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1. MAINTENANCE WORK ON CHASSIS AND ENGINE A WARNING A ALL MAINTENANCE AND ADJUSTEM ENT OPERATIONS THAT ARE MARKED WITH A x REQUIRE SPECIALIST KNOW LEDGE FOR YOUR OWN SAFETY LET THESE TASKS BE CARRIED OUT BY A KTM DEALER CAUTION WHEN CLEANING THE MOTORCYCLE DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE OTHERWISE WATER WILL PENETRATE THE BEARINGS CARBURETOR ELECTRIC CONNECTORS ETC WHEN TRANSPORTING YOUR KTM ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES IF THE MOTORCYCLE SHOULD FALL OVER FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK DO NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE INSTEAD USE SELF LOCKING NUTS LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED DISPOSE OF OIL GREASE FILTERS FUELS CLEANING AGENTS ETC ACCORDING TO YOUR LOCAL REGULATIONS UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER USED OIL CONTAM INATES 1 000 000 LITERS WATER Tool set The tool set 0 is located in the tool box under the right side cover Removing the seat Remove the collar screws from the underside of the fender Lift the rear of the seat pull backwards
2. Checking of brake fluid level front brake The brake fluid reservoir is linked with the hand brake cylinder at the handlebar and the reservoir is provided with an inspection glass With the reservoir in a horizontal position the brake fluid level should not go below middle of the glass A WARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HASA LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IM M EDIATELY Refilling the front brake fluid reservoir Loosen screws and remove lid and membrane Place hand brake cylinder in a horizontal position and fill the brake fluid reservoir to 5 mm 0 2 in below the rim with brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 Replace membrane and lid tighten screws Rinse off spilled or overflowing brake fluid with water A WARNING A Never USE DOT5 BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REM OVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the f
3. 23 SHITE IEVEr sc ne na prei jakna Nj prak kve Eve JE 7 Replacing the parking light bulb 23 Kickstarter ieh euere 7 Replacing the brake light and tail light bulb 24 Foot brake pedal 8 Cooling system nee 24 Compression damping of fork 8 Checking the cooling liquid level 25 Rebound damping of Ork au 8 Adjusting idling speed 25 Compression damping of shock absorber 8 Adjusting the throttle cable 25 Rebound damping of shock absorber 8 Adjusting the choke cable 26 Baggage Cartier ehren 9 Adjusting the clutch cable 26 Checking the adjustment of the hand decompression cable 26 DRIVING INSTRUCTIONS e ana 10 Engine Oil a hen kite ta V Nea gals 26 PERIO DIC MAINTENANCE SCHEDULE 13 Checking the engine oil level 26 MAINTENANCE WORK ON CHASSIS AND ENGINE 14 Oleee enean bena deci Net v tni 27 Tool SET sinensis weg a a A a beens 14 Oil change and bleeding of the oil system 27 REMOVING the seat 14 Changing the fine screen filter 28 Ch
4. 45 60 40 75 85 NOTE DURING THE STAGE OF RUNNING THE ENGINE IN THAT IS THE FIRST 1000 KM 620 MILES THE ENGINE OIL USED SHOULD BE OF A MINE RAL OIL FORMULA THIS ALSO APPLIES IF THE ENGINE HAS BEEN REPAIRED Starting when the engine is cold Open the fuel tap O Switch on ignition turn ignition key into position Switch on emergency OFF switch symbol must be visible Switch transmission to idle green indicator lamp N lights up O perate cold starting device choke Do not accelerate operate starter button If the engine starts push the choke lever back a little bit as soon as the engine runs unevenly 8 Lift motorcycle off center stand A WARNING A TO AVOID INJURIES IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE KICKSTARTER DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING l CAUTION MAXIMUM PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV ENGINE WHEN COLD BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER IT CAN CAUSE ENGINE DAMAGE ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM NAO BWNE IF THE ENGIN
