Page 1 OWNER'S MANUAL 2009 450 XC ATV 525 XC ATV ART. NO. 3211377en...
Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous DEAR KTM CUSTOMER pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below.
Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
Page 5: Table Of Contents
Refueling................. 60 Indicator lamp overview ............ 35 SERVICE SCHEDULE............61 Emergency OFF switch with rip cord........35 Important maintenance work to be carried out by an Opening filler cap ............. 36 authorized KTM workshop..........61 Closing filler cap .............. 36...
Page 6 CONTENTS Important maintenance work to be carried out by an Checking the play in the Bowden cable using the reverse authorized KTM workshop. (as additional order)....63 gear release lever.............. 96 Important checks and maintenance work to be carried out Adjusting the play in the Bowden cable using the reverse by the rider.
Page 7 CONTENTS Mounting wheel/wheels ........... 124 Radiator fan..............150 Tire condition checking........... 125 Checking antifreeze and coolant level ....... 151 Checking tire air pressure ..........126 Checking the coolant level..........152 Removing the battery ............126 Draining coolant ............153 Installing the battery............127 Filling coolant / bleeding cooling system ......
Page 8 CONTENTS Tires ................189 Capacity - fuel..............189 TECHNICAL DATA - FRONT SHOCK ABSORBER....190 TECHNICAL DATA - REAR SHOCK ABSORBER..... 191 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ..192 SUBSTANCES..............194 AUXILIARY SUBSTANCES........... 197 STANDARDS..............200 INDEX ................201...
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 done in an authorized KTM workshop! There, your vehicle will be serviced optimally by specially trained experts using the specialist tools required.
Page 10: Important Notes
IMPORTANT NOTES 2 I MPORTANT NOTES Use definition KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid regulations and categories of the top international motorsport organizations. Warning Danger of accidents Incorrect assessment of riding situations.
Page 11 Spare parts, accessories For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Page 12 If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the first time. A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you.
Page 13 IMPORTANT NOTES...
Page 14: Overview Of Labels
IMPORTANT NOTES Overview of labels 700376-01...
Page 15 IMPORTANT NOTES Hangtag Information on use Emission control 450 XC ATV Emission control 525 XC ATV Warning label Information on not riding as a passenger Information on putting into operation Information on chain tension...
Page 16 IMPORTANT NOTES 700367-01 Hangtag...
Page 17 IMPORTANT NOTES 700372-01 Information on use 700373-01 Emission control 450 XC ATV...
Page 18 IMPORTANT NOTES 700374-01 Emission control 525 XC ATV...
Page 19 IMPORTANT NOTES 700368-01 Warning label...
Page 20 IMPORTANT NOTES 700370-01 Information on not riding as a passenger 700371-01 Information on putting into operation...
Page 21 IMPORTANT NOTES 700369-01 Information on chain tension Notes/warnings Be sure to pay attention to the notes and warnings given here. Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are missing, you or others may not recognize dangers and may therefore be injured.
Page 22 IMPORTANT NOTES Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death. Warning Danger that will probably lead to severe and permanent injury or death. Note Danger of serious damage to machine or material. Warning Risk of environmental damage.
Page 24: View Of Vehicle
VIEW OF VEHICLE 3 V IEW OF VEHICLE View of the vehicle from the left front (symbol display) 600148-10...
Page 25 VIEW OF VEHICLE Hand brake lever Fuse box Headlight Front shock absorber Right-hand brake caliper Steering damper holder (steering damper is optional) Front left shock absorber Outside brake disk guard Shift lever Left footrest Heel protector Emergency OFF switch with rip cord Clutch lever...
Page 26: View Of The Vehicle From The Right Rear (Symbol Display)
VIEW OF VEHICLE View of the vehicle from the right rear (symbol display) 600149-10...
Page 27 VIEW OF VEHICLE Light switch, electric starter button, ENG. STOP switch Filler cap Main silencer Rear shock absorber Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Compensating tank for coolant Manifold Top A-arm Front right fender Throttle lever Ignition switch...
Page 28: Location Of Serial Numbers
LOCATION OF SERIAL NUMBERS 4 L OCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper  control arm. 100002-10 Type label The type label is located on the frame tube on the right in front of the radiator. ...
Page 29: Key Number
LOCATION OF SERIAL NUMBERS Key number The key number is indicated on the KEYCODECARD.  Info You need the key number to order a replacement key. Keep the KEYCODECARD in a safe place. 100089-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. ...
Page 30: Setting Number, Front Shock Absorber
LOCATION OF SERIAL NUMBERS Setting number, front shock absorber The setting number is stamped into the top of the shock absorber.  100033-10 Setting number, rear shock absorber The setting number is stamped into the top of the shock absorber. ...
Page 31: Operating Elements
OPERATING ELEMENTS 5 O PERATING ELEMENTS 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 32: Handbrake Lever, Parking Brake
OPERATING ELEMENTS Handbrake lever, parking brake The hand brake lever is located on the right side of the handlebar and operates the front  wheel brakes. The parking brake is combined with the handbrake lever so that the front wheels can be blocked to prevent the vehicle from rolling.
