON CHASSIS AND ENGINE – Loosen nuts  300273-10 – Remove screws with bushings   300274-10 – Insert tool in the heim joint and clip onto the A-arm.  Camber gauge (83019014000) – Check the camber on both heim joints. »...

  • Page 75: Fork Offset

    MAINTENANCE ON CHASSIS AND ENGINE – Position the A-arm with bushings . Mount and tighten screws   Guideline Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) 300274-10 – Align the heim joint at right angles to screws and tighten nut ...

  • Page 76: Adjusting The Fork Offset

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting the fork offset 9.20 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( p. 50) –...

  • Page 77: Adjusting The Toe Width Of Rear Axle

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting the toe width of rear axle 9.22 Warning Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior. – Following modifications, ride slowly at first to get the feel of the new ride behavior. –...
  • Page 78 MAINTENANCE ON CHASSIS AND ENGINE Setting a wide toe width: – Mount the spacer with the cone facing inward.  0 0 2 0 0 3 – Mount the conical ring with the cone facing outward.  – Mount the wheel hub ...

  • Page 79: Handlebar Position

    MAINTENANCE ON CHASSIS AND ENGINE Handlebar position 9.23 The handlebar position can be adjusted 4-fold by turning the handlebar support and the  handlebar support  The holes on the handlebar support are placed at a distance of from the center. ...

  • Page 80: Adjusting Handlebar Position

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting handlebar position 9.24 – Remove the handlebar cushion. Info Protect the vehicle and its attachments from damage by covering them. Do not bend the cables and lines. 301846-10...
  • Page 81 MAINTENANCE ON CHASSIS AND ENGINE – Remove the four screws . Remove the handlebar clamps , swing the handlebar for-   ward and set it down. – Remove the nuts and remove the handlebar support with the screws.  ...

  • Page 82: Checking The Play In The Throttle Cable

    MAINTENANCE ON CHASSIS AND ENGINE Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure cables and wiring are positioned correctly. – Mount the handlebar cushion. Checking the play in the throttle cable 9.25 – Move the handlebar to the straight-ahead position. Move the throttle lever back and forth slightly to ascertain the play in the throttle cable ...

  • Page 83: Adjusting Play In Throttle Cable

    MAINTENANCE ON CHASSIS AND ENGINE – Adjust the play in the throttle cable. ( p. 81) Adjusting play in throttle cable 9.26 – Check throttle cable route. – Move the handlebar to the straight-ahead position. – Loosen the nut and use the screw to adjust the play in the throttle cable ...

  • Page 84: Cleaning The Chain

    MAINTENANCE ON CHASSIS AND ENGINE Cleaning the chain 9.28 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. Info The service life of the chain depends largely on its maintenance. –...

  • Page 85: Checking Rear Sprocket / Engine Sprocket For Wear

    MAINTENANCE ON CHASSIS AND ENGINE – Park the vehicle on a horizontal surface and shift gears to neutral. – Push the upper chain section at the end of the chain sliding component upwards to measure the chain tension  Info The lower chain section must be taut.

  • Page 86: Checking Chain Wear

    MAINTENANCE ON CHASSIS AND ENGINE Checking chain wear 9.31 – Park the vehicle on a horizontal surface and shift gears to neutral. – Pull on the lower part of the chain with the specified weight  Guideline Chain-wear measuring weight 10…...

  • Page 87: Adjusting Chain Tension

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting chain tension 9.32 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, bearings in transmission and rear wheel eccentric element) are under additional load.
  • Page 88 MAINTENANCE ON CHASSIS AND ENGINE – Loosen the screws by four turns.  Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric ele-   ment. Alternative 2 – Position the special tool at the rear wheel eccentric element. Hook wrench (83019011000) –...

  • Page 89: Greasing The Rear Wheel Eccentric Element

    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 90: Checking The Free Travel Of The Hand Brake Lever

    MAINTENANCE ON CHASSIS AND ENGINE » If the brake disc thickness is less than the specified value: – Change the brake disc. – Check the front and rear brake discs for damage, cracking and deformation. » If the brake disc exhibits damage, cracking or deformation: –...