5. The motorcycle has been out of The easily inflammable components of the new fuels evapo operation for a longer period of rate during longer periods of standstill time Therefore old fuel has accu When the motorcycle has been out of operation for more mulated in the float chamber than a week it is therefore recommended to drain the old fuel from the float chamber The engine will immediately start off when the float chamber is filled with new fuel Fuel supply interrupted Loosen fuel hose at carburettor lead into a basin and open fuel tap if fuel leaks out the carburetor might need cleaning if no fuel leaks out check tank ventilation i e clean fuel tap Flooded engine Fully open the throttle when starting or exchange the spark plug respectively Sooty or wet spark plug Clean and dry the spark plug or exchange it respectively Electrode gap too large Adjust spark plug elektrode gap to 0 7 mm Spark plug connector or spark plug Dismount spark plug connect ignition cable hold to ground faulty blank place on engine and actuate starter a strong spark must be produced at the spark plug If no spark is created exchange the spark plug If the new spark plug doesn t produce a spark either dis connect the spark plug connector from the ignition cable hold it a distance of approx 5 mm from ground and start If aspark now occurs replace spark plug cap If no spark is produced control ignition system The plug c
6. CAUTION IF THERE IS NO PLAY IN THE CHOKE CABLE THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED THIS RESULTS IN HIGH FUEL CONSUMPTION AN UNEVEN RUNNING ENGINE AND AN EXTREME WEAR OF PISTON AND CYLINDER Hand brake lever The hand brake lever is mounted on the handlebar on the right and actuates the front wheel brake A WARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Speedometer indicator lamps The mileage indicator in the speedometer indicates overall mileage The day mileage indicator can be set to 0 by means of the setting wheel Turn the setting wheel forward until only zeros can be seen in the display aD The green indicator lamp flashes when the flasher light is working in the same rhythm as the flasher light N The green indicator lamp lights up when the gear is switched to idle D The blue indicator lamp lights up when the high beam is on E The red cooling liquid temperature warning lamp lights up at a cooling liquid temperature of 110 C 230 F l CAUTION H IF THE RED COOLING LIOUID TEMPERATURE WARNING LAMP LIGHTS UP WHILE YOU ARE DRIVING THE COOLING SYSTEM IS PROBABLY DEFECT IMMEDIATELY STOP THE ENGINE AND CHECK THE COO
7. Kickstart instructions Start as described above then push the kickstarter hard ALL THE WAY A WARNING A WHEN STARTING THE ENGINE PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH Starting off Pull the clutch lever Put the engine into first gear slowly release the clutch lever and open throttle at the same time A WARNING A BEFORE YOU START OFF CHECK THAT THE MAIN STAND HAS BEEN SWUNG UP FULLY IF THE STAND DRAGS ON THE GROUND THE MOTORCYCLE CAN GO OUT OF CONTROL ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE Shifting Riding You are now in first gear refered to as the drive or uphill gear Depending on the conditions traffic road gradient etc you can shift to a higher gear Close throttle at the same time pull clutch lever and shift to the next higher gear Let clutch lever go again and open throttle If you turned on the choke make sure you turn it off again as soon as engine is warm W hen you reach full speed through turning the throttle grip all the way turn throttle back to 3 4 the speed hardly decreases although the engine will use less gas Never open the throttle wider than the engine can handle Excessive turning of the throttle grip will increase full consumption By shifting down use the brakes if necessary and close throttle at the same time
8. Pull clutch lever and shift down to the next gear Let clutch lever go slowely and open throttle or shift down again If the engine is killed f ex at a crossing simply pull the clutch lever and start It is not necessary to switch the gear to NEUTRAL A WARNING A OBSERVE THE TRAFFIC REGULATIONS DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE ADJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS DRIVE CAREFULLY ON UNKNOWN ROADS WHEN DRIVING OFF ROAD ALWAYS HAVE A FRIEND ON A SECOND MOTORCYCLE TO KEEP YOU COMPANY SO THAT YOU CAN HELP EACH OTHER SHOULD DIFFICULTIES ARISE REPLACE THE HELMET VISOR RESPECTIVELY GOGGLE GLASSES IN PLENTY OF TIME WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES YOU WILL BE PRACTICALLY BLIND AFTER FALLING WITH THE MOTORCYCLE CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN CAUTION HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO WARM UP AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED BE TAKEN THE ENGINE HAS REACHED ITS OPERA TING TEM PERATURE AS SOON AS THE RADIATORS BECOME WARM NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR THE ENGINE WILL OVERSPEED DAMAGING THE VALVES IN ADDITION