Page 33: Throttle Lever
OPERATING ELEMENTS Throttle lever The throttle lever is fitted on the right side of the handlebar.  The throttle lever is used to control the engine speed. 100007-10 Light switch The light switch is fitted on the left side of the handlebar. ...
Page 34: Light Switch
OPERATING ELEMENTS Light switch The light switch is fitted on the left side of the handlebar.  Possible states High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on. Low beam on –...
Page 35: Eng. Stop Switch
OPERATING ELEMENTS ENG. STOP switch The ENG. STOP switch is fitted on the left side of the handlebar.  Possible states ENG. STOP switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started. ENG.
Page 36: Electric Starter Button
OPERATING ELEMENTS Electric starter button 5.10 Electric starter button is fitted on the left side of the handlebar.  Possible states • Electric starter button in basic position is pressed – In this position, the electric starter is actuated. • Electric starter button 700377-01 Ignition switch...
Page 37: Indicator Lamp Overview
OPERATING ELEMENTS Indicator lamp overview 5.12 Possible states lights up red – Reverse gear is engaged. Reverse gear indicator lamp  lights up yellow – Ignition is switched on. Ignition indicator lamp  lights up blue – High beam is switched on. High beam indicator lamp ...
Page 38: Opening Filler Cap
OPERATING ELEMENTS Opening filler cap 5.14 – Press release button , turn filler cap counterclockwise and lift it free.  100012-10 Closing filler cap 5.15 – Replace the filler cap and turn clockwise until the release button locks in place. ...
Page 39: Fuel Tap
OPERATING ELEMENTS Fuel tap 5.16 The fuel tap is on the right of the fuel tank. With the tap handle on the fuel tap, you can open or close the supply of fuel to the car-  buretor. Possible states Fuel supply off OFF –...
Page 40: Choke
OPERATING ELEMENTS Choke 5.17 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 41: Shift Lever
OPERATING ELEMENTS Shift lever 5.19 The shift lever is mounted on the left side of the engine.  100018-10 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. Reverse gear can only be engaged with the vehicle at a standstill and the lever pulled.
Page 42: Foot Brake Pedal
OPERATING ELEMENTS Foot brake pedal 5.20 The foot brake pedal is located in front of the right footrest and operates the rear wheel  brake. 100016-10...
Page 43: Tips On Putting Into Operation
– A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you. Warning Risk of injury Risk of injury by missing/inadequate protective clothing.
Page 44 TIPS ON PUTTING INTO OPERATION Warning Danger of accidents Accident risk caused by presence of a passenger. – Your vehicle is not designed to carry passengers. Do not ride with a passenger. Warning Danger of accidents Brake system failure. – If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake.
Page 45 TIPS ON PUTTING INTO OPERATION – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully.
Page 46: Running In The Engine
TIPS ON PUTTING INTO OPERATION Running in the engine – During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline Maximum engine speed During the first 3 service hours 7,000 rpm Maximum engine performance during the running-in period ≤...
Page 47: Riding Instructions
RIDING INSTRUCTIONS 7 R IDING INSTRUCTIONS Checks before putting into operation Info Make sure that the vehicle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. –...
Page 48: Starting
RIDING INSTRUCTIONS – Check that all operating elements are correctly adjusted and free to move. – Check that the electrical equipment is functioning properly. Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Page 49 RIDING INSTRUCTIONS – Turn the key in the ignition switch to the position The yellow ignition indicator lamp ON lights up. Info Under no circumstances should you open the throttle when switching on the ignition! The vehicle is equipped with a safety system that switches off the engine in case of a malfunction in the throttle lever, Bowden cable or carburetor.
Page 50: Starting Up
RIDING INSTRUCTIONS Starting up Info Switch your lights on before leaving. You will then be seen earlier by other motorists. – Pull and release the handbrake lever. Locking pawl moves into its basic position, parking brake is deactivated. – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting Warning Danger of accidents If you change down at high engine speed, the rear wheels can block.
Page 51: Shifting To Reverse Gear
RIDING INSTRUCTIONS Shifting to reverse gear Warning Danger of accidents Danger of accidents from blocked rear wheels if reverse gear is engaged while the vehicle is rolling. – To engage reverse gear, it is important to stop the vehicle first and have the engine at idle speed. Note Transmission damage Danger of transmission damage when engaging reverse gear while the vehicle is rolling.
Page 52: Braking
Adapt your braking to the traffic situation and the road conditions. Warning Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Page 53: 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 54: Riding In Bends
RIDING INSTRUCTIONS – Ride with a lower engine speed instead of with a high engine speed and a slipping clutch. Riding in bends Info When riding in bends, the outer wheels cover a greater distance than the inner wheels. Because the rear axle of the ATV is rigid in design, the rear wheels turn at the same speed.
Page 55: Riding Downhill
RIDING INSTRUCTIONS Riding downhill 7.10 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 56: Riding Uphill
RIDING INSTRUCTIONS Riding uphill 7.11 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 57: Riding Perpendicular To The Slope
RIDING INSTRUCTIONS Riding perpendicular to the slope 7.12 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 58 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 59: Riding Through Water
After riding through water, dry the brakes by lightly activating both brakes until normal braking power is available again. – If the vehicle became submerged, an authorized KTM workshop must perform a thor- ough check and comprehensive service. Do not start the engine. Switching off the engine 7.15...
