KTM 505 SX Owner's Manual
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KTM 505 SX Owner's Manual

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OWNER'S MANUAL
2012
505 SX ATV
Art. no. 3211728en

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  • Page 1 OWNER'S MANUAL 2012 505 SX ATV Art. no. 3211728en...
  • 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 a lot of enjoyment in riding this vehicle.
  • Page 4 DEAR KTM CUSTOMER 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. Issued by: TÜV Management Service KTM-Sportmotorcycle AG 5230 Mattighofen, Austria...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Starting ................32 TABLE OF CONTENTS MEANS OF REPRESENTATION ..........7 Starting off ..............33 IMPORTANT INFORMATION ........... 8 Shifting ................33 VIEW OF VEHICLE..............12 Braking ................34 View of the vehicle from the left front (example) ....12 Riding ................
  • Page 6 TABLE OF CONTENTS Front shock absorber - adjusting the rebound damping..57 Adjusting the toe width of rear axle ....... 90 Front shock absorber - adjusting the cross over....59 Checking chain dirt ............92 Front shock absorber - adjusting the spring preload ..... 60 Cleaning the chain............
  • Page 7 TABLE OF CONTENTS Topping up brake fluid of rear brake ......117 Draining the carburetor float chamber ......146 Checking rear brake linings ..........119 Ignition curve plug connection ......... 147 Changing the ignition curve ..........148 Removing rear brake linings ........
  • Page 8 TABLE OF CONTENTS TECHNICAL DATA - FRONT SHOCK ABSORBER....176 TECHNICAL DATA - REAR SHOCK ABSORBER..... 178 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS ................180 SUBSTANCES..............182 AUXILIARY SUBSTANCES........... 186 STANDARDS..............189 INDEX ................190...

  • 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 IMPORTANT INFORMATION Transport Note Danger of damage Danger of damage from accidental rolling of vehicle. – Park the vehicle on a surface that is as horizontal as possible and apply the parking brakes. Note Fire hazard Some vehicle components become very hot when the vehicle is operated. –...
  • Page 13 IMPORTANT INFORMATION Info Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are missing, you or others may not recognize potential hazards and may therefore be injured. 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.

  • Page 14: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 401377-10...
  • Page 15 VIEW OF VEHICLE Hand brake lever, parking brake ( p. 20) Fuse box Shock absorber compression adjustment Front shock absorber Shock absorber rebound adjustment Heel protector Shift lever ( p. 25) Kill switch/emergency OFF switch with rip cord ( p. 21) Clutch lever ( p.

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

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 401378-10...
  • 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 lever ( p. 26) Handlebar bridge Throttle lever ( p. 142) Handlebar cushion...

  • Page 18: Serial Numbers

    SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper A-arm. 301771-10 Type label The type label is located on the frame tube on the right and left in front of the radiator. 301858-10...

  • Page 19: Engine Number

    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. 301832-10...

  • Page 20: Shock Absorber Part Number, Rear

    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: 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 24: Opening Filler Cap

    CONTROLS Opening filler cap Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • 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 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 Lever

    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 lever 5.11 The foot brake lever is located in front of the right footrest and operates the rear wheel brake.

  • Page 29: Preparing For Use

    – 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 PREPARING FOR USE 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 Failure of brake system. – If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.

  • Page 31: Running In The Engine

    PREPARING FOR USE – 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 PREPARING FOR USE Guideline Maximum engine speed During the first operating hour 7,000 rpm Maximum engine performance ≤ 75 % During the first 3 operating hours – Avoid fully opening the throttle!

  • Page 33: Riding Instructions

    RIDING INSTRUCTIONS Checks and maintenance measures when preparing for use Info Before each use, check the condition of the vehicle and its operating safety. The vehicle must be in perfect technical condition when it is being operated. – Check the engine oil level. ( p.

  • Page 34: Starting

    RIDING INSTRUCTIONS Starting Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.

  • Page 35: Starting Off

    RIDING INSTRUCTIONS – 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. The electric starter does not turn over when the electric starter button is pressed.

  • Page 36: Braking

    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.) Warning Danger of accidents Reduced braking efficiency due to wet or dirty brakes.

  • 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 Riding in bends Info When riding in bends, the outer wheels cover a greater distance than the inner wheels. Because the rear axle of the ATV is rigid in design, the rear wheels turn at the same speed. The difference in distance is compensated by slippage of the tires. Warning Danger of accidents Excessive speed and turning at sharp angles can cause the vehicle to roll over.