  • Page 91: Adjusting Basic Position Of Hand Brake 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. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)

  • Page 92: 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. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.)
  • Page 93 MAINTENANCE ON CHASSIS AND ENGINE 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. Info Never user DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

  • Page 94: Checking The Front Brake Linings

    301802-10 Checking the front brake linings 9.39 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) – Remove the wheel/wheels. ( p. 107)

  • Page 95: Removing Front Brake Linings

    9.40 Warning Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) Info The operations are the same on the left and right. – Remove the wheel/wheels. ( p.

  • Page 96: Installing The Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.

  • Page 97: Changing The Front Brake Linings

    MAINTENANCE ON CHASSIS AND ENGINE – Insert the inside brake lining into the brake caliper and fix with bolt  – Insert the external brake lining into the brake caliper and slide the bolts in all the way. 100072-10 – Mount locking split pins ...
  • Page 98 Warning Danger of accidents Reduced braking due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 99: Checking Free Travel Of Foot Brake Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the front brake linings. p. 93) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir.

  • Page 100: Adjusting Basic Position Of Foot Brake Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Disconnect spring  – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play  Guideline Free play at foot brake lever 3…...

  • Page 101: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake lin- ings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

  • Page 102: Adding Rear Brake Fluid

    Warning Danger of accidents Reduced braking due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Park the vehicle on a horizontal surface.
  • Page 103 Warning Danger of accidents Reduced braking due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 104: Checking Rear Brake Linings

    9.47 Warning Danger of accidents Reduced braking efficiency caused by worn brake linings. – Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in) Minimum thickness ...

  • Page 105: Removing Rear Brake Linings

    Danger of accident Brake system failure. – Maintenance work and repairs must be carried out professionally. (Your authorized KTM workshop will be glad to help.) – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 106: Installing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 107 MAINTENANCE ON CHASSIS AND ENGINE – Check that sliding plate is seated correctly in the brake caliper support and insert  the brake linings. Info Make sure that decoupling plate is mounted on the piston side of the brake  pad.

  • Page 108: Changing Rear Brake Linings

    Warning Danger of accidents Reduced braking due to old brake fluid. – Change the brake fluid of the front and rear brakes according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 109: Removing Wheel/Wheels

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the rear brake linings. p. 103) – Remove screw with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir. –...

  • Page 110: Installing The Wheel/Wheels

    MAINTENANCE ON CHASSIS AND ENGINE – Loosen the wheel nuts  – Jack up the vehicle. ( p. 50) – Remove the wheel nuts. Remove the wheel. Info Carefully remove the wheel, making sure it does not become jammed with the threads of the screws.
  • Page 111 MAINTENANCE ON CHASSIS AND ENGINE Info Proceed in the same way on the other wheels if necessary. – Position the wheel on the hub. Info Note the direction of travel of the front wheels. Carefully position the wheel on the hub, being careful not to damage the threads of the screws.

  • Page 112: Checking The Tire Condition

    The tire's date of manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits indicate the week of manufacture and the last two digits the year of manufacture. KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear. »...

  • Page 113: Removing The Battery

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the dust cap. – Check the tire air pressure when the tires are cold. Tire pressure gauge (83519001000) Tire air pressure off road 0.3 bar (4 psi) » If the tire pressure does not meet specifications: –...

  • Page 114: Installing The Battery

    MAINTENANCE ON CHASSIS AND ENGINE – Disconnect the negative (minus) cable of the battery.  – Pull back the plus pole cover and disconnect the positive (plus) cable of the battery.  – Loosen the rubber band  – Remove the battery. 300279-10 Installing the battery 9.56...