Page 60: Stopping, Parking
RIDING INSTRUCTIONS Alternative 1 Switch off the engine using the ignition key. – Turn the key in the ignition switch to the position Info All power-consuming components are switched off. Alternative 2 Switch off the engine using the ENG. STOP switch. –...
Page 61 RIDING INSTRUCTIONS 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 activate the parking brake. Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running. –...
Page 62: Refueling
RIDING INSTRUCTIONS Refueling 7.17 Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately. –...
Page 63: Service Schedule
SERVICE SCHEDULE 8 S ERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. S15A S30A Engine Change the engine oil and oil filter, clean the oil screens. p. 163) • • • Replace spark plug.
Page 64 SERVICE SCHEDULE S15A S30A Brakes Check the front brake fluid level. ( p. 106) • • • Check the rear brake fluid level. ( p. 115) • • • Check brake lines for damage and leakage. • • • Check the free play of the hand brake lever. ( p.
Page 65: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Order)
S15A: Every 15 service hours - corresponds to about 105 liters of fuel / after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) Competition use...
Page 66 SERVICE SCHEDULE Competition use Hobby use S15A S30A S45A S30A S60A S90A Check wear of valve guides. • • Check valves. • • Check valve springs. • • Check the radial clearance of the rocker arm rollers. • • Measure length of timing chain. •...
Page 67: Important Checks And Maintenance Work To Be Carried Out By The Rider
SERVICE SCHEDULE Important checks and maintenance work to be carried out by the rider. NB1A Check the engine oil level. ( p. 162) • Check the front brake fluid level. ( p. 106) • Check the rear brake fluid level. ( p.
Page 68: Maintenance On Chassis And Engine
MAINTENANCE ON CHASSIS AND ENGINE 9 M AINTENANCE ON CHASSIS AND ENGINE Jacking up the vehicle Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. –...
Page 69: Front Shock Absorber - Adjusting The Compression Damping
MAINTENANCE ON CHASSIS AND ENGINE Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced. When changing the chassis settings, always start with the standard setting. Between test rides, always change only one setting.
Page 70: Front Shock Absorber - Adjusting The Rebound Damping
MAINTENANCE ON CHASSIS AND ENGINE – Turn the adjusting wheel clockwise until it stops.  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value 100027-10 Experience has shown that settings outside of this range are detrimental to vehi-...
Page 71 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers. – Only make adjustments within the recommended range. Info The rebound damping setting has an impact on the compression of the shock absorber. –...
Page 72: Front Shock Absorber - Adjusting The Cross Over
Less cross over makes the spring action at the front harder and the front of the vehicle lies higher. – Jack up the vehicle. ( p. 66) – Clean the shock absorber thoroughly. – Loosen the adjusting ring . Suitable tools are available from an authorized KTM   workshop. Hook wrench, Öhlins (83019001000) 100084-10...
Page 73: Front Shock Absorber - Adjusting The Spring Preload
MAINTENANCE ON CHASSIS AND ENGINE – The cross over setting is measured between the sliding bushing and the collar of   the spring retainer  0 0 0 Guideline Cross over 14±1.5 mm (0.55±0.059 in) – Change the settings accordingly and lock the adjusting ring. Info The sliding bushing is made of plastic.
Page 74 MAINTENANCE ON CHASSIS AND ENGINE Before you change the spring preload, make a note of the groove in which the securing clip is positioned. When making adjust- ments, always start from the standard setting. – Jack up the vehicle. ( p.
Page 75: Rear Shock Absorber - Adjusting The Compression Damping
MAINTENANCE ON CHASSIS AND ENGINE – Press together the spring pack, position the securing clip in the corresponding groove and release the spring pack. Guideline 0 0 A Clip position, spring preload Standard 8th position from top Corresponds to a spring preload of 9 mm (0.35 in) Info The spring preload...
Page 76 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers. – Only make adjustments within the recommended range. Info The compression damping setting has an impact on the compression of the shock absorber. –...
Page 77: Rear Shock Absorber - Adjusting The Rebound Damping
MAINTENANCE ON CHASSIS AND ENGINE Rear shock absorber - adjusting the rebound damping Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte- nance on it yourself.
Page 78: Rear Shock Absorber - Adjusting The Spring Preload
MAINTENANCE ON CHASSIS AND ENGINE – Turn back to the left by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value Experience has shown that settings outside of this range are detrimental to vehi- cle handling.
Page 79 Loosen the lock nut . Hold adjusting ring while doing so. Suitable tools    available from an authorized KTM workshop. Hook wrench (83019002000) Info Do not loosen lock nut at the top of the shock absorber.  –...
Page 80: Removing The Rear Shock Absorber
MAINTENANCE ON CHASSIS AND ENGINE – Measure the overall spring length when not under tension. Info The spring preload is the difference in length between the spring when it is  unloaded and when it is installed. – Tighten the spring by turning adjusting ring to measurement . Guideline Spring preload Standard...
Page 81 MAINTENANCE ON CHASSIS AND ENGINE Note Danger of damage The chain sliding piece and frame can be damaged from incorrect handling. – When removing the rear shock absorber, secure the swingarm with a tension belt to prevent it from swinging down further. –...