9. gt 123 16 17 18 lt 2 lt a cm Chain wear In order to check the chain wear regard the following instructions Shift the gear into idling and pull the upper chain strand with approx 10 15 kilogramm 33 Ib upwards see figure Now one can measure a space of 18 chain reels at the lower chain strand The chain should be replaced at the latest when a space of 272 mm 10 70 in is measured Chains do not always wear off evenly therefore repeat the measurement at different places on the chain NOTE If you mount a new chain the sprockets should also be replaced New chains wear faster if used on old used sprockets General informations about KTM disc brakes BRAKE CALIPERS The brake calipers of this series float This means that the brake calipers are not solidly attached to the caliper support Thus the brake pads are always in optimum contact with the brake disc BRAKE PADS The motorcycles are delivered with organic brake pads and have also been type coded with these pads Said pads are suitable for almost the entire range of application of these motorcycles It is only for competitive racing in extremely dirty conditions e g water in combination with sand and mud that we recommend brake pads that have sintered linings However take notice of the fact that brake pads with sinte red linings have not been type coded Besides they may cause greater wear on the brake discs BRAKE FLUID RESERVO IRS The
10. BELOW THE KTM LOGO ON THE TYPE LABEL OF THE MUFFLER ONLY HGS KAT MUFFLERS ARE EQUIPPED WITH CATALYTIC CONVERTERS A WARNING A GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES ALWAYS SWITCH OFF THE ENGINE BEFORE REFUEL LING BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT WIPE UP SPILLS PROMPTLY IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES SEEK A DOCTOR S ADVICE IMMEDIATELY Fuel expands when its temperature rises Therefore do not fill the tank to the top see fig Fuel tap OFF In this position the fuel tap is closed No fuel may flow to the carburetor ON When using the motorcycle the twist grip must be set to the ON position Now fuel may flow to carburetor In this position the tank empties down to the fuel reserve of approx 2 5 liters RES The reserve approximately 2 5 liters cannot be tapped until the twist grip is turned to the RES position Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time too CAUTION THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED IF THE TAP IS NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL CAN GET INTO THE ENGINE ENGLISH OFF ON RES Shift lever The shift lever is moun
11. THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD TO ENGINE DAMAGE F THE RED COOLING LIQUID TEMPERATURE LAMP LIGHTS UP WHILE YOU ARE DRIVING THIS INDICATES COOLING SYSTEM TROUBLE IMMEDIATELY STOP AND TURN OFF THE ENGINE DRIVING WITH THE WARNING LAMP ON WILL CAUSE ENGINE DAMAGE PLACE A CLOTH ON THE RADIATOR CAP OPEN THE CAP SLOWLY SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE CAUTION SCALDING HAZARD AND CHECK THE COOLING LIQUID LEVEL DO NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COO LING SYSTEM HOWEVER CALL ON ONE OF KTM S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REMEDIED CAUTION F ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT IN THE EVENT THAT WHILE RIDING ON YOUR MOTORCYCLE YOU NOTICE ANY UNUSUAL OPERATION RELATED NOISE STOP IMMEDIA TELY TURN THE ENGINE OFF AND CONTACT AN AUTHORIZED KTM DEALER Braking Close throttle and apply the hand and foot brakes at the same time When driving on sandy wet or slippery ground use mainly the rear wheel brake Always brake with feeling blocking wheels can cause you to skid or fall Also change down to lower gears depending on your speed When driving downhill use the braking effect of the engine Change down one or two gears but do not overspeed the engine In this way you will
