KTM 450 SMR 2021 Owner's Manual
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KTM 450 SMR 2021 Owner's Manual

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OWNER'S MANUAL
2021
450 SMR
Art. no. 3214231en

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Summary of Contents for KTM 450 SMR 2021

  • Page 1 OWNER'S MANUAL 2021 450 SMR Art. no. 3214231en...
  • Page 3 KTM accepts no liability for delivery options, deviations from fig- ures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS PREPARING FOR USE......... 20 TABLE OF CONTENTS MEANS OF REPRESENTATION ...... 5 Advice on preparing for first use ..20 Symbols used ........5 Running in the engine ...... 21 Formats used........5 Starting power of lithium-ion SAFETY ADVICE..........
  • Page 5 TABLE OF CONTENTS 10.17 Adjusting the handlebar position ..40 11.42 Checking/correcting the fluid level of the hydraulic clutch ......70 11 SERVICE WORK ON THE CHASSIS....42 11.43 Changing the hydraulic clutch fluid ..........71 11.1 Raising the motorcycle with a lift stand ..........
  • Page 6 TABLE OF CONTENTS 16.5 Adjusting the idle speed ....102 16.6 Teaching the throttle valve position......... 103 16.7 Checking the basic position of the shift lever........104 16.8 Adjusting the basic position of the shift lever ........104 17 SERVICE WORK ON THE ENGINE ....105 17.1 Changing the fuel screen .....

  • Page 7: Means Of Representation 1

    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! Your motorcycle will be cared for there to the highest degree by specially trained experts using the special tools required.

  • Page 8: Safety Advice

    2 SAFETY ADVICE Use definition – intended use This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle com- plies with the currently valid regulations and categories of the top international motorsports organizations. Info Only operate this vehicle in closed-off areas remote from public road traffic.

  • Page 9: Tampering Warning

    Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

  • Page 10: Protective Clothing

    – Always wear protective clothing that is in good condition and meets the legal regulations. In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing suitable pro- tective clothing. Work rules Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

  • Page 11: Important Notes 3

    Manufacturer warranty, implied warranty The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and con- firmed in the KTM Dealer.net, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.

  • Page 12: View Of Vehicle

    4 VIEW OF VEHICLE View of vehicle, front left (example) E01949-10 Hand brake lever ( p. 14) Clutch lever ( p. 14) Fuel tank filler cap Air filter box cover Engine number ( p. 12) Shift lever ( p. 18) Cold start button ( p.

  • Page 13: View Of Vehicle, Rear Right (Example)

    VIEW OF VEHICLE 4 View of vehicle, rear right (example) E01948-10 Fork air pressure adjustment Combination switch ( p. 15) Stop button ( p. 14) Start button ( p. 15) Throttle grip ( p. 14) Fork compression adjuster Shock absorber compression adjustment Foot brake lever ( p.

  • Page 14: Serial Numbers

    5 SERIAL NUMBERS Vehicle identification number The vehicle identification number is stamped on the right side of the steering head. 401945-10 Type label The type label is fixed to the front of the steering head. 401946-10 Engine number The engine number is stamped on the left side of the engine.

  • Page 15: Shock Absorber Article Number

    SERIAL NUMBERS 5 Shock absorber article number The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side. 401948-10...

  • Page 16: Controls

    6 CONTROLS Clutch lever The clutch lever is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. E01951-10 Hand brake lever Hand brake lever is fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever. H01726-10 Throttle grip The throttle grip...

  • Page 17: Start Button

    Malfunction indicator lamp lights up/flashes orange – The OBD has detected an error in the vehicle elec- tronics. Come safely to a halt, and contact an autho- rized KTM workshop. Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

  • Page 18: Opening Fuel Tank Filler Cap

    6 CONTROLS Opening fuel tank filler cap Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 19: Cold Start Button

    CONTROLS 6 6.10 Cold start button Cold start button is fitted to the bottom of the throttle valve body. The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

  • Page 20: Shift Lever

    6 CONTROLS 6.12 Shift lever Shift lever is mounted on the left of the engine. 401950-10 The gear positions can be seen in the figure. The neutral or idle position is between the first and second gears. 401950-13 6.13 Foot brake lever Foot brake lever is located in front of the right footrest.