Page 82: Installing The Rear Shock Absorber
MAINTENANCE ON CHASSIS AND ENGINE Installing the rear shock absorber 9.12 – Check parts for damage and wear. Replace damaged or worn parts. – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw ...
Page 83 MAINTENANCE ON CHASSIS AND ENGINE – Load the vehicle with the specified weight. Guideline Standard rider weight 70… 80 kg (154… 176 lb.) – Move the handlebar into the straight-ahead position and fix it. Handlebar fixation for straight-ahead position (83019015100) 500228-01...
Page 84 MAINTENANCE ON CHASSIS AND ENGINE 400333-10 – Measure distances   » If distances are not equal:   – Adjust the toe. p. 83)
Page 85: Adjusting The Toe
MAINTENANCE ON CHASSIS AND ENGINE – Measure distances   Guideline Front 0 mm (0 in) Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv-  ...
Page 86 MAINTENANCE ON CHASSIS AND ENGINE 400333-11 – Loosen nuts   – Adjust the distances to the same value by rotating the tie rods   ...
Page 87: Checking/Adjusting Camber
MAINTENANCE ON CHASSIS AND ENGINE – Adjust the distances to the specified value by evenly rotating the tie rods    Guideline Front 0 mm (0 in) Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv- ...
Page 88 MAINTENANCE ON CHASSIS AND ENGINE – Loosen nuts  600128-10 – Remove screws with bushings   – Check parts for damage and wear. Replace damaged or worn parts. 600126-10 – Insert the tool in the heim joint and clip onto the A-arm. ...
Page 89: Fork Offset
MAINTENANCE ON CHASSIS AND ENGINE – Position the A-arm with the bushings . Mount and tighten screws   Guideline Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) 600126-10 – Align the heim joint at right angles to the screws and tighten the nut ...
Page 90: Adjusting The Fork Offset
MAINTENANCE ON CHASSIS AND ENGINE Adjusting the fork offset 9.17 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( p. 66) –...
Page 91: Adjusting The Toe Width Of Rear Axle
MAINTENANCE ON CHASSIS AND ENGINE Adjusting the toe width of rear axle 9.19 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. –...
Page 92 MAINTENANCE ON CHASSIS AND ENGINE Setting a wide toe width: – Mount the spacing sleeve 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 93: Handlebar Position
MAINTENANCE ON CHASSIS AND ENGINE Handlebar position 9.20 The handlebar position can be adjusted 4-fold by turning the handlebar support and the  handlebar support  The holes on the handlebar support are placed at a distance of from the center. ...
Page 94: Adjusting Handlebar Position
MAINTENANCE ON CHASSIS AND ENGINE Adjusting handlebar position 9.21 – Pull the instrument support off the handlebar and swing it to the side. Info Protect the vehicle and its attachments from damage by covering them. Do not bend the cables and lines. 100100-10...
Page 95 MAINTENANCE ON CHASSIS AND ENGINE – Remove the four screws . Remove the handlebar clamps , swing the handlebar for-   ward and set it down. – Remove the nuts and remove the handlebar support with the screws.  ...
Page 96: Checking Play In Gas Bowden Cable
MAINTENANCE ON CHASSIS AND ENGINE – Position the handlebar and fix it with the handlebar clamps . Mount and tighten  screws  Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure cables and wiring are positioned correctly. –...
Page 97: Adjusting Play In Gas Bowden Cable
MAINTENANCE ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. –...
Page 98: Checking The Play In The Bowden Cable Using The Reverse
MAINTENANCE ON CHASSIS AND ENGINE Checking the play in the Bowden cable using the reverse gear release lever 9.24 – Move the handlebar to the straight-ahead position. Move the reverse gear release lever back and forth slightly to ascertain the play in the Bowden cable ...
Page 99: Checking Chain Dirt
MAINTENANCE ON CHASSIS AND ENGINE Checking chain dirt 9.26 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 97) Cleaning the chain 9.27 Warning Environmental hazard Problem materials cause environmental damage. –...
Page 100: Checking The Chain Tension
MAINTENANCE ON CHASSIS AND ENGINE Checking the chain tension 9.28 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel eccentric element) are under additional load.
Page 101: Checking Rear Sprocket / Engine Sprocket For Wear
MAINTENANCE ON CHASSIS AND ENGINE Checking rear sprocket / engine sprocket for wear 9.29 – Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Replace the rear sprocket / engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).
Page 102 MAINTENANCE ON CHASSIS AND ENGINE – Pull the lower chain section 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 103: Adjusting Chain Tension
MAINTENANCE ON CHASSIS AND ENGINE Adjusting chain tension 9.31 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel eccentric element) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.
Page 104 MAINTENANCE ON CHASSIS AND ENGINE – Loosen the screws by four turns.  Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric ele-   ment. Alternative 2 – Use a special tool on the rear wheel eccentric. Hook wrench (83019011000) –...
Page 105: Greasing The Rear Wheel Eccentric Element
 Long-life grease ( p. 196) 100092-10 Checking brake discs 9.33 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop.