  • 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 Through Water

    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: Switching Off The Engine

    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 Stopping, parking 7.14 Warning Danger of burns Some vehicle components become very hot when the vehicle is operated. – Do not touch hot components such as exhaust system, radiator, engine, shock absorber and brakes. Allow these components to cool down before starting work on them. Note Danger of damage Danger of damage from accidental rolling of vehicle.

  • Page 45: Refueling

    RIDING INSTRUCTIONS Refueling 7.15 Danger Fire hazard Fuel is highly flammable. – Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...

  • Page 46: Service Schedule

    SERVICE SCHEDULE Service schedule S10A S20A Check that the electrical equipment is functioning properly. • • • • • Check and charge the battery. • • • Change the engine oil and oil filter, clean the oil screen. p. 151) Check the front brake linings.
  • Page 47 • • Create a service entry in the KTM DEALER.NET and in the service record. S1N: Once after 1 operating hour - corresponds to about 7 liters of fuel (1.8 US gal) S10A: Every 10 operating hours - corresponds to about 70 liters of fuel (18.5 US gal) / after every race...

  • Page 48: Maintenance Work (As An Additional Order)

    SERVICE SCHEDULE Maintenance work (as an additional order) S20A S40A S80A • Change the front brake fluid. • Change the rear brake fluid. • Change the sealing sleeves of the foot brake cylinder. Change the hydraulic clutch fluid. • Lubricate the steering column bearing. •...
  • Page 49 SERVICE SCHEDULE S20A S40A S80A Change the outer clutch hub. • • • • Check the oil pressure regulator valve. • • Check the oil pumps and lubrication system. • • Check the timing assembly. Change all engine bearings. • S20A: Every 20 operating hours - corresponds to about 140 liters of fuel (37 US gal) S40A: Every 40 operating hours - corresponds to about 280 liters of fuel (74 US gal) S80A: Every 80 operating hours - corresponds to about 560 liters of fuel (148 US gal)

  • Page 50: Tuning The Chassis

    TUNING THE CHASSIS Basic information on changing the chassis settings The standard setting of the chassis is the result of many fine tuning tests. It is laid out for the weight of the average rider (with a full set of protective clothing) and for a sporty driving style.

  • Page 51: Rear Shock Absorber - Adjusting The Low-Speed Compression Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting has an impact on the slow to normal compression of the shock absorber.

  • Page 52: Rear Shock Absorber - Adjusting The High-Speed Compression Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting has an impact on the fast compression of the shock absorber.

  • Page 53: Rear Shock Absorber - Adjusting The Rebound Damping

    TUNING THE CHASSIS – Turn adjusting screw all the way clockwise with a socket wrench. Info Do not loosen nut – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 301791-10 Comfort 1.5 turns Standard...
  • Page 54 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The rebound damping setting has an impact on the rebound of the shock absorber.

  • Page 55: Rear Shock Absorber - Adjusting The Spring Preload

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.
  • Page 56 TUNING THE CHASSIS – Release counter ring . Hold adjusting ring while doing so. Hook wrench (83019002000) – Turn adjusting ring until the spring pack is no longer under tension. 200601-01 – Measure the overall spring pack when not under tension. Info The spring preload is the difference in length between the spring pack when...

  • Page 57: Front Shock Absorber - Adjusting The Low-Speed Compression Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The low-speed setting has an impact on the slow to normal compression of the shock absorber.

  • Page 58: Front Shock Absorber - Adjusting The High-Speed Compression Damping

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The high-speed setting has an impact on the fast compression of the shock absorber.

  • Page 59: Front Shock Absorber - Adjusting The Rebound Damping

    TUNING THE CHASSIS – Turn adjusting screw all the way clockwise with a socket wrench. Info Do not loosen nut – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed 301786-10 Comfort 1.5 turns Standard...
  • Page 60 Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The rebound damping setting has an impact on the rebound of the shock absorber.

  • Page 61: Front Shock Absorber - Adjusting The Cross Over

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info The cross over setting is used to adjust the suspension travel of the short (soft) spring.