  • Page 21: Service Hour Counter

    CONTROLS 6 6.15 Service hour counter The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The service hour counter begins counting when the engine is started and stops when the engine is switched off. Info The value indicated by the service hour counter cannot be cleared or adjusted.

  • Page 22: Preparing For Use

    When using the motorcycle, remember that others may be disturbed by excessive noise. – Ensure that the pre-sales inspection work has been carried out by an authorized KTM workshop. You will receive a delivery certificate when the vehicle is handed over.

  • Page 23: Running In The Engine

    PREPARING FOR USE 7 – Adjust the basic position of the foot brake lever. p. 78) – Adjust the basic position of the shift lever. p. 104) – Get used to the handling characteristic of the motorcycle on suitable terrain before undertaking a more chal- lenging ride.

  • Page 24: Riding Instructions

    8 RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition when it is being operated. –...

  • Page 25: Activating Launch Control

    RIDING INSTRUCTIONS 8 – Remove plug-in stand – Shift the transmission into neutral. 402001-10 Condition Ambient temperature: < 20 °C (< 68 °F) – Push the cold start button in all the way. – Press start button Info Press the start button for a maximum of 5 seconds. Wait for 30 seconds before a further attempt at start- ing.

  • Page 26: Activating Traction Control

    Do not change into a low gear at high engine speed. Info If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. First-gear is used for starting off and for steep inclines. –...

  • Page 27: Applying The Brakes

    Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency. – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) Warning Danger of accidents Moisture and dirt impair the brake system.

  • Page 28: Transporting

    8 RIDING INSTRUCTIONS Note Fire hazard Hot vehicle components pose a fire hazard and explosion risk. – Do not park the vehicle near to materials which are highly flammable or explosive. – Allow the vehicle to cool down before covering it. –...
  • Page 29 In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. – Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Improper handling of fuel is a danger to the environment.

  • Page 30: Service Schedule

    Different service intervals may apply in your country, depending on the local operating conditions. Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.

  • Page 31: Recommended Work

    Final check: Check the vehicle for operating safety and take a test ride. ○ ● ● ● ● ● Read out the error memory after the test ride using the KTM diagnostics tool. ○ ● ● ● ● ● Make a service entry in KTM Dealer.net.
  • Page 32 9 SERVICE SCHEDULE every 48 months every 12 months Every 100 operating hours Every 50 operating hours After 20 operating hours After 10 operating hours ● Perform major engine service including removing and installing the engine. (Change valves, valve springs, valve spring seats, and valve spring retainers. Change the con- necting rod, conrod bearing and crank pin.

  • Page 33: Tuning The Chassis 10

    – As delivered, KTM motorcycles are adjusted for a standard rider weight (with full protective clothing). Guideline Standard rider weight 75 …...

  • Page 34: Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.

  • Page 35: Adjusting The High-Speed Compression Damping Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.

  • Page 36: Measuring The Rear Wheel Dimension Unloaded

    10 TUNING THE CHASSIS Info Turn clockwise to increase the damping; turn counter- clockwise to reduce damping when the shock absorber rebounds. 10.7 Measuring the rear wheel dimension unloaded Preparatory work – Raise the motorcycle with a lift stand. ( p.

  • Page 37: Checking The Static Sag Of The Shock Absorber

    TUNING THE CHASSIS 10 10.8 Checking the static sag of the shock absorber – Measure dimension of rear wheel unloaded. ( p. 34) – Hold the motorcycle upright with aid of an assistant. – Measure the distance again between the rear axle and mark- ing SAG on the rear fender using the sag gage.

  • Page 38: Adjusting The Spring Preload Of The Shock Absorber

    The shock absorber is filled with highly compressed nitrogen. – Please follow the description provided. (Your authorized KTM workshop will be glad to help.) Info Note the current adjustment before changing the spring preload - e.g. measure the spring length.

  • Page 39: Adjusting The Riding Sag

    TUNING THE CHASSIS 10 10.11 Adjusting the riding sag Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the shock absorber. p. 52) – After removing the shock absorber, clean it thoroughly. Main work –...