12. and kickstarter API SF SG SH Engine oil Use only oil brands Shell Advance Ultra 4 which meet qua lity requirements of API classes SF SG or SH informations TEM PERATURE on bottles or higher Both mineral and synthetic oils with 0 C above specifications can be used I T 32 F CAUTION 10W 40 10W 50 10W 60 POOR OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE WEAR 15W 40 15W 50 15W 60 BASIC CARBURETOR SETTING 400 LCA 400 LCA 25kW 31kW Carburetor PHM 38 ND PHM 38 ND Carburetor setting number 100197 100197 Main jet 130 130 Needle jet AR 264 AR 264 Idling jet 50 50 Jet needle K 23 K 23 Needle position from top 2 nd 2 nd M ixture adju screw open 1 5 turn 1 5 turn Throttle valve 50 1 50 1 Starting jet 45 50 55 45 50 55 Performance restrictor slide stop 51 mm BASIC CARBURETOR SETTING 640 LC4 640 LC4 25 kW 37 kw Carburetor BST40 225 BST40 225 Carburetor setting number 080298 080298 Main jet 142 5 142 5 Needle jet 689 X 6 689 X 6 Idling jet 45 45 Jet needle 665 665 Needle position from top 3 rd 3 rd M ixture adju screw open Throttle valve Starting jet Performance restrictor slide stop 17 mm KITM SPORTMOTORCYCLEE AG A 5230 Mattighofen Postfach 91 Austria Internet http www ktm co at FN 102019 d Landesgericht Ried im Innkreis TAIN
13. and unhook it from the oval head screw To mount the seat hook it into the oval head screw lower the rear part of the seat and push the whole seat forwards If necessary push the middle of the seat slightly down to let the retaining bracket engage with the seat Finally fasten the seat with the corresponding screw Checking and adjusting steering head bearing Check steering head bearing for play periodicaly To check this put motorcycle on a stand so that the front wheel is off the ground Now try to move the fork forward and backward To adjust loosen the five clamp screws of the top triple clamp and turn steering stem bolt clockwise until there is no more play Don t tighten the steering stem bolt all the way otherwise the bearings will be damaged With a plastic hammer lightly rap on the triple clamp to avoid tension Re tighten the five clamp screws with 15 Nm 11 ft lb A WARNING A IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY THE MOTOR CYCLE WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL CAUTION IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS FIRST THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED At least once a year the steering head bearings should be greased Changing the spring preload of the shock absorber KTM sets the shock absorber for a driver only weigh
14. brake fluid reservoirs on the front and rear wheel brakes have been designed in such a way that even if the brake pads are worn it is not necessary to top up the brake fluid If the brake fluid level drops below the minimum either the brake system has a leak or the brake pads are completely worn down In this case consult an authorized 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 If you do not have any DOT 5 1 for refilling you may use DOT 4 brake fluid However you should replace it as soon as possible by DOT 5 1 Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjusting screw In this way the position of the point of pressure i e the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc can be adjusted for any hand size CAUTION AT THE HAND BRAKE LEVER FREE TRAVEL MUST AT LEAST BE 3 MM ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED TO BE RECOGNIZED BY THE GREA TER RESISTANCE OF THE HAND BRAKE LEVER IF THIS FREE TRAVEL IS NOT PROVIDED PRESSURE WILL BUILD UP IN THE BRAKING SYSTEM AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING N ENGLISH HSIIDN3
15. clearance 355 mm 13 8 in Dead weight without fuel 136kg 300 Ibs Max permissible front axle load 211 kg 465 Ibs Max permissible rear axle load Max permissible laden weight 335 kg 740 Ibs 350 kg 773 Ibs STANDARD ADJUSTMENT FORK STANDARD ADJUSTMENT SHOCK ABSO RBER 918S757 1185701 Compression adjuster 12 Compression adjuster 3 Rebound adjuster 12 Rebound adjuster 5 Spring 4 4 N mm Spring 66 260 Spring preload 10 mm 0 4 in Spring preload 23 mm 0 9 in Air chamber length 160 mm 6 3 in Capacity per fork leg ca 800 cc Fork oil SAE5 TORQUES Collar screw front axle M 10 40 Nm 30 ft lb Brake caliper front M 8 Loctite 242 25 Nm 20 ft ib Collar nut rear axle M 20x1 5 80Nm 60 ft ib Hex nut swing arm bolt M 14x1 5 100Nm 74 ft lb Clamping screw upper fork bridge M 8 25Nm 11ft lb Clamping screw lower fork bridge M 8 20Nm 15 ft lb Clamping screws fork stubs M 8 10 Nm 7 ft lb Other screws chassis M6 10 Nm 7 ft lb M8 25Nm 20 ft lb M10 45Nm 33 ft lb TECHNICAL DATA ENGINE 400 640 LC4 98 Engine 400 LC4 640 LC4 Design Liguid cooled single cylinder 4 stroke engine with balancer shaft and electric starter Displacement 398 ccm 625 ccm Bore Stroke 89 64 mm 101 78 mm Ratio 10 8 1 11 1 Fuel unleaded premium gasoline with a least RON