  • Page 115: Recharging The Battery

    – 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 116 MAINTENANCE ON CHASSIS AND ENGINE Info Even if there is no load on the battery, it still loses power steadily. The charge state and the type of charge are very important for the service life of the battery. Rapid charging with a high charging current has a negative impact on the service life. If the charging current, charging voltage and charging time are exceeded, electrolyte escapes via the safety valves.

  • Page 117: Changing The Main Fuse

    MAINTENANCE ON CHASSIS AND ENGINE – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the alternator. With this device, you cannot overcharge the battery. Info Never remove the lid ...

  • Page 118: Changing The Fuses Of Individual Power Consumers

    MAINTENANCE ON CHASSIS AND ENGINE – The main fuse is located in the starter relay in front of the battery.   – Remove protection covers  – Remove the faulty main fuse. Info You can recognize a blown fuse by its broken filament ...
  • Page 119 MAINTENANCE ON CHASSIS AND ENGINE – Open the cover of the fuse box   Info The designation of the fuses is located on the inside cover of the fuse box  – Remove the faulty fuse. Guideline Fuse 1 - 10A - CDI controller Fuse 2 - 10A - radiator fan Fuse 3 - not used Fuse 4 - not used...

  • Page 120: Ignition Curve Plug Connection

    MAINTENANCE ON CHASSIS AND ENGINE – Close the cover of the fuse box. – Install the front cover. ( p. 123) Ignition curve plug connection 9.60 Plug-in connector is located under the trim at the front on the frame tube. ...

  • Page 121: Removing The Seat

    MAINTENANCE ON CHASSIS AND ENGINE Removing the seat 9.62 – Pull the release hook back. Lift up the seat at the rear, pull it back and then remove  from above. 301809-10 Mounting the seat 9.63 – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the seat ...

  • Page 122: Removing The Radiator Spoiler

    MAINTENANCE ON CHASSIS AND ENGINE – Push down the rear of the seat until release hook engages.  – Make sure that the seat is correctly locked in. 301809-11 Removing the radiator spoiler 9.64 Info The operations are the same on the left and right. –...

  • Page 123: Installing The Radiator Spoiler

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the screws on the radiator.  – Detach the radiator spoiler and remove it. 301816-10 Installing the radiator spoiler 9.65 Info The operations are the same on the left and right. – Hook catch of the radiator spoiler into holder of the fuel tank and position it on ...

  • Page 124: Removing The Front Cover

    MAINTENANCE ON CHASSIS AND ENGINE – Mount and tighten screws on the radiator.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount and tighten screws on the fuel tank.  Guideline Screw on fuel tank 6 Nm (4.4 lbf ft) –...

  • Page 125: Installing The Front Cover

    MAINTENANCE ON CHASSIS AND ENGINE Installing the front cover 9.67 – Position the front cover in slots on both sides of the front trim.  – Mount and tighten the screw. 301812-10 Removing the front trim 9.68 – Remove the front cover. ( p.
  • Page 126 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws  – Raise the front trim and disconnect the plug-in connector from the emergency OFF switch with the rip cord. – Remove the front trim. 301820-10...

  • Page 127: Installing The Front Trim

    MAINTENANCE ON CHASSIS AND ENGINE Installing the front trim 9.69 – Connect the plug-in connector of the emergency OFF switch with the rip cord and posi- tion the front trim. – Mount all screws. – Fully tighten screws  Guideline Screw on fuel tank 6 Nm (4.4 lbf ft) –...
  • Page 128 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws  301822-10 – Raise the rear of the air filter box lid . At the same time, use your other hand to press  on the carburetor connection boot to kink it at that location. This prevents the carbure- tor connection boot from disconnecting from the carburetor.

  • Page 129: Installing The Rear Fender

    MAINTENANCE ON CHASSIS AND ENGINE Installing the rear fender 9.71 – Raise the rear of air filter box lid . At the same time, use your other hand to press on  the carburetor connection boot to kink it at that location. This prevents the carburetor connection boot from disconnecting from the carburetor.
  • Page 130 MAINTENANCE ON CHASSIS AND ENGINE – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( p. 119) 301822-11...