  • Page 62: Front Shock Absorber - Adjusting The Spring Preload

    Caution Danger of accidents Disassembly of pressurized parts can lead to injury. – The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.) Info Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.
  • Page 63 TUNING THE CHASSIS Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring. – Raise the vehicle with the lifting gear. ( p. 67) – Clean the shock absorber thoroughly. –...
  • Page 64 TUNING THE CHASSIS – Tighten the spring packet by turning adjusting ring to measurement Guideline Spring preload Comfort 3 mm (0.12 in) Standard 5 mm (0.2 in) Sport 8 mm (0.31 in) Info Spring preload is the difference in length between the spring pack when it is unloaded and when it is installed.

  • Page 65: Handlebar Position

    TUNING THE CHASSIS Handlebar position 9.12 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. Distance between holes 3.5 mm (0.138 in) The holes on the handlebar bridge are placed at a distance of from the center.

  • Page 66: Adjusting Handlebar Position

    TUNING THE CHASSIS Adjusting handlebar position 9.13 – 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 67 TUNING THE CHASSIS – 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. – Remove screws – Remove screws .
  • Page 68 TUNING THE CHASSIS Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure cables and wiring are positioned correctly. – Mount the handlebar cushion.

  • Page 69: Maintenance Work On The Chassis

    MAINTENANCE WORK ON THE CHASSIS Raising the vehicle with the lifting gear 10.1 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. – Raise the vehicle on the frame underneath the engine.
  • Page 70 MAINTENANCE WORK ON THE CHASSIS 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 71: Installing The Rear Shock Absorber

    MAINTENANCE WORK ON THE CHASSIS Installing the rear shock absorber 10.4 – 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 72: Installing The Radiator Spoiler

    MAINTENANCE WORK ON THE CHASSIS – Remove the screws on the fuel tank. 301817-10 – Remove the screws on the radiator. – Detach the radiator spoiler and remove it. 301816-10 Installing the radiator spoiler 10.6 Info The operations are the same on the left and right.
  • Page 73 MAINTENANCE WORK ON THE CHASSIS – Hook catch of the radiator spoiler into holder of the fuel tank and position it on the radiator. 301819-10 – Mount and tighten screws on the radiator. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) –...

  • Page 74: Removing The Front Cover

    MAINTENANCE WORK ON THE CHASSIS Removing the front cover 10.7 – Remove screw – Slide the front cover up and remove it. 301811-10 Installing the front cover 10.8 – Position the front cover in slots on both sides of the front trim. –...

  • Page 75: Removing The Rear Fender

    MAINTENANCE WORK ON THE CHASSIS Removing the rear fender 10.9 – Remove the seat ( p. 78) – Remove screws 301822-10...

  • Page 76: Installing The Rear Fender

    MAINTENANCE WORK ON THE CHASSIS – 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. Info This prevents the carburetor connection boot from disconnecting from the carbu- retor.

  • Page 77: Removing The Front Trim

    MAINTENANCE WORK ON THE CHASSIS – Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( p. 78) 301822-11 Removing the front trim 10.11 – Remove the front cover. ( p. 72)
  • Page 78 MAINTENANCE WORK ON THE CHASSIS – 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 79: Installing The Front Trim

    MAINTENANCE WORK ON THE CHASSIS Installing the front trim 10.12 – 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 80: Removing The Seat

    MAINTENANCE WORK ON THE CHASSIS Removing the seat 10.13 – 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 10.14 – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the seat and slide tab under fuel tank...

  • Page 81: Removing The Air Filter

    MAINTENANCE WORK ON THE CHASSIS – Push down the rear of the seat until release hook engages. – Make sure that the seat is correctly locked in. 301809-11 Removing the air filter 10.15 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. –...

  • Page 82: Installing The Air Filter

    MAINTENANCE WORK ON THE CHASSIS – 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. Info This prevents the carburetor connection boot from disconnecting from the carbu- retor.

  • Page 83: Cleaning The Air Filter And Air Filter Box

    MAINTENANCE WORK ON THE CHASSIS – Put in both parts together, position them and fix them with the air filter support Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. –...

  • Page 84: Checking The Toe

    MAINTENANCE WORK ON THE CHASSIS Info Only press the air filter to dry it; never wring it out. – Oil the dry air filter with a high/quality filter oil. Oil for foam air filter ( p. 187) – Clean the air filter box. –...
  • Page 85 MAINTENANCE WORK ON THE CHASSIS 400333-10 – Measure distances » If distances are not equal: – Adjust the toe. p. 84) – Measure distances Guideline Front 0 mm (0 in)

  • Page 86: Adjusting The Toe

    MAINTENANCE WORK ON THE CHASSIS 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 87 MAINTENANCE WORK ON THE CHASSIS 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 Guideline Front 0 mm (0 in)

  • Page 88: Checking/Adjusting The Camber

    MAINTENANCE WORK ON THE CHASSIS 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 89 MAINTENANCE WORK ON THE CHASSIS – 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. » If marking is not aligned with the top edge of the A-arm: –...