Page 106: Checking The Free Play Of The Hand Brake Lever
MAINTENANCE ON CHASSIS AND ENGINE – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement  Info Wear reduces the thickness of the brake disc around the area used by the brake linings.
Page 107: Adjusting Basic Position Of Handbrake Lever
MAINTENANCE ON CHASSIS AND ENGINE – Push the hand brake lever forward and check free play.  ≥ 3 mm (≥ 0.12 in) Free play of hand brake lever » If the free travel does not meet specifications: – Adjust the basic position of the handbrake lever. ( p.
Page 108: Checking Front Brake Fluid Level
Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Page 109 If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...
Page 110: Checking The Front Brake Linings
Clean up overflowed or spilt brake fluid immediately with water. 100036-10 Checking the front brake linings 9.38 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. – Remove the wheel/wheels. ( p. 123)
Page 111: Removing Front Brake Linings
Removing front brake linings 9.39 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. Info The operations are the same on the left and right. – Remove the wheel/wheels. ( p.
Page 112: 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 113: Changing The Front Brake Linings
MAINTENANCE ON CHASSIS AND ENGINE – Check parts for damage and wear. Replace damaged or worn parts. – 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 –...
Page 114 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...
Page 115: Checking Free Play Of Foot Brake Lever
MAINTENANCE ON CHASSIS AND ENGINE – Remove the front brake linings. p. 109) – 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 116: Adjusting Basic Position Of Footbrake Lever
MAINTENANCE ON CHASSIS AND ENGINE – Disconnect spring  – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play  Guideline Free play at foot brake lever 3…...
Page 117: Checking Rear Brake Fluid Level
If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake lin- ings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.
Page 118: Topping Up Brake Fluid Of Front Brake
MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Park the vehicle on a horizontal surface. –...
Page 119 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...
Page 120: Checking Rear Brake Linings
Checking rear brake linings 9.46 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in) Minimum thickness ...
Page 121: Removing Rear Brake Linings
Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.
Page 122: Mounting The Rear Brake Linings
Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
Page 123 MAINTENANCE ON CHASSIS AND ENGINE – Check parts for damage and wear. Replace damaged or worn parts. – 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 ...
Page 124: Changing Rear Brake Linings
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...
Page 125: Removing Wheel/Wheels
MAINTENANCE ON CHASSIS AND ENGINE – Remove the rear brake linings. p. 119) – Remove screw with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir. –...
Page 126: Mounting Wheel/Wheels
MAINTENANCE ON CHASSIS AND ENGINE – Loosen the wheel nuts  – Jack up the vehicle. ( p. 66) – Remove the wheel nuts. Remove the wheel. Info Carefully remove the wheel, making sure it does not become jammed with the threads of the screws.
Page 127: Tire Condition Checking
Tire condition checking 9.52 Info Fit only tires approved by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the vehicle.
Page 128: Checking Tire Air Pressure
MAINTENANCE ON CHASSIS AND ENGINE Checking tire air pressure 9.53 Info Low tire air pressure leads to abnormal wear and overheating of the tire. Correct tire air pressure ensures optimal riding comfort and maximum tire service life. Check the tire pressure on all wheels and correct it if necessary. –...
Page 129: Installing The Battery
MAINTENANCE ON CHASSIS AND ENGINE – Switch off all power-consuming components and switch off the engine. – Remove the rear fender. ( p. 140) – Disconnect the negative (minus) cable of the battery.  – Pull back the plus pole cover and disconnect the positive (plus) cable of the battery.
Page 130: Recharging The Battery
MAINTENANCE ON CHASSIS AND ENGINE Recharging the battery 9.56 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 131 MAINTENANCE ON CHASSIS AND ENGINE – Switch off all power-consuming components and switch off the engine. – Remove the rear fender. ( p. 140) – Disconnect the minus (negative) cable of the battery to avoid damage to the vehicle's electronics. –...
Page 132: Changing Main Fuse
Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Insert a new fuse. Fuse (58011109120) Info If the new fuse burns out, contact an authorized KTM workshop. 100091-10 The spare fuse should always be present in the starter relay so that it is avail- ...
Page 133: Changing The Fuses Of Individual Power-Consuming Components
MAINTENANCE ON CHASSIS AND ENGINE Changing the fuses of individual power-consuming components 9.58 – Remove the front cover. ( p. 137) – Switch off all power-consuming components and switch off the engine. – Open the cover of the fuse box ...
Page 134 Insert a new fuse of the appropriate strength. Fuse (58011109110) Fuse (58011109115) Info If the new fuse burns out, contact an authorized KTM workshop. The spare fuse should always be present in the starter relay so that it is avail- able if needed. –...
Page 135: Ignition Curve Plug Connection
MAINTENANCE ON CHASSIS AND ENGINE Ignition curve plug connection 9.59 The plug-in connector is located under the trim at the front on the frame tube.  Possible states Soft – The plug-in connector is connected for better driveability. • Performance – The plug-in connector is disconnected for better performance. •...
Page 136: Removing The Seat
MAINTENANCE ON CHASSIS AND ENGINE Removing the seat 9.61 – Pull the release hook back. Lift up the seat at the rear, pull it back and then remove  from above. 100041-10 Mounting the seat 9.62 – Check parts for damage and wear. Replace damaged or worn parts. –...