  • Page 131: Removing The Engine Guard

    MAINTENANCE ON CHASSIS AND ENGINE Removing the engine guard 9.72 – Remove screws . Remove the engine guard.   301823-10 Installing the engine guard 9.73 – Position the engine guard on the frame bearer. Mount and tighten screws  ...

  • Page 132: Removing The Air Filter

    MAINTENANCE ON CHASSIS AND ENGINE Removing the air filter 9.74 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. Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 133: Installing The Air Filter

    MAINTENANCE ON CHASSIS AND ENGINE Installing the air filter 9.75 – Mount the clean air filter onto the air filter support. – Grease the air filter in area  Long-life grease ( p. 180) 301262-10 – Put in both parts together, position them and fix them with the air filter support ...

  • Page 134: Cleaning Air Filter

    MAINTENANCE ON CHASSIS AND ENGINE Cleaning air filter 9.76 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. Info Do not clean the air filter with fuel or petroleum since these substances attack the foam. –...

  • Page 135: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting basic position of clutch lever 9.77 – Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw  Info Turn the adjusting screw counterclockwise to increase the distance between the clutch lever and the handlebar.

  • Page 136: Cooling System

    MAINTENANCE ON CHASSIS AND ENGINE – Position the cover with the membrane. Mount and tighten screws. Cooling system 9.79 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 137: Checking Antifreeze And Coolant Level

    MAINTENANCE ON CHASSIS AND ENGINE Checking antifreeze and coolant level 9.81 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. – Do not remove the radiator cap or remove radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down.

  • Page 138: Checking The Coolant Level

    MAINTENANCE ON CHASSIS AND ENGINE Alternative 2 Coolant (mixed ready to use) ( p. 175) – Mount the radiator cap. Checking the coolant level 9.82 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. –...

  • Page 139: Draining Coolant

    MAINTENANCE ON CHASSIS AND ENGINE Alternative 2 Coolant (mixed ready to use) ( p. 175) – Mount the radiator cap. Draining coolant 9.83 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. –...

  • Page 140: Filling Coolant/Bleeding The Cooling System

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the radiator cap . Completely drain the coolant.  – Mount screw with a new seal and tighten it.  Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) – Mount screw with a new seal and tighten it.
  • Page 141 MAINTENANCE ON CHASSIS AND ENGINE – Remove the radiator cap  – Fill the coolant into the radiator. Coolant 1.50 l (1.59 qt.) Coolant ( p. 175) Coolant (mixed ready to use) ( p. 175) 301838-11 – Open screw to bleed the radiator. Tighten the screw when coolant emerges from the ...

  • Page 142: Carburetor - Idle

    MAINTENANCE ON CHASSIS AND ENGINE Carburetor - idle 9.85 The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly.
  • Page 143 MAINTENANCE ON CHASSIS AND ENGINE Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 25) Idle speed 1,500… 1,600 rpm Info If the idle speed is set significantly higher, the engine does not start. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark.

  • Page 144: Draining The Carburetor Float Chamber

    MAINTENANCE ON CHASSIS AND ENGINE Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 25) Idle speed 1,500… 1,600 rpm Info Following extreme air temperature or altitude changes, adjust the idle speed again. Draining the carburetor float chamber 9.87 Danger...

  • Page 145: Checking The Engine Oil Level

    MAINTENANCE ON CHASSIS AND ENGINE Info Carry out this work with a cold engine. – Turn handle of the fuel tap to the OFF position. (Figure 301779-10 p. 24)  No more fuel flows from the tank to the carburetor. –...
  • Page 146 MAINTENANCE ON CHASSIS AND ENGINE 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. The engine oil reaches the middle of the viewer ...

  • Page 147: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    MAINTENANCE ON CHASSIS AND ENGINE Changing the engine oil and oil filter, cleaning the oil screen 9.89 – Drain the engine oil. p. 145) – Remove the oil filter. p. 147) – Install the oil filter. p. 149) – Fill up with engine oil. p.