  • Page 90: Fork Offset

    MAINTENANCE WORK ON THE CHASSIS – 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 Guideline Nut, A-arm top M12x1.25...

  • Page 91: Adjusting The Fork Offset

    MAINTENANCE WORK ON THE CHASSIS Adjusting the fork offset 10.22 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Raise the vehicle with the lifting gear. ( p.

  • Page 92: Adjusting The Toe Width Of Rear Axle

    MAINTENANCE WORK ON THE CHASSIS Adjusting the toe width of rear axle 10.24 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 93 MAINTENANCE WORK ON THE CHASSIS 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 94: Checking Chain Dirt

    MAINTENANCE WORK ON THE CHASSIS Checking chain dirt 10.25 – Check the chain for heavy soiling. » If the chain is very dirty: – Clean the chain. ( p. 92) 400678-01 Cleaning the chain 10.26 Warning Environmental hazard Hazardous substances cause environmental damage. –...

  • Page 95: Checking The Chain Tension

    MAINTENANCE WORK ON THE CHASSIS – Clean the chain regularly and then treat with chain spray. Chain cleaner ( p. 186) Off-road chain spray ( p. 187) 400725-01 Checking the chain tension 10.27 Warning Danger of accidents Danger caused by incorrect chain tension. –...

  • Page 96: Checking The Chain, Rear Sprocket, Engine Sprocket, And Chain Guide

    MAINTENANCE WORK ON THE CHASSIS – 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. Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 97 MAINTENANCE WORK ON THE CHASSIS – Pull on the lower part of the chain with the specified weight Guideline Chain-wear measuring weight 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the upper chain section. Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.
  • Page 98 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding guard at the top 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. B00465-01...
  • Page 99 MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding guard at the bottom 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. –...

  • Page 100: Adjusting Chain Tension

    MAINTENANCE WORK ON THE CHASSIS – Check the chain sliding piece for wear. » If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece. – Check the chain sliding piece for tightness. »...
  • Page 101 MAINTENANCE WORK ON THE CHASSIS – Check the chain tension. ( p. 93) – 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 –...

  • Page 102: Checking The Frame

    If the frame exhibits cracking or deformation due to a mechanical impact: – Change the frame. Info A frame that has been damaged due to a mechanical impact must always be changed. Repair of the frame is not authorized by KTM. 401385-01 Checking the swingarm 10.31 –...

  • Page 103: Greasing The Rear Wheel Eccentric Element

    MAINTENANCE WORK ON THE CHASSIS Greasing the rear wheel eccentric element 10.32 – Use a grease gun to fill the rear wheel eccentric element via grease nipple until grease emerges from the left shaft seal ring Long-life grease ( p. 184) –...

  • Page 104: Additionally Securing The Rubber Grip

    MAINTENANCE WORK ON THE CHASSIS Additionally securing the rubber grip 10.34 – Check the rubber grip. ( p. 101) – Secure the rubber grip at two points using the securing wire. Securing wire (54812016000) Wire twister forceps (U6907854) The twisted wire ends face away from the hands and are bent toward the rubber grip.

  • Page 105: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE WORK ON THE CHASSIS – Position the cover with the membrane. Mount and tighten screws. Adjusting basic position of clutch lever 10.36 – 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 106: Installing The Engine Guard

    MAINTENANCE WORK ON THE CHASSIS Installing the engine guard 10.38 – Position the engine guard on the frame bearer. Mount and tighten screws Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Remaining screws, chassis 25 Nm (18.4 lbf ft) 301823-10...

  • Page 107: Brakes

    BRAKES Checking the free travel of the hand brake lever 11.1 Warning Danger of accidents Brake system failure. – If there is no free travel on the hand brake lever, pressure builds up in the front brake circuit. The front brake can fail due to overheating.

  • Page 108: Checking Brake Discs

    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...

  • Page 109: Checking Front Brake Fluid Level

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.