  • Page 40: Adjusting The Fork Air Pressure

    A little air escapes from the fork leg when connecting. Info This is due to the volume of the hose and not due to a defect in the fork airpump or the fork. Read the accompanying KTM PowerParts instructions. – Adjust the air pressure as specified. Guideline Air pressure 10.4 bar (151 psi)

  • Page 41: Adjusting The Compression Damping Of The Fork

    TUNING THE CHASSIS 10 When disconnecting, excess pressure will escape from the hose – the fork leg itself does not lose any air. The fork airpump indicator switches off automatically after 80 seconds. – Mount the protection cap. Info Only tighten the protection cap by hand. Finishing work –...

  • Page 42: Handlebar Position

    10 TUNING THE CHASSIS Guideline Rebound damping Comfort 17 clicks Standard 12 clicks Sport 7 clicks Info Turn clockwise to increase damping; turn counterclock- wise to reduce damping. – Mount protection cap 10.16 Handlebar position On the upper triple clamp, there are 2 holes at a distance of each other.
  • Page 43 TUNING THE CHASSIS 10 Info Make sure the cables and wiring are positioned cor- rectly. – Position handlebar clamps. – Mount screws but do not tighten yet. – First bolt the handlebar clamps with screws onto the longer, higher side of the handlebar supports so that both parts touch.

  • Page 44: 11 Service Work On The Chassis

    11 SERVICE WORK ON THE CHASSIS 11.1 Raising the motorcycle with a lift stand Note Danger of damage The parked vehicle can roll away or fall over. – Park the vehicle on a firm and level surface. – Raise the motorcycle at the frame underneath the engine. Lift stand (78129955100) Neither wheel is in contact with the ground.

  • Page 45: Cleaning The Dust Boots Of The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.4 Cleaning the dust boots of the fork legs Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) – Remove the fork protector. ( p. 43) Main work – Push dust boots of both fork legs downward.

  • Page 46: Installing The Fork Protector

    11 SERVICE WORK ON THE CHASSIS 11.6 Installing the fork protector – Position the fork protector on the left fork leg. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis – Position the brake line and clamp. Mount and tighten screws –...

  • Page 47: Installing The Fork Legs

    SERVICE WORK ON THE CHASSIS 11 11.8 Installing the fork legs Main work – Position the fork legs. Air release screw of the right fork leg is positioned to the front. Valve of the left fork leg faces the front. Info Grooves are milled into the side of the upper end of the fork legs.

  • Page 48: Installing The Lower Triple Clamp

    11 SERVICE WORK ON THE CHASSIS Main work – Remove indicator lamp holder. – Open cable holder on the left and detach the wiring har- ness. – Remove screw – Remove screw – Take off the upper triple clamp with the handlebar and place to one side.
  • Page 49 SERVICE WORK ON THE CHASSIS 11 – Position the upper triple clamp with the handlebar. – Mount screw , but do not tighten yet. Guideline Screw, top steering M20x1.5 12 Nm (8.9 lbf ft) head V01434-10 – Position the fork legs. Air bleeder screw of the right fork leg is positioned to the front.

  • Page 50: Checking Steering Head Bearing Play

    Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and dam- ages components. – Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.) Info If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.

  • Page 51: Adjusting Steering Head Bearing Play

    SERVICE WORK ON THE CHASSIS 11 Main work – Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable on the steering head bearing. » If there is detectable play: –...

  • Page 52: Lubricating The Steering Head Bearing

    11 SERVICE WORK ON THE CHASSIS 11.13 Lubricating the steering head bearing – Remove the lower triple clamp. p. 45) – Install the lower triple clamp. p. 46) Info The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.

  • Page 53: Installing Front Fender

    SERVICE WORK ON THE CHASSIS 11 Main work – Remove screws . Take off the front fender. F01526-10 11.17 Installing front fender Main work – Position front fender. Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis F01526-10 Finishing work...

  • Page 54: Removing The Shock Absorber

    11 SERVICE WORK ON THE CHASSIS 11.18 Removing the shock absorber Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Remove the cable ties. – Remove screws along with the washers. – Remove screw –...

  • Page 55: Installing The Shock Absorber

    SERVICE WORK ON THE CHASSIS 11 – Remove nut and pull out the swingarm pivot. – Push the link fork back and secure it against falling over. E01960-10 – Hold the shock absorber and remove screw – Remove the shock absorber carefully at the bottom. E01961-10 11.19 Installing the shock absorber...
  • Page 56 11 SERVICE WORK ON THE CHASSIS – Position the foot brake cylinder. Push rod engages in the foot brake cylinder. Info Ensure that the dust boot is correctly seated. – Mount and tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) K01098-01 chassis –...

