KTM 400 Owner's Handbook Manual
Ktm-sportmotorcycle ag motorcycle user manual
Hide thumbs
Also See for 400:
- Owner's handbook manual (41 pages) ,
- Owner's handbook manual (42 pages) ,
- Owner's manual (50 pages)
Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for KTM 400
Summary of Contents for KTM 400
-
Page 2: Frame Number
BODY AND YOUR LIFE. IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE. Please insert the series numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer... - Page 3 Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
-
Page 4: Table Of Contents
Chain wear ........20 General informations about KTM disc brakes ..20 Adjusting of free travel at the hand brake lever . -
Page 5: Serial Number Locations
TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE ’ BRAKE SYSTEM T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A is needed only if a fall on your motorcycle CAUTION... -
Page 6: Digital Speedometer, Indicator Lamps (Exc)
Digital speedometer, indicator lamps (EXC) The green control lamp the same rhythm as the flashing indicator. The blue control lamp Speedometer – digital (EXC) Some models are equipped with a digital speedometer KMH = Speed, max. 200 km/h (is always indicated) Aside from speed indication the following indications can be selected: = Trip distance = Stopwatch max. -
Page 7: Combination Switch (Exc)
Leave the is arranged adjacent to the actuates the E-starter. WARNING NEUTRAL F YOU START THE MOTORCYCLE WITH A GEAR is arranged adjacent to the throttle grip. actuates the E-starter. WARNING NEUTRAL F YOU START THE MOTORCYCLE WITH A GEAR... -
Page 8: Filler Cap
Reserve EXC ....1.0 l (0,3 US gallons) HE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE without kinks. -
Page 9: Choke
Push the side stand to the ground with your foot and load it with the motorcycle. Make sure that you put your bike on solid ground and in a secure position. For off-road riding, you can use the rubber band additionally secure the center stand in its folded-up position. -
Page 10: Compression Damping Of Fork
Control). Low and high speed refers to the movement of the shock absorber during compression and not to the speed of the motorcycle. The low and high-speed technology overlaps. The low-speed setting is primarily for slow to normal shock absorber com- pression rates. -
Page 11: Compression Damping Of Shock Absorber (Mxc, Exc)
Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping. -
Page 12: Driving Instructions
Arrange for the braking system to be checked by a KTM specialist, as complete failure of the braking system can be avoided. Also check the state of the brake hose and the thickness of the brake linings. - Page 13 – M AXIMAL PERIOD FOR CONTINUOUS STARTING SECONDS BEFORE TRYING AGAIN – D ’ T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON COLD ECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER IT CAN CAUSE ENGINE DAMAGE...
-
Page 14: Stopping And Parking
MXC/EXC R STARTER ALLOWS YOU TO START AGAIN AT ANY TIME HEREFORE TURN OFF THE ENGINE IF YOU INTEND TO RUN YOUR MOTORCYCLE IN IDLE OR AT STANDSTILL FOR LONGER PERIODS OF TIME MORE THAN MINUTES – A VOID LETTING THE CLUTCH SLIP FREQUENTLY AND FOR EXTENDED... -
Page 15: Periodic Maintenance Schedule
Treat battery connections with contact grease Change hydraulic clutch fluid Change brake fluid IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN AINTENANCE WORK DONE BY... - Page 16 Treat ignition and steering locks and light switches with contact spray Check tightness of screws, nuts and hose clamps regular Continued tests of the 400/520 racing motor for KTM's specialized workshop (additional order for KTM's specialized workshop) a 100 l fuel consumption is equivalent to approx. 15 operating hours...
-
Page 17: Maintenance Work On Chassis And Engine
MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF. -
Page 18: Breather Plug Front Fork
To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to have this job performed in the course of the periodical mainten- ance service. -
Page 19: How To Change The Handlebar Position
How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar to the position that is the most convenient for you. The upper tri- ple clamp includes 2 bores arranged at a distance of 15 mm (0,6 in) from one another. -
Page 20: Check Chain Tension
JUMPING OFF THE CHAIN WHEELS F THIS HAPPENS THE REAR WHEEL OR DAMAGE THE ENGINE – I N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut , loosen lock nuts screws equally far. -
Page 21: Chain Wear
KTM dealer immediately. BRAKE FLUID: KTM fills the brake systems with SHELL ADVANCE BRAKE DOT 5.1 brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color. -
Page 22: Adjusting Of Free Travel At The Hand Brake Lever
min. 3 mm 5 mm min. 1 mm Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw . In this way, the position of the point of pressure (i.e., the resi- stance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. -
Page 23: Replacing The Front Brake Pads
Replacing front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and grease guide bolts if necessary. -
Page 24: Checking The Rear Brake Pads
ENSURE THAT THE BRAKE PADS WILL LIE AGAINST THE BRAKE DISK AND THE PRESSURE POINT IS ESTABLISHED Dismounting and mounting the front wheel To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen the 2 clamping screws... -
Page 25: Dismounting And Mounting The Rear Wheel