  • Page 148: Cleaning The Oil Screen

    MAINTENANCE 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. – Clean the sealing area on the engine.

  • Page 149: Removing The Oil Filter

    MAINTENANCE ON CHASSIS AND ENGINE – Loosen screw plug by striking it lightly with a hammer a few times.  – Remove screw plug with oil screen and the O-rings.   – Drain the remaining engine oil. – Thoroughly clean parts and sealing area. –...
  • Page 150 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws . Take off the oil filter cover with the O-ring.  301843-10 – Pull oil filter element out of the oil filter case.  Circlip pliers reverse (51012011000) – Completely drain the engine oil. –...

  • Page 151: Installing The Oil Filter

    MAINTENANCE ON CHASSIS AND ENGINE Installing the oil filter 9.93 – Fill oil filter with engine oil and place it in the oil filter housing.  301844-10 – Oil the O-ring of the oil filter cover and install it with the oil filter cover. –...

  • Page 152: Adding Engine Oil

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the filler cap on the clutch cover and fill up with engine oil.  Engine oil 2.00 l (2.11 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 176) External Engine oil (SAE temperature:...
  • Page 153 MAINTENANCE ON CHASSIS AND ENGINE – Check the engine for leakage. – Remove the filler cap on the clutch cover and fill up with engine oil.  Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p.

  • Page 154: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Operating error Follow the instructions on starting the engine. p. 32) – Vehicle was out of use for a long time Drain the carburetor float chamber. and there is old fuel in the float cham- p.
  • Page 155 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Switch for throttle lever faulty Check the wiring harness. (visual check) – Check the electrical system. – Throttle valve sensor incorrectly set or Check the throttle position sensor. faulty –...
  • Page 156 TROUBLESHOOTING Faults Possible cause Action – Engine has no idle. Ignition system defective Check the spark plug connector. – Check the ignition coil. – Check the ignition pulse generator. – Check the alternator. – Check the CDI controller. – Engine stalls or is backfiring into the Lack of fuel Turn the handle of the fuel tap to ON.
  • Page 157 TROUBLESHOOTING Faults Possible cause Action – Engine has a lack of power Air filter excessively dirty Clean the air filter. p. 132) – Exhaust system leaky, deformed or too Check exhaust system for damage. little glass fiber yarn filling in main silencer –...

  • Page 158: Cleaning

    CLEANING Cleaning the vehicle 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 electrical components, socket connects, throttle cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 159 CLEANING – After rinsing the vehicle with a gentle water spray, allow it to dry thoroughly. – Clean and dry the air filter box. – Drain the carburetor float chamber. p. 142) Warning Danger of accidents Reduced braking due to wet or dirty brakes. –...

  • Page 160: Storage

    STORAGE Storage 12.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 161: Putting The Vehicle Into Operation After Storage

    STORAGE Guideline Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. – Cover the vehicle with a tarp or cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 162: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design Single cylinder 4-stroke engine, water-cooled Displacement (450 SX ATV) 449.3 cm³ (27.418 cu in) Displacement (505 SX ATV) 477.5 cm³ (29.139 cu in) Stroke 60.8 mm (2.394 in) Bore (450 SX ATV) 97 mm (3.82 in) Bore (505 SX ATV) 100 mm (3.94 in)

  • Page 163: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 3rd gear 20:26 4th gear 23:25 5th gear 26:24 Alternator 12 V, 200 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK CR 9 EKB Spark plug electrode gap 0.7 mm (0.028 in) Cooling Water cooling, permanent circulation of coolant by water pump...

  • Page 164: 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 165 TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, exhaust flange 10 Nm (7.4 lbf ft) Loctite 243™ – Screw, generator cover 10 Nm (7.4 lbf ft) ® Screw, ignition pulse generator cable 10 Nm (7.4 lbf ft) Loctite 243™ holder ®...
  • Page 166 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 167: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4125L Needle position 3 th position from top Idle mixture adjusting screw Open 1.5 turns Pump membrane stop 2.15 mm (0.0846 in) Hot start button Bore diameter in carburetor body 2.5 mm (0.098 in) Main jet Jet needle...