  • Page 57: Removing The Seat

    SERVICE WORK ON THE CHASSIS 11 11.20 Removing the seat – Remove screw F01533-10 – Raise the rear of the seat, pull the seat back, and lift it off. H02218-10 11.21 Mounting the seat – Mount the front of the seat on the collar bushing of the fuel tank and the rear in the bracket.

  • Page 58: Removing The Air Filter Box Cover

    11 SERVICE WORK ON THE CHASSIS 11.22 Removing the air filter box cover – Pull off the air filter box cover sideways in areas and remove toward the rear. E01962-10 11.23 Installing the air filter box cover – Attach catch of the air filter box in area and push for- ward.

  • Page 59: Installing The Air Filter

    SERVICE WORK ON THE CHASSIS 11 Main work – Detach retaining tab – Remove air filter with air filter support. – Remove air filter from air filter support. E01964-10 11.25 Installing the air filter Main work – Mount the clean air filter on the air filter support. –...

  • Page 60: Removing The Main Silencer

    11 SERVICE WORK ON THE CHASSIS Main work – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 128) Info Only press the air filter to dry it, never wring it out. –...

  • Page 61: Installing The Main Silencer

    SERVICE WORK ON THE CHASSIS 11 11.28 Installing the main silencer – Position the main silencer. – Mount screws with the washers, but do not tighten yet. E01967-11 – Attach spring Spring hook (50305017000C1) – Tighten screws Guideline Remaining screws, 10 Nm (7.4 lbf ft) chassis E01966-11...

  • Page 62: Removing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS Main work – Remove all the screws on the silencer cap. – Take off silencer cap and O-ring – Pull glass fiber yarn filling out of the silencer cap. – Pull glass fiber yarn filling from the inner tube.
  • Page 63 SERVICE WORK ON THE CHASSIS 11 – Unplug connector of the fuel pump. – Pull the fuel tank breather hose off the fuel tank lid. – Clean quick release coupling thoroughly with compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 64: Installing The Fuel Tank

    11 SERVICE WORK ON THE CHASSIS 11.31 Installing the fuel tank Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 65: Checking For Chain Dirt Accumulation

    SERVICE WORK ON THE CHASSIS 11 – Plug in connector for the fuel pump. – Remove the wash cap set and thoroughly clean the quick release coupling using compressed air. Info Under no circumstances should dirt enter into the fuel line.

  • Page 66: Checking The Chain Tension

    11 SERVICE WORK ON THE CHASSIS Main work – Rinse off loose dirt with a soft jet of water. – Remove old grease residue with chain cleaner. Chain cleaner ( p. 128) – After drying, apply chain spray. Off-road chain spray ( p.

  • Page 67: Adjusting The Chain Tension

    SERVICE WORK ON THE CHASSIS 11 11.35 Adjusting the chain tension Warning Danger of accidents Incorrect chain tension damages components and results in accidents. If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded. If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket.

  • Page 68: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    11 SERVICE WORK ON THE CHASSIS 11.36 Checking the chain, rear sprocket, engine sprocket, and chain guide Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Shift the transmission to neutral position. – Check the chain, rear sprocket and engine sprocket for wear.
  • Page 69 SERVICE WORK ON THE CHASSIS 11 – Check the chain sliding guard for wear. » If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard. – Check that the chain sliding guard is firmly seated.

  • Page 70: Checking The Frame

    If the link fork shows signs of damage, cracking, or defor- mation: – Change the link fork. Info Always replace a damaged link fork. Repairing the link fork is not authorized by KTM. 401520-01 11.39 Checking the throttle cable routing Preparatory work –...

  • Page 71: Checking The Rubber Grips

    SERVICE WORK ON THE CHASSIS 11 Main work – Check the throttle cable routing. Both throttle cables must be routed, side by side, on the back of the handlebars and above the fuel tank bracket, to the throttle valve body. Both throttle cables must be secured behind the rubber strap of the fuel tank support.

  • Page 72: Adjusting The Basic Position Of The Clutch Lever

    11 SERVICE WORK ON THE CHASSIS 11.41 Adjusting the basic position of the clutch lever – Adjust the basic position of the clutch lever to your hand size by turning adjusting screw Info When the adjusting screw is turned counterclockwise, the clutch lever moves away from the handlebar.