16. fail Blown fuse Replace fuse below the headlight mask The NEUTRAL lamp is not on even though the gear is in NEUTRAL Defect indicator lamp Defect neutral switch Loose connections defect cable Replace indicator lamp Connect cable to ground neutral switch must be replaced if indicator lamp lights up Check connections and cables The battery is discharged The ignition power consumer hasn t been switched off The battery isn t charged by the generator because Recharge the battery according to the relevant instructions Remove seat and check voltage regulator connections voltage regulator and generator should be checked by a KTM dealer CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge The hard dirt can be removed before with the help of a soft water jet CAUTION NEVER CLEAN YOUR MOTORCYCLE WITH A HIGH PRESSURED CLEANER OR A HIGH PRESSURED WATER JET THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS CONNECTORS SHEATHED CABLES BEARINGS CARBURETOR ETC AND CAUSE DISTURBINGS OR LEAD TO A PREMATURE DESTRUC TION OF THESE PARTS You should use normal trade mark detergents to clean the engine Strongly dirted parts should be cleaned additionally with the help of a paint brush After the motorcycle has been
17. in wide Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit CAUTION NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK ABSO RBER A WARNING A THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COM PRESSED NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RESULT Checking chain tension Support the motorcycle on the center stand or side stand respectively Switch transmission to neutral Push the chain upwards appr 30 mm 1 2 in from the end of the chain sliding component until the upper part of the chain is tensioned see illustration Now the distance between chain and swingarm should be 0 mm The upper part of the chain must be tight see illustration Correct chain tension if necessary A WARNING A IF CHAIN TENSION IS TOO GREAT PARTS WITHIN THE SECONDARY POWER TRANSM IS SION CHAIN CHAIN SPROCKETS TRANSMISSION AND REAR WHEEL BEARINGS WILL BE SUBJECTED TO UNNECESSARY STRESS RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE TOO MUCH SLACK IN THE CHAIN ON THE OTHER HAND CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS IF THIS HAPPENS THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE In EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE Correct chain tension Loosen collar nut loose
18. necessary to check the electrolyte level or to refill water Simply keep the battery poles clean and slightly grease them with an acid free grease if necessary Removing the battery First disconnect the negative and then the positive pole of the battery Remove screws and swing retaining bracket and voltage regulator out of the way Remove battery When replacing connect first the positive and then the negative pole A WARNING A F ELECTROLYTE SULPHURIC ACID LEAKS FROM THE BATTERY PROCEED WITH GREAT CARE THE ELECTROLYTE CAN CAUSE SEVERE BURNS IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER IN THE CASE OF CONTACT WITH THE EYES THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 15 MINUTES IMMEDIATELY CONSULT A DOCTOR THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLOSIVE GASES AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY DEFECT BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING THIS WILL DESTROY THE RECTIFIER REGULATOR BATTERY STO RAGE 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 Charging the battery Remove the battery and check the charging level Use a voltmeter to m