  • Page 110: Topping Up The Front Brake Fluid

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

  • Page 111: Checking The Front Brake Linings

    B00886-10 Checking the front brake linings 11.6 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. 125)

  • Page 112: Removing Front Brake Linings

    11.7 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 113: Mounting 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 114: Changing The Front Brake Linings

    BRAKES – 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 the locking split pins –...
  • Page 115 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 116: Checking Free Travel Of Foot Brake Lever

    BRAKES – Remove the front brake linings. p. 110) – 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 117: Adjusting Basic Position Of Foot Brake Lever

    BRAKES – Disconnect spring – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free travel Guideline Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in) »...

  • Page 118: 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. Check the brake system and not continue riding. (Your authorized KTM workshop will be glad to help.)

  • Page 119: Topping Up Brake Fluid Of Rear Brake

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) – Park the vehicle on a horizontal surface.
  • Page 120 Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.

  • Page 121: Checking Rear Brake Linings

    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 122: 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 onto the brake disc by hand in order to push back the brake pis- ton.

  • Page 123: Mounting 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 124 BRAKES – Check that the sliding plate is seated correctly in the brake caliper support and insert the brake linings. Info Make sure that the decoupling plate is mounted on the piston side of the brake lining. 300265-10 – Grease the bearing bolt and insert the brake caliper with the bearing bolt into the brake caliper support Lubricant (T625) (...

  • Page 125: Changing Rear Brake Linings

    Warning Danger of accidents Reduced braking efficiency due to old brake fluid. – Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.) Warning Environmental hazard Hazardous substances cause environmental damage.
  • Page 126 BRAKES – Remove the rear brake linings. p. 120) – Remove screw cap 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. – Mount the rear brake linings.

  • Page 127: Wheels, Tires

    WHEELS, TIRES Removing wheel/wheels 12.1 Info Proceed in the same way on the other wheels if necessary. – Pull the hand brake lever, push the locking pawl down and release the hand brake lever. (Figure 301776-10 p. 20) – Loosen the wheel nuts –...

  • Page 128: Installing The Wheel/Wheels

    WHEELS, TIRES Installing the wheel/wheels 12.2 Note Material damage Damage and destruction of components from incorrect positioning and mounting. – Do not swap the wheels; the tire valves must always be on the outside when the wheels are positioned and mounted. Info Proceed in the same way on the other wheels if necessary.

  • Page 129: Checking The Tire Condition

    12.3 Info Only mount tires that have been approved and/or recommended by KTM. Other tires could have a negative effect on vehicle handling. The type, condition and air pressure of the tires all have an important impact on the handling characteristics of the vehicle.

  • Page 130: Checking The Tire Air Pressure

    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, regard- less of the actual state of wear.

  • Page 131: Electrical System

    ELECTRICAL SYSTEM Removing the battery 13.1 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 132: Installing The Battery

    Environmental hazard The battery contains elements that are harmful to the environment. – 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.
  • Page 133 ELECTRICAL SYSTEM 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 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.

  • Page 134: Changing The Main Fuse

    ELECTRICAL SYSTEM – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) In addition, this battery charger can be used to test the open-circuit current, the start ability of the battery and the alternator. With this device, you cannot overcharge the battery.

  • Page 135: Changing The Fuses Of Individual Power Consumers

    ELECTRICAL SYSTEM – 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 Warning Fire hazard The electrical system can be overloaded if the wrong fuses are used.
  • Page 136 ELECTRICAL SYSTEM – 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 Fuse 5 - power supply for auxiliary equipment...
  • Page 137 ELECTRICAL SYSTEM – Close the cover of the fuse box. – Install the front cover. ( p. 72)

  • Page 138: Cooling System

    COOLING SYSTEM Cooling system 14.1 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 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

  • Page 139: Checking Antifreeze And Coolant Level

    COOLING SYSTEM Checking antifreeze and coolant level 14.3 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 140: Checking The Coolant Level

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 182) – Mount the radiator cap. Checking the coolant level 14.4 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is operated. –...

  • Page 141: Draining Coolant

    COOLING SYSTEM Alternative 2 Coolant (mixed ready to use) ( p. 182) – Mount the radiator cap. Draining coolant 14.5 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 142: Filling Coolant/Bleeding The Cooling System

    COOLING SYSTEM – Remove radiator cap . Completely drain the coolant. – Mount screw with a new seal and tighten. Guideline Screw, water pump cover 10 Nm (7.4 lbf ft) – Mount screw with a new seal and tighten. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 301838-10...
  • Page 143 COOLING SYSTEM – Remove the radiator cap – Fill the coolant into the radiator. Coolant 1.50 l (1.59 qt.) Coolant ( p. 182) Coolant (mixed ready to use) ( p. 182) 301838-11 – Open screw to bleed the radiator. Tighten the screw when coolant emerges from the opening.