  • Page 73: Changing The Hydraulic Clutch Fluid

    SERVICE WORK ON THE CHASSIS 11 Info Clean up overflowed or spilled brake fluid immediately with water. 11.43 Changing the hydraulic clutch fluid Warning Skin irritation Brake fluid causes skin irritation. – Keep brake fluid out of the reach of children. –...
  • Page 74 11 SERVICE WORK ON THE CHASSIS – Now press the fluid into the system until it emerges from hole of the master cylinder without bubbles. – Occasionally extract the fluid from the master cylinder reser- voir to prevent overflowing. – Tighten the bleeder screw and remove the bleeding syringe with the hose.

  • Page 75: Brake System 12

    Warning Danger of accidents Worn-out brake discs reduce the braking effect. – Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the front and rear brake disc thickness at multiple...

  • Page 76: Checking The Front Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 77: Checking The Front Brake Linings

    Checking the front brake linings Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...

  • Page 78: Changing The Front Brake Linings

    Changing the front brake linings Warning Danger of accidents Incorrect servicing will cause the brake system to fail. – Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) Warning Skin irritation Brake fluid causes skin irritation.
  • Page 79 BRAKE SYSTEM 12 – Move the brake reservoir mounted on the handlebar to a hori- zontal position. – Remove screws – Take off cover with membrane V01453-11 – Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.

  • Page 80: Checking The Free Travel Of Foot Brake Lever

    12 BRAKE SYSTEM – Fill brake fluid up to the MAX marking. Brake fluid DOT 4 / DOT 5.1 ( p. 126) – Position cover with membrane . Mount and tighten screws Info Clean up overflowed or spilled brake fluid immediately with water.

  • Page 81: Checking The Rear Brake Fluid Level

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Preparatory work –...

  • Page 82: Adding Rear Brake Fluid

    Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.

  • Page 83: Checking The Brake Linings Of The Rear Brake

    Checking the brake linings of the rear brake Warning Danger of accidents Worn-out brake linings reduce the braking effect. – Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.) – Check the brake linings for minimum thickness ≥...
  • Page 84 Danger of accidents Old brake fluid reduces the braking effect. – Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) Note Environmental hazard Hazardous substances cause environmental damage.
  • Page 85 BRAKE SYSTEM 12 – Insert the new brake linings, insert pin , and mount cotter pins Info Always change the brake linings in pairs. Make sure that decoupling plate is mounted on the piston side brake lining. – Operate the foot brake lever repeatedly until the brake lin- ings are in contact with the brake disc and there is a pressure F00406-10 point.

  • Page 86: 13 Wheels, Tires

    13 WHEELS, TIRES 13.1 Removing the front wheel Preparatory work – Raise the motorcycle with a lift stand. ( p. 42) Main work – Remove screws with washers – Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc.

  • Page 87: Installing The Front Wheel

    WHEELS, TIRES 13 13.2 Installing the front wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. –...

  • Page 88: Removing The Rear Wheel

    13 WHEELS, TIRES – Remove the motorcycle from the lift stand. ( p. 42) – Operate the front brake and compress the fork a few times firmly. The fork legs straighten. – Tighten screws Guideline Screw, fork stub 15 Nm (11.1 lbf ft) E01977-11 13.3 Removing the rear wheel...

  • Page 89: Installing The Rear Wheel

    WHEELS, TIRES 13 – Remove spacers H03002-10 13.4 Installing the rear wheel Warning Danger of accidents Oil or grease on the brake discs reduces the braking effect. – Always keep the brake discs free of oil and grease. – Clean the brake discs with brake cleaner when necessary. Main work –...

  • Page 90: Checking The Tire Condition

    Checking the tire condition Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on handling characteristics. The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

  • Page 91: Checking Tire Pressure

    Other spokes will become looser as a result. – Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)
  • Page 92 13 WHEELS, TIRES – Strike each spoke briefly using a screwdriver blade. Info The frequency of the sound depends on the spoke length and spoke diameter. If spokes of the same length and diameter vibrate with a different tone, this is an indication that the spoke tensions differ.