Page 137: Removing The Radiator Spoiler
MAINTENANCE ON CHASSIS AND ENGINE – Push down the rear of the seat until the release hook engages.  – Make sure that the seat is correctly locked in. 100043-10 Removing the radiator spoiler 9.63 Info The operations are the same on the left and right. –...
Page 138: Installing The Radiator Spoiler
MAINTENANCE ON CHASSIS AND ENGINE – Remove the screws on the radiator.  – Unhinge and remove the radiator spoiler and the fuel tank. 100057-10 Installing the radiator spoiler 9.64 Info The operations are the same on the left and right. –...
Page 139: Removing The Front Cover
MAINTENANCE ON CHASSIS AND ENGINE – Fit and tighten screws on the radiator.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Fit and tighten screws on the fuel tank.  Guideline Screw on fuel tank 6 Nm (4.4 lbf ft) –...
Page 140: Installing The Front Cover
MAINTENANCE ON CHASSIS AND ENGINE Installing the front cover 9.66 – Check parts for damage and wear. Replace damaged or worn parts. – Position the front cover in the slots on both sides of the front trim.  – Mount and tighten screw . 100055-10 Removing the front trim 9.67...
Page 141 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws  – Raise the front trim and disconnect the plug-in connectors from the head light and the emergency OFF switch with the rip cord. – Remove the front trim. 100075-10...
Page 142: Installing The Front Trim
MAINTENANCE ON CHASSIS AND ENGINE Installing the front trim 9.68 – Check parts for damage and wear. Replace damaged or worn parts. – Connect the plug-in connectors of the head light and the emergency OFF switch with the rip cord and position the front trim. –...
Page 143 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws . Remove the collar sleeves.  200149-10 – Raise the rear of the air filter box lid . At the same time, use your other hand to press  on the carburetor connection boot to kink it at that location. This prevents the carbure- tor connection boot from disconnecting from the carburetor.
Page 144: Installing The Rear Fender
MAINTENANCE ON CHASSIS AND ENGINE Installing the rear fender 9.70 – Check parts for damage and wear. Replace damaged or worn parts. – Raise the rear of the air filter box lid . At the same time, use your other hand to press ...
Page 145 MAINTENANCE ON CHASSIS AND ENGINE – Fit and tighten screws with collar sleeves.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat ( p. 134) 200149-11...
Page 146: Removing The Engine Guard
MAINTENANCE ON CHASSIS AND ENGINE Removing the engine guard 9.71 – Remove screws . Remove the engine guard.   600133-10 Installing the engine guard 9.72 – Check parts for damage and wear. Replace damaged or worn parts. – Position the engine guard on the frame bearer. Mount and tighten screws ...
Page 147: Removing The Air Filter
MAINTENANCE ON CHASSIS AND ENGINE Removing the air filter 9.73 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Problem materials cause environmental damage.
Page 148 MAINTENANCE ON CHASSIS AND ENGINE – Raise the rear of the air filter box lid . At the same time, use your other hand to press  on the carburetor connection boot to kink it at that location. This prevents the carbu- ...
Page 149: Installing The Air Filter
MAINTENANCE ON CHASSIS AND ENGINE Installing the air filter 9.74 – Check parts for damage and wear. Replace damaged or worn parts. – Mount the clean air filter onto the air filter support. – Put in both parts together, position them and fix them with the air filter support ...
Page 150: Adjusting Basic Position Of Clutch Lever
MAINTENANCE ON CHASSIS AND ENGINE – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 197) Info Only press the air filter to dry it, never wring it out. –...
Page 151: Checking Fluid Level Of Hydraulic Clutch
MAINTENANCE ON CHASSIS AND ENGINE Checking fluid level of hydraulic clutch 9.77 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...
Page 152: Cooling System
MAINTENANCE ON CHASSIS AND ENGINE Cooling system 9.78 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 . The specified coolant temperature is therefore permissible without danger of function problems.
Page 153: Checking Antifreeze And Coolant Level
MAINTENANCE ON CHASSIS AND ENGINE Checking antifreeze and coolant level 9.80 Warning Danger of scalding The coolant gets very hot and is under high pressure when the vehicle is driven. – Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cool- ing system to cool down.
Page 154: Checking The Coolant Level
MAINTENANCE ON CHASSIS AND ENGINE – Open the compensating tank cover  – Check antifreeze of coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the cooling liquid does not meet specifications: – Correct antifreeze of coolant. –...
Page 155: Draining Coolant
MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
Page 156 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
Page 157 MAINTENANCE ON CHASSIS AND ENGINE – Remove the radiator cap . Completely drain the coolant.  600123-11 – Open the plug of the compensation tank  – Remove the screws and empty the compensating tank   – Check parts for damage and wear. Replace damaged or worn parts. –...
Page 158: Filling Coolant / Bleeding Cooling System
MAINTENANCE ON CHASSIS AND ENGINE Filling coolant / bleeding cooling system 9.83 Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor.
Page 159 MAINTENANCE ON CHASSIS AND ENGINE – Open the screw to bleed the cylinder head. Tighten the screw when coolant   emerges from the opening. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) Info Ensure that the radiator is always filled with a sufficient amount of coolant. 600121-10 –...