  • Page 168: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Double cradle of chromium molybdenum steel tubes, powder- coated Wheel suspension Front Single wheel suspension with double transverse control arm Rear Rigid axle Suspension travel Front 244 mm (9.61 in) Rear 258 mm (10.16 in) Fork offset Front 50 mm (1.97 in)
  • Page 169 TECHNICAL DATA - CHASSIS Maximum allowable axle load Front 144 kg (317 lb.) Rear 149 kg (328 lb.) Maximum permissible overall weight 293 kg (646 lb.) Vehicle length 1,810 mm (71.26 in) Vehicle width 1,265 mm (49.8 in) Vehicle height 1,100 mm (43.31 in) Brake system Front...

  • Page 170: Tires

    20 x 6.00 - 10 18 x 10.00 - 8 MAXXIS Razr MX‑931 MAXXIS Razr MX‑932 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 16.2 Total fuel tank capacity approx. 10.3 l (2.72 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.

  • Page 171: Technical Data - Front Shock Absorber

    TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber part number 03.18.7J.16 Shock absorber WP Suspension 3612 BAVP DCC Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 12 clicks Rebound damping Comfort...
  • Page 172 TECHNICAL DATA - FRONT SHOCK ABSORBER Spring length, main spring 275 mm (10.83 in) Spring length, auxiliary spring 60 mm (2.36 in) Fitted length 463 mm (18.23 in) Gas pressure 10 bar (145 psi) Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p.

  • Page 173: Technical Data - Rear Shock Absorber

    TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber part number 15.18.7J.16 Shock absorber WP Suspension PDS 4618 BAVP DCC Compression damping, high-speed Comfort 1.5 turns Standard 1 turn Sport 1 turn Compression damping, low-speed Comfort 20 clicks Standard 15 clicks Sport 15 clicks Rebound damping...
  • Page 174 TECHNICAL DATA - REAR SHOCK ABSORBER Spring length, main spring 200 mm (7.87 in) Spring length, auxiliary spring 55 mm (2.17 in) Fitted length 440.5 mm (17.342 in) Gas pressure 10 bar (145 psi) Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p.

  • Page 175: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw on fuel tank 6 Nm (4.4 lbf ft) – Screw, clamping nut, rear axle 10 Nm (7.4 lbf ft) ®...
  • Page 176 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Screw, front shock absorber 45 Nm (33.2 lbf ft) – Screw, steering column at bottom of 25 Nm (18.4 lbf ft) steering lever – Nut, ball head, A-arm top M10x1.25 35 Nm (25.8 lbf ft) ®...

  • Page 177: Operating 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 178 SAE ( p. 182) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
  • Page 179 – ISO VG (15) Guideline – Use only hydraulic 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 – Hydraulic Fluid 75...
  • Page 180 OPERATING SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 181: 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 611 Cleaning and polishing materials for metal, rubber and plastic Guideline –...
  • Page 182 AUXILIARY SUBSTANCES Long-life grease Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Fett 2000 Lubricant (T625) Guideline – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Motorcycle cleaner Guideline – ® KTM recommends Motorex products.
  • Page 183 AUXILIARY SUBSTANCES Oil for foam air filter Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power...

  • Page 184: 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 specification. Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines.
  • Page 185 INDEX installing ........94 INDEX removing ........93 Accessories .
  • Page 186 INDEX Clutch Engine oil level checking fluid level ......133 checking ........143 Clutch lever .
  • Page 187 INDEX Front trim installing ........125 Oil filter removing .
  • Page 188 INDEX installing ........66 Spare parts ........9 rebound damping, adjusting .
  • Page 189 INDEX Use definition ........8 Vehicle cleaning .
  • Page 190 *3211488en* 3211488en 05/2009 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

505 sx atv

Table of Contents