  • Page 93: Electrical System 14

    ELECTRICAL SYSTEM 14 14.1 Removing the 12-V battery Warning Risk of injury 12 V batteries contain harmful substances. – Keep 12 V batteries out of the reach of children. – Keep sparks and open flames away from 12 V batteries. – Only charge 12 V batteries in well-ventilated rooms.

  • Page 94: Installing The 12 V Battery

    14 ELECTRICAL SYSTEM 14.2 Installing the 12 V battery Main work – Position the 12 V battery in the battery compartment with the terminals facing forward, and secure with holding bracket 12 V battery (HJTZ5S-FP-C) ( p. 122) – Mount and tighten screw Guideline Remaining nuts, 10 Nm (7.4 lbf ft)
  • Page 95 It is also impossible to overcharge the 12-V battery with these battery chargers. The charging time may be longer at low temperatures. These battery chargers are only suitable for lithium iron phosphate batteries. Read the accompanying KTM Pow- erParts instructions. Info Never remove cover –...

  • Page 96: Changing Main Fuse

    14 ELECTRICAL SYSTEM Finishing work – Install the 12 V battery. p. 92) – Mount the seat. ( p. 55) 14.4 Changing main fuse Warning Fire hazard Incorrect fuses overload the electrical system. – Only use fuses with the required ampere value. –...

  • Page 97: Cooling System 15

    COOLING SYSTEM 15 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 operat- ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 98: Checking The Coolant Level

    15 COOLING SYSTEM 15.3 Checking the coolant level Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 99: Refilling Coolant

    COOLING SYSTEM 15 Warning Danger of poisoning Coolant is toxic and a health hazard. – Keep coolant out of the reach of children. – Do not allow coolant to come into contact with the skin, the eyes and clothing. – Consult a doctor immediately if coolant is swallowed. –...

  • Page 100: Changing The Coolant

    15 COOLING SYSTEM 15.6 Changing the coolant Warning Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure. – Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

  • Page 101: Tuning The Engine 16

    TUNING THE ENGINE 16 16.1 Checking the play in the throttle cable – Check the throttle grip for smooth operation. – Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable Play in throttle cable 3 …...

  • Page 102: Adjusting The Characteristic Map Of The Throttle Response

    16 TUNING THE ENGINE Main work – Move the handlebar to the straight-ahead position. – Push back sleeve – Loosen nut – Turn adjusting screw in as far as possible. – Loosen nut – Push cold start button all the way to the stop. –...
  • Page 103 TUNING THE ENGINE 16 – Remove guide plate from handle tube – Position the required guide plate on the grip tube. Guideline The label OUTSIDE must be visible. Marking must be positioned at marking Grey guide plate (79002014000) Alternative 1 Black guide plate (79002014100) Info The gray guide plate opens the throttle valve more...

  • Page 104: Changing The Mapping

    16.5 Adjusting the idle speed Warning Danger of accidents The engine may go out spontaneously if the idle speed is set too low. – Set the idle speed to the specified value. (Your authorized KTM workshop will be glad to help.)

  • Page 105: Teaching The Throttle Valve Position

    TUNING THE ENGINE 16 – Run the engine until warm. The cold start button is deactivated – The cold start but- ton is in its basic position. ( p. 17) Danger Danger of poisoning Exhaust gases are toxic and inhal- ing them may result in unconsciousness and death. –...

  • Page 106: Checking The Basic Position Of The Shift Lever

    16 TUNING THE ENGINE 16.7 Checking the basic position of the shift lever Info When driving, the shift lever must not touch the rider's boot when in the basic position. When the shift lever keeps touching the boot, the transmission will be subject to an excessive load. –...

  • Page 107: Service Work On The Engine 17

    SERVICE WORK ON THE ENGINE 17 17.1 Changing the fuel screen Danger Fire hazard Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled. – Do not fuel the vehicle in the vicinity of open flames or lit cigarettes. –...

  • Page 108: Checking The Engine Oil Level

    17 SERVICE WORK ON THE ENGINE 17.2 Checking the engine oil level Info The engine oil level can be checked when the engine is cold or warm. Preparatory work – Stand the motorcycle upright on a horizontal surface. Condition The engine is cold. –...
  • Page 109 SERVICE WORK ON THE ENGINE 17 Main work – Position an appropriate container under the engine. – Remove oil drain plug with the magnet and seal ring. K01068-10 – Remove screw plug with the short oil screen and the O- rings.
  • Page 110 17 SERVICE WORK ON THE ENGINE – Mount and tighten screw plug with the O-ring. Guideline Screw plug, oil M20x1.5 15 Nm (11.1 lbf ft) screen – Mount and tighten oil drain plug with the magnet and a new seal ring. Guideline Oil drain plug with M12x1.5...