  • Page 144: Tuning The Engine

    TUNING THE ENGINE Throttle lever 15.1 The throttle lever is fitted on the right side of the handlebar. The throttle lever is used to control the engine speed. 301773-10 Checking the play in the throttle cable 15.2 – Check the throttle lever for smooth operation. –...

  • Page 145: Adjusting Play In Throttle Cable

    TUNING THE ENGINE – Start the engine and let it run idle. Move the handlebar to and fro over the entire steer- ing range. The idle speed must not change. » If the idle speed changes: – Adjust the play in the throttle cable. ( p.

  • Page 146: Carburetor - Idle

    TUNING THE ENGINE Carburetor - idle 15.4 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. Info The carburetor and its components are subject to increased wear caused by engine vibration.
  • Page 147 TUNING THE 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 148: Draining The Carburetor Float Chamber

    TUNING THE 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 15.6 Danger Fire hazard Fuel is highly flammable.

  • Page 149: Ignition Curve Plug Connection

    TUNING THE 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. – Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning.

  • Page 150: Changing The Ignition Curve

    TUNING THE ENGINE Changing the ignition curve 15.8 – Remove the front trim. ( p. 75) Changing the ignition curve from Performance to Soft. – Disconnect plug-in connector . (Figure 301829-10 p. 147) Soft – The plug-in connector is disconnected for better driveability. ( p.

  • Page 151: Adjusting The Basic Position Of The Shift Lever

    TUNING THE ENGINE Adjusting the basic position of the shift lever 15.10 – Remove screw and take off shift lever B00881-10 – Clean gear teeth of the shift lever and shift shaft. – Position the shift lever in the desired position on the shift shaft and engage the gearing. Info The range of adjustment is limited.

  • Page 152: Maintenance Work On The Engine

    MAINTENANCE WORK ON THE ENGINE Checking the engine oil level 16.1 Info The engine oil level can be checked on a cold or hot engine. – Park the vehicle on a horizontal surface. Condition The engine is at operating temperature. –...

  • Page 153: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    MAINTENANCE WORK ON THE ENGINE Changing the engine oil and oil filter, cleaning the oil screen 16.2 – Drain the engine oil. p. 151) – Remove the oil filter. p. 152) – Install the oil filter. p. 154) – Fill up with engine oil. p.

  • Page 154: Removing The Oil Filter

    MAINTENANCE WORK ON THE 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 155: Cleaning The Oil Screen

    MAINTENANCE WORK ON THE 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 156: Installing The Oil Filter

    MAINTENANCE WORK ON THE 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. – Place a suitable container under the engine. – Loosen screw plug by striking it lightly with a hammer a few times.

  • Page 157: Filling Up With Engine Oil

    MAINTENANCE WORK ON THE ENGINE – Oil the O-ring of the oil filter cover and mount it along with the oil filter cover. – Mount and tighten screws Guideline Screw, oil filter cover 6 Nm (4.4 lbf ft) 301843-11 Filling up with engine oil 16.7 Info A lack of engine oil or poor-quality engine oil results in premature wear to the engine.

  • Page 158: Adding Engine Oil

    MAINTENANCE WORK ON THE ENGINE Danger Danger of poisoning Exhaust gases are poisonous and inhaling them may 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 an enclosed space without an effective exhaust extraction system.
  • Page 159 MAINTENANCE WORK ON THE ENGINE Info To ensure optimal engine oil performance, it is advisable to not use different engine oils. We recommend making an oil change in this case. – Mount and tighten filler cap...