40 Nm (30 ft.lb). Loosen the clamping screews Take the motorcycle off the stand and bounce the fork hard a few times to align the fork legs. Then tighten clamping screws –... -
Page 26: Tires, Air Pressure
(see photo). A clear tone must be the result. Dull tones are indicators of loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. – S... -
Page 27: Adjusting Digital Speedometer
TOTAL MILEAGE „DST“ AFTER CHANGING BATTERY 3. by pushing the right but- ton you jump to the next figure TIME „CLK“ 1. make sure the time is indicated and push the button back approx. 5 seconds (time starts blinking) 4. repeat nos. 2 + 3 until correct time is indicated 1. -
Page 28: Check/Set Distance Of Magnetic Sensor
WHEEL CIRCUMFERENCE „WS“ 1. make sure that the indication "TRP" is active and push the but- ton on the back approx. 5 seconds ("WS" appears) 3. push the left button until the right figure is showed in the display mm x 3,14 Wheel circumference with standard tires = 2205 mm 2. -
Page 29: Battery (Mxc/Exc)
SHOWN IN THE ILLUSTRATION OTHERWISE ELECTROLYTE CAN ESCAPE BATTERY STORAGE: When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0 - 35°C (30 - 95°F). Do not expose to direct sun radiation. -
Page 30: Fuse (Mxc/Exc)
Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere. -
Page 31: Cooling System
Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down. Dirty radiators also reduce the cooling efficiency. Pressure induced by heating of the coolant in the system is controlled by a valve in the radiator cap (248°... -
Page 32: Cleaning The Air Filter
Then, drill open the rivets and remove the end cap. NOTE! In every exhaust repair procedure, the O-rings must be replaced by new ones. Glass fiber yarn packings are available at your licensed KTM mechanic. WARNING... -
Page 33: Checking Adjustment Of The Hand Decompression Release Cable
SAE 10 hydraulic oil. Refill oil, until oil is discharged from the bore master cylinder in a bubble-free state. Make sure that the oil does not over- flow. The bleeder syringe can be purchased at your KTM dealer.Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct.If necessary, fill up with biodegradable... -
Page 34: Carburetor Adjust Idling
CARBURETOR – Adjust idling (Keihin-CR39) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel mixture control screw . -
Page 35: Draining Of Float Chamber Of The Carburetor
Checking the engine oil level The engine oil level can be checked with the engine being either warm or cold. Place the motorcycle in an upright position and on a horizontal surface (not on the side stand). If the engine is cold, the engine oil must be visible at the lower edge of the... -
Page 36: Engine Oil
N ENGINE AT OPERATING TEMPERATURE AND THE ENGINE OIL IT CONTAINS ARE VERY DO NOT BURN OR SCALD YOURSELF Place the motorcycle on a horizontal surface, remove the plug the oil to drain into a receptacle. Clean plug (with magnet) thoroughly. - Page 37 Check the O-rings of the oil filter covers for damage and, if neces- sary, replace them. Put the motorcycle on its side and fill the oil filter housings about halfway with engine oil. Insert the long oil filter at the front and the short oil filter at the back of the housing.
-
Page 38: Trouble Shooting
We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. - Page 39 Dismount seat and fuel tank and check connections, have capacitor and voltage regulator checked Dismount left side paneling and filter box cover, replace fuse Remove seat and fuel tank and check voltage regulator connections; voltage regulator and generator should be checked by a KTM dealer. REMEDY...
-
Page 40: Cleaning
– Befor cleaning with water, plug the exhaust pipe to prevent water ingress – After the motorcycle has been rinsed with a soft water jet, it should be dried by air pressure and a cloth. Drain the float chamber of the carburetor. -
Page 41: Technical Specifications - Engine
TECHNICAL DATA – ENGINE 400/520 SX, MXC, EXC RACING 2002 Type Design Displacement Bore/Stroke Ratio Fuel Valve Timing Camshaft Valve diameter Intake Valve diameter Exhaust Valve clearence cold Intake Valve clearence cold Exhaust Crank shaft bearing Connecting rod bearing Top end bearing... -
Page 42: Tightening Torques
TIGHTENING TORQUES Hexagon collar screw engine case, clutch cover, ignition cover Oil drain plug Allan head plug oil screen short Hexagon plug oil screen long Plug pressure valve Jet screw and hollow screw oil line Screws oil pump cover Hexagon collar screw cylinderhead top section Hex.collar screw cylinderhead top section, water pump cover Hexagon collar screw exhaust flange Cylinder head screw... - Page 43 Conrod bearing radial clearance axial clearance Cylinder bore diameter size I bore diameter size II Piston 400 (cast) diameter size I diameter size II assembly clearance size I assembly clearance size II wear limit Piston ring end gap compression ring...
-
Page 44: Technical Specifications - Chassis
TECHNICAL DATA – CHASSIS 400/520 SX, MXC, EXC RACING 2002 400/520 SX RACING Frame Fork WP USD 4860 MXMA Wheel travel front/rear Rear suspension Front brake Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Rear brake Disk brake with carbon-steel brake disc Ø... -
Page 45: Head Word Index
Flasher switch ...6 Foot brake pedal...8 Fuel ...7 Fuel tap ...7 Fuse (MXC/EXC) ...29 General informations about KTM disc brakes ...20 Hand brake lever ...4 Hand decompression lever ...4 Head word index ...44 Headlamp switch (EXC USA)...6 How to change the handlebar position ...18 Kickstarter...8... - Page 46 321017...