  • Page 111: Adding Engine Oil

    126) Info For optimal performance of the engine oil, do not mix different types of engine oil. 401955-10 KTM recommends changing the engine oil where neces- sary. – Mount and tighten the filler plug together with the O-ring. Danger Danger of poisoning Exhaust gases are toxic and inhal-...

  • Page 112: 18 Cleaning, Care

    18 CLEANING, CARE 18.1 Cleaning the motorcycle Note Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly. The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc. Pressure which is too high causes malfunctions and destroys components. –...
  • Page 113 CLEANING, CARE 18 – Treat bare metal (except for brake discs and the exhaust sys- tem) with a corrosion inhibitor. Preserving materials for paints, metal and rubber p. 128) – Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

  • Page 114: 19 Storage

    – Store the vehicle in a dry location that is not subject to large fluctuations in temperature. Info KTM recommends jacking up the motorcycle. – Raise the motorcycle with a lift stand. ( p. 42) – Cover the vehicle with a tarp or a similar cover that is perme-...

  • Page 115: Preparing For Use After Storage

    STORAGE 19 Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and the exhaust system to rust.

  • Page 116: 20 Troubleshooting

    Check the electrical system. – Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool. – Engine does not speed up Malfunction in the electronic Read out the fault memory using the fuel injection KTM diagnostics tool.
  • Page 117 Check the wiring for damage and the electrical plug-in connections for corro- sion and damage. – Read out the fault memory using the KTM diagnostics tool. – High oil consumption Engine vent hose bent Route the vent hose without bends or change it if necessary.

  • Page 118: 21 Blink Code

    21 BLINK CODE Blink code for malfunction indicator lamp 02 Malfunction indicator lamp flashes 2x short Crankshaft speed sensor – circuit fault Error level condition Blink code for malfunction indicator lamp 02a Malfunction indicator lamp flashes 2x per second Error level condition Teaching of throttle valve position required Blink code for malfunction indicator lamp...
  • Page 119 BLINK CODE 21 Blink code for malfunction indicator lamp 33 Malfunction indicator lamp flashes 3x long, 3x short Injection valve cylinder 1 – circuit fault Error level condition Blink code for malfunction indicator lamp 37 Malfunction indicator lamp flashes 3x long, 7x short Ignition coil –...

  • Page 120: 22 Technical Data

    22 TECHNICAL DATA 22.1 Engine Design 1-cylinder 4-stroke engine, water-cooled Displacement 449.9 cm³ (27.455 cu in) Stroke 63.4 mm (2.496 in) Bore 95 mm (3.74 in) Compression ratio 12.75:1 Idle speed 2,100 … 2,200 rpm Control OHC, 4 valves controlled via rocker arm Valve diameter, intake 40 mm (1.57 in) Valve diameter, exhaust...

  • Page 121: Engine Tightening Torques

    TECHNICAL DATA 22 22.2 Engine tightening torques Screw, oil jet for piston cooling 2 Nm (1.5 lbf ft) Loctite ® 243™ Crankshaft speed sensor screw and 6 Nm (4.4 lbf ft) Loctite ® 243™ cable retainer Oil nozzle for clutch lubrication 2 Nm (1.5 lbf ft) Loctite ®...

  • Page 122: Capacities

    22 TECHNICAL DATA Oil nozzle for conrod bearing lubri- M6x0.75 2 Nm (1.5 lbf ft) cation Plug, oil channel 9 Nm (6.6 lbf ft) Loctite ® 243™ Screw, rocker arm bearing M7x1 15 Nm (11.1 lbf ft) Crankshaft clamp screw plug 10 Nm (7.4 lbf ft) Plug, timing chain tensioner 8 Nm (5.9 lbf ft)

  • Page 123: Chassis

    TECHNICAL DATA 22 22.4 Chassis Frame Central tube frame made of chrome molybdenum steel tubing Fork WP XACT 5448 Suspension travel front 285 mm (11.22 in) rear 266 mm (10.47 in) Fork offset 16 mm (0.63 in) Shock absorber WP XACT 5750 Brake system front Single disc brake with radially screwed four-piston...