Page 160: Carburetor - Idle
MAINTENANCE ON CHASSIS AND ENGINE – Top up the compensating tank to level . Mount the cap   – Install the front trim. ( p. 140) – Make a short test ride. – Check the coolant level. ( p. 152) 600125-10 Carburetor - idle 9.84...
Page 161: Carburetor - Adjusting Idle
MAINTENANCE ON CHASSIS AND ENGINE Carburetor - adjusting idle 9.85 – Screw in the idle adjusting screw until it stops and then to the prescribed basic set-  ting. Guideline Idle mixture adjusting screw Open 1.0 turn Adjustment tool for mixture control screw (59029034000) –...
Page 162 MAINTENANCE ON CHASSIS AND ENGINE – Adjust to the point between these two positions with the highest idle speed. Info If there is a big engine speed rise, reduce the idle speed to a normal level and repeat the above steps. The extremely sporty rider will set the mixture about 1/4 of a turn back from this ideal value (leaner, in a clockwise direction) since the engine becomes hotter in sporting use.
Page 163: Emptying The Carburetor Float Chamber
MAINTENANCE ON CHASSIS AND ENGINE Emptying the carburetor float chamber 9.86 Danger Fire hazard Fuel can easily catch fire. – Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components.
Page 164: Checking Engine Oil Level
MAINTENANCE ON CHASSIS AND ENGINE – Guide the hose coming down behind the engine into a suitable container. Info Water in the float chamber results in malfunctioning. – Undo the screw (turn it counterclockwise) a few turns and drain the fuel from the ...
Page 165: Changing Engine Oil And Oil Filter, Cleaning Oil Screens
MAINTENANCE ON CHASSIS AND ENGINE Condition Engine is cold. – Check the engine oil level. The engine oil reaches the bottom of the viewer  » When the engine oil does not reach the bottom of the viewer  – Top up the engine oil.
Page 166 MAINTENANCE ON CHASSIS AND ENGINE Info Drain the engine oil only when the engine is warm. – Park the vehicle on a horizontal surface. – Remove the engine guard. ( p. 144) – Place a suitable container under the engine. –...
Page 167 MAINTENANCE ON CHASSIS AND ENGINE – Remove the plug screw and large oil screen with both O-rings.  – Completely drain the engine oil. 600136-10 – Check parts for damage and wear. Replace damaged or worn parts. – Thoroughly clean parts and sealing area. –...
Page 168: Removing The Oil Filter
MAINTENANCE ON CHASSIS AND ENGINE – Insert the oil screen with the O-rings into the plug screw and tighten.    Guideline Locking screw, oil sieve, M16x1.5 10 Nm lubricated with short (7.4 lbf ft) engine oil 600140-10 – Fit oil drain plug with seal ring and tighten it.
Page 169 MAINTENANCE ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. – Place a suitable container under the engine. – Disconnect the ground cable from the engine.
Page 170: Mounting The Oil Filter
MAINTENANCE ON CHASSIS AND ENGINE Mounting the oil filter 9.91 – Check parts for damage and wear. Replace damaged or worn parts. – Fill the oil filters with engine oil and place in the oil filter container.   600147-10 –...
Page 171: Topping Up Engine Oil
MAINTENANCE ON CHASSIS AND ENGINE – Remove the screw cap on the clutch cover and fill up with engine oil.  Engine oil 2.00 l (2.11 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 195) External Engine oil (SAE temperature:...
Page 172 MAINTENANCE ON CHASSIS AND ENGINE – Check the engine for leakage. – Remove the screw cap on the clutch cover and fill up with engine oil.  Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p.
Page 173: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Operating error Follow the instructions on starting the engine. ( p. 46) – Vehicle was out of use for a long time and Empty the carburetor float chamber. there is old fuel in the float chamber p.
Page 174 TROUBLESHOOTING...
Page 175 – Do not touch parts of the ignition system. Have work on the ignition system car- ried out in an authorized KTM workshop. – Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.
Page 176 Check electrical system. – Low external temperature Recharge the battery. Establish the rea- son for discharging or have it checked in a KTM workshop. – Engine does not speed up. Carburetor running over because float nee- Have carburetor checked. dle dirty or worn –...
Page 177 TROUBLESHOOTING Faults Possible cause Action – Engine does not speed up. Electronic ignition adjustment defective Have ignition system checked. – Engine has no idle. Idling jet blocked Clean carburetor. – Adjusting screws on carburetor distorted Have the carburetor adjusted. – Spark plug defective Change spark plug.
Page 178 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power. Fuel feed interrupted Check the tank breather. – Clean fuel tap. – Clean carburetor. – Air filter very dirty Clean the air filter. p. 147) – Exhaust system leaky, deformed or too lit- Check exhaust system for damage.
Page 179: Cleaning
CLEANING CLEANING Cleaning the vehicle 11.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.
Page 180 CLEANING – After rinsing the vehicle with a gentle water spray, allow it to dry thoroughly. – Clean and dry the air filter box. – Empty the carburetor float chamber. p. 161) Warning Danger of accidents Reduced braking due to wet or dirty brakes. –...