  • Page 160: Cleaning, Care

    CLEANING, CARE Cleaning the vehicle 17.1 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 161 CLEANING, CARE – First remove coarse dirt particles with a gentle spray of water. – Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush. Motorcycle cleaner ( p. 187) Info Clean the vehicle using a soft sponge and warm water containing normal motor- cycle cleaner.
  • Page 162 CLEANING, CARE – Treat all plastic parts and powder-coated parts with a mild cleaning and care product. Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces ( p. 188)

  • Page 163: Storage

    STORAGE Storage 18.1 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 164: Preparing The Vehicle For Use After Storage

    STORAGE – Store the vehicle in a dry location that is not subject to large fluctuations in tempera- ture. – Cover the vehicle with a tarp or similar cover that is permeable to air. Info Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 165: 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 166 TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Kill switch/emergency OFF switch with Check the wiring harness. (visual check) rip cord faulty – Check the electrical system. – Throttle lever activated Do not activate the throttle lever. –...
  • Page 167 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. – Engine stalls or is backfiring into the Lack of fuel Turn the handle of the fuel tap to ON.
  • Page 168 TROUBLESHOOTING Faults Possible cause Action – Engine has a lack of power Air filter excessively dirty Clean the air filter and air filter box. p. 81) – Exhaust system leaky, deformed or too Check exhaust system for damage. little glass fiber yarn filling in main silencer –...

  • Page 169: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design Single cylinder 4-stroke engine, water-cooled Displacement 477.5 cm³ (29.139 cu in) Stroke 60.8 mm (2.394 in) Bore 100 mm (3.94 in) Compression ratio 12.5:1 Idle speed 1,500… 1,600 rpm Control DOHC, four valves controlled via cam lever, drive via helical gear pair and tooth-wheel chain Valve diameter, intake 40.4 mm (1.591 in)

  • Page 170: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 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 Starting aid Electric starter Capacity - engine oil...

  • Page 171: 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 172 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, clutch spring 10 Nm (7.4 lbf ft) – Screw, engine case 10 Nm (7.4 lbf ft) ® Screw, exhaust flange 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, ignition pulse generator cable 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 173 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 174: 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 Diameter of bore in carburetor body 2.5 mm (0.098 in) Main jet Jet needle...

  • Page 175: 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 176 TECHNICAL DATA - CHASSIS Fuel tank full 173 kg (381 lb.) 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)

  • Page 177: Tires

    20 x 6.00 - 10 18 x 10.00 - 8 DWT MXF V2 202 DWT MXR V1 202 Additional information is available in the Service section under: http://www.ktm.com Capacity - fuel 23.2 Total fuel tank capacity approx. 10.3 l (2.72 US gal) Super unleaded (ROZ 95/RON 95/PON 91) ( p.

  • Page 178: 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 179 TECHNICAL DATA - FRONT SHOCK ABSORBER 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. 184)

  • Page 180: 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 181 TECHNICAL DATA - REAR SHOCK ABSORBER 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. 184)

  • Page 182: Technical Data - Tightening Torques For Chassis

    TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Screw, battery terminal 2.5 Nm (1.84 lbf ft) – 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) –...
  • Page 183 TECHNICAL DATA - TIGHTENING TORQUES FOR CHASSIS – Screw, footrest 45 Nm (33.2 lbf ft) – 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 184: Substances

    – Guideline – Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the correspond- ® ing properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 185 SAE ( p. 189) (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 186 – ISO VG (15) Guideline – Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 187 SUBSTANCES Super unleaded (ROZ 95/RON 95/PON 91) According to – DIN EN 228 (ROZ 95/RON 95/PON 91) Guideline – Only use unleaded super fuel that matches or is equivalent to the specified fuel grade. – Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use. Info Do not use fuel containing methanol (e.

  • Page 188: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean Cleaning and preserving materials for metal, rubber and plastic Guideline –...
  • Page 189 AUXILIARY SUBSTANCES Lubricant (T625) Guideline – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Motorcycle cleaner Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Clean 900 Off-road chain spray Guideline – ® KTM recommends Motorex products.
  • Page 190 AUXILIARY SUBSTANCES Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces Guideline – ® KTM recommends Motorex products. Supplier ® Motorex – Clean & Polish Rubber grip adhesive (00062030051) Supplier KTM-Sportmotorcycle AG – GRIP GLUE...

  • Page 191: 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 192: Index

    INDEX Brake linings of front brake INDEX changing ........112 Accessories .
  • Page 193 INDEX Chassis number ....... . . 16 Engine oil adding ........156 Choke .
  • Page 194 INDEX Front cover installing ........72 Ignition curve removing .
  • Page 195 INDEX perpendicular to the slope ..... . . 39 Preparing for use advice on first use ......27 riding through water .
  • Page 196 INDEX Swingarm checking ........100 Use definition .
  • Page 197 *3211728en* 3211728en 08/2011 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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