  • Page 124: Electrical System

    165/630 R 17 TL Bridgestone Battlax Supermoto BM01Z Bridgestone Battlax Racing R02Z The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com 22.7 Fork Fork article number 0262C108U406000 WP XACT 5448...

  • Page 125: Shock Absorber

    TECHNICAL DATA 22 22.8 Shock absorber Shock absorber article number 0262C408U408000 WP XACT 5750 Shock absorber Lowspeed compression damping Comfort 17 clicks Standard 15 clicks Sport 13 clicks Highspeed compression damping Comfort 2 turns Standard 1.5 turns Sport 1 turn Rebound damping Comfort 17 clicks...
  • Page 126 22 TECHNICAL DATA Remaining nuts, chassis 5 Nm (3.7 lbf ft) Remaining screws, chassis 5 Nm (3.7 lbf ft) Screw, battery terminal 2.5 Nm (1.84 lbf ft) Screw, frame protector 3 Nm (2.2 lbf ft) Screw, shock absorber adjusting 5 Nm (3.7 lbf ft) ring Nut, cable on starter motor 4 Nm (3 lbf ft)
  • Page 127 TECHNICAL DATA 22 Screw, front brake caliper 45 Nm (33.2 lbf ft) Loctite ® 243™ Screw, handlebar support 40 Nm (29.5 lbf ft) Loctite ® 243™ Screw, top shock absorber 60 Nm (44.3 lbf ft) Loctite ® 2701™ Nut, fuel pump 15 Nm (11.1 lbf ft) Nut, angle lever to link fork M14x1.5...

  • Page 128: 23 Substances

    23 SUBSTANCES Brake fluid DOT 4 / DOT 5.1 Standard/classification – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties. Recommended supplier Castrol – REACT PERFORMANCE DOT 4 MOTOREX ®...
  • Page 129 SUBSTANCES 23 Fork oil (SAE 4) (48601166S1) Standard/classification – SAE ( p. 130) (SAE 4) Guideline – Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties. Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification –...

  • Page 130: 24 Auxiliary Substances

    24 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ® – Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ® – Chain Clean Fuel additive Recommended supplier MOTOREX ® – Fuel Stabilizer High viscosity grease Recommended supplier ® – LGHB 2 Long-life grease Recommended supplier...
  • Page 131 AUXILIARY SUBSTANCES 24 Silicone spray Recommended supplier MOTOREX ® – Silicone Spray Special cleaner for glossy and matte paint finishes, metal and plastic surfaces Recommended supplier MOTOREX ® – Quick Cleaner Special grease (00062010053) Recommended supplier Klüber Lubrication ® – KLÜBERFOOD NH1 34‑401 Universal oil spray Recommended supplier...

  • Page 132: 25 Standards

    25 STANDARDS JASO T903 MA2 Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard. Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor- cycle specification. Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

  • Page 133: Index Of Special Terms 26

    INDEX OF SPECIAL TERMS 26 Launch control Vehicles electronics functions for achieving the best possible acceleration from a standing position On-board diagnosis Vehicle system, which monitors the specified parame- ters of the vehicle electronics...

  • Page 134: 27 List Of Abbreviations

    27 LIST OF ABBREVIATIONS Art. no. Article number circa compare e.g. for example etc. et cetera i.a. inter alia number poss. possibly...

  • Page 135: List Of Symbols 28

    Malfunction indicator lamp lights up/flashes orange – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop. Malfunction indicator lamp flashes orange rapidly – Launch control is activated.

  • Page 136: Index

    INDEX Chain guide INDEX checking ......66 12 V battery Chain tension installing ......92 adjusting .
  • Page 137 INDEX Fork part number ..... . . 12 Fork protector Main fuse installing ......44 changing .
  • Page 138 INDEX Rubber grips fork ......122 checking ......69 shock absorber .
  • Page 139 *3214231en* 3214231en 09/2020 KTM Sportmotorcycle GmbH 5230 Mattighofen/Austria Photo: Mitterbauer/KISKA/KTM http://www.ktm.com...

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