Page 181: Storage
STORAGE STORAGE Storage 12.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.
Page 182: Putting The Vehicle Into Operation After Storage
STORAGE – Recharge the battery. p. 128) Guideline Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. – Cover the vehicle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Page 183: Technical Data - Engine
TECHNICAL DATA - ENGINE TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine with balancer, water-cooled Displacement (450 XC ATV) 448 cm³ (27.34 cu in) Displacement (525 XC ATV) 510 cm³ (31.12 cu in) Stroke 72 mm (2.83 in) Bore (450 XC ATV) 89 mm (3.5 in)
Page 184: Capacity - Engine Oil
TECHNICAL DATA - ENGINE 2nd gear 17:33 3rd gear 19:30 4th gear 21:28 5th gear 23:26 Reverse gear 14:19:34 Generator 12 V, 200 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK DCPR 8 E Spark plug electrode gap 0.6 mm (0.024 in) Cooling...
Page 185: Technical Data - Engine Tightening Torques
TECHNICAL DATA - ENGINE TIGHTENING TORQUES TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Screw, cable holder in generator cover Loctite 243™ ® Screw, timing chain securing guide 6 Nm (4.4 lbf ft) Loctite 243™ ® Screw, locking lever 6 Nm (4.4 lbf ft) Loctite 243™...
Page 186 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, engine housing M6x75 10 Nm (7.4 lbf ft) ® Screw, shift drum locating 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, shift lever 10 Nm (7.4 lbf ft) Loctite 243™ ® Screw, timing chain tensioning rail 6 Nm (4.4 lbf ft) Loctite...
Page 187 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Ignition rotor nut M12x1 60 Nm (44.3 lbf ft) – Spark plug M12x1.25 17 Nm (12.5 lbf ft) ® Bleeder flange, engine case M12x1.5 Loctite 243™ – Oil drain plug with magnet M12x1.5 20 Nm (14.8 lbf ft) –...
Page 188: Technical Data - Carburetor
TECHNICAL DATA - CARBURETOR TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 39 Carburetor identification number 3925H Needle position (450 XC ATV) 2nd position from top Needle position (525 XC ATV) 3rd position from top Idle mixture adjusting screw Open 1.0 turn...
Page 189: Technical Data - Chassis
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 275 mm (10.83 in) Rear 272 mm (10.71 in) Fork offset Front...
Page 190 TECHNICAL DATA - CHASSIS Maximum allowable axle load Front 144 kg (317 lb.) Rear 149 kg (328 lb.) Maximum permissible overall weight 293 kg (646 lb.) Vehicle length 1,810 mm (71.26 in) Vehicle width 1,148 mm (45.2 in) Vehicle height 1,125 mm (44.29 in) Brake system Front...
Page 191: Lighting Equipment
21 x 7.00 - 10 20 x 11.00 - 9 MAXXIS Razr M‑931 MAXXIS Razr M‑932 For further information, see the Service section under: http://www.ktm.com Capacity - fuel 16.3 Total fuel tank capacity approx. 13.4 l (3.54 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( p.
Page 192: Technical Data - Front Shock Absorber
TECHNICAL DATA - FRONT SHOCK ABSORBER TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber type 36PRC Setting number KT 8700 Compression damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value Rebound damping Standard 20 clicks −5… 5 clicks Maximum deviation from standard value Cross over 14±1.5 mm (0.55±0.059 in)
Page 193: Technical Data - Rear Shock Absorber
TECHNICAL DATA - REAR SHOCK ABSORBER TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber type 46PRCQ Setting number KT 8710 Compression damping Standard 17 clicks −5… 5 clicks Maximum deviation from standard value Rebound damping Standard 15 clicks −5… 5 clicks Maximum deviation from standard value Spring preload Standard...
Page 194: Technical Data - Chassis Tightening Torques
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – 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 195 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Engine carrying screw 60 Nm (44.3 lbf ft) – Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) – Screw, A-arm bottom M10x70 45 Nm (33.2 lbf ft) – Screw, front shock absorber 45 Nm (33.2 lbf ft) –...
Page 196: Substances
– Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
Page 197 SAE ( p. 200) (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 198 – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
Page 199: Auxiliary Substances
AUXILIARY SUBSTANCES AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –...
Page 200 AUXILIARY SUBSTANCES High-luster polish for paint Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Polish Lubricant (T625) Specification – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Motorcycle cleaner Specification – ® KTM recommends Motorex products.
Page 201 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Power...
Page 202: Standards
STANDARDS STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, 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 and ATV engines.With most motorcycles and ATVs, the gearbox and the clutch are lubricated with the same oil as the engine.
Page 203: Index
INDEX installing ........110 INDEX removing ........109 Accessories .
Page 204 INDEX topping up ....... . . 169 Clutch checking fluid level ......149 Engine oil level Clutch lever .
Page 205 INDEX Front trim installing ........140 Main fuse removing .
Page 206 INDEX removing ........135 Service schedule ......61-65 Rear shock absorber Shifting compression damping, adjusting .
Page 207 INDEX adjusting ........83 checking ........80 rear toe width, adjusting .
Page 208 *3211377en* 3211377en 05/2008 Photo Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

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