19. observe the following instructions Clean motorcycle thoroughly see chapter CLEANING Change engine oil oil filter and fine screen filter old engine oil contains aggressive contaminations Check antifreezer and amount of cooling liquid Warm up the engine once again close the fuel cock and wait until the engine dies Then open the drain plug of the float chamber to remove the remaining fuel Remove spark plug and fill in approx 5 ccm of engine oil into the cylinder through the opening Actuate kick starter 10 times in order to distribute the oil onto the cylinder walls and mount the spark plug Set piston to compression so that the valves will be closed slowly operate the kickstarter until you can hear the automatic decompressor click release Let fuel flow out of tank into an appropriate container Correct tire pressure Lubricate pivot points of the control levers foot rests etc as well as the chain Service the shock absorber linkage Disassemble and charge battery see chapter BATTERY The storage place should be dry and not subject to excessive temperature fluctuations Cover the motorcycle with an air permeated tarpaulin or blanket Do not use non air permeable materials as a possible humidity might not be able to escape and could cause corrosion CAUTION IT WOULD BE VERY BAD TO LET THE ENGINE RUN FOR A SHORT TIME DURING THE STORAGE PERIOD THE ENGINE WOULD NOT GET WARMED UP ENOUGH AND TH
20. rinsed with a soft water jet it should be dried by air pressure and a cloth Then take a short drive until the engine has reached the working temperature and also use the brakes Due to the heat the water also evaporates at the unapproachable parts of the engine and the brakes Slide back the protective covers on the handlebar mounted instruments so that any water that may have seeped into this part of the motorcycle is allowed to evaporate After the motorcycle has cooled down oil and grease all sliding and pivot points Treat the chain with a chain spray too To prevent failures in the electric system you should treat the ignition lock the emergency OFF switch light switch and the socket connectors with contact spray CONSERVATION FOR WINTER OPERATION In the event that the motorcycle is also used in winter and on roads where one has to expect salt spraying you will have to take precautions against the aggressive road salt clean motorcycle thoroughly and let it dry treat engine carburetor swing arm and all other bare or galvanized parts except for brake discs with a wax based anti corrosion agent A WARNING A KEEP ANTI CORROSION AGENT FROM GETTING INTO CONTACT WITH THE BRAKE DISCS FOR OTHERWISE THIS WILL SIGNIFICANTLY REDUCE THE BRAKING POWER H CAUTION AFTER RIDES ON SALTED ROADS CLEAN MOTORCYCLE THOROUGHLY WITH COLD WATER AND LET IT DRY WELL Should you desire to make a pause over a longer space of time please
21. the cylinder and the cylinder head After the engine has reached its operating temperature about 70 C 158 F the thermostat opens and the cooling liquid is also pumped through both aluminum radiators Air blowing in through the radiators cools the cooling liquid The slower the speed of the motorcycle the less the cooling liquid is cooled down Dirty radiator fins also reduce the cooling efficiency If little or no air blows through the radiators for example when riding through slow traffic or waiting at traffic lights the coolant temperature will rise If the coolant temperature rises to 85 C 185 F the fan on the left radiator will switch on This fan will provide additional air circulation through the radiator thereby preventing the cooling system from overheating CAUTION IF THE RED COOLING LIQUID TEMPERATURE WARNING LAMP LIGHTS UP THIS WILL MOST LIKELY BE DUE TO A DEFECT IN THE COOLING SYSTEM IN THIS CASE STOP IMME DIATELY AND TURN OFF THE ENGINE LET THE ENGINE COOL DOWN AND CHECK THE COOLING SYSTEM FOR LEAKS ALSO CHECK IF THERE IS ENOUGH COOLING LIQUID CAUTION SCALDING HAZARD Do NOT DRIVE ON UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE A mixture of 40 antifreezer and 60 water is used as co
22. 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft camshaft drive through single chain Camshaft 249 249 1 Valve timing by 1 mm 10 22 BTDC EO 60 BBDC 10 13 BTDC EO 53 BBDC valve clearence IC 47 ABDC EC 4 ATDC IC 51 ABDC EC 11 ATDC Valve diameter Intake 36 mm Exhaust 30 mm Valve clearence cold Intake 0 20 mm Exhaust 0 20 mm 0 15 mm Exhaust 0 15 mm Crank shaft bearing 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston forged cast aluminium alloy Piston rings 1 compression ring 1 taper face ring 1 oil scraper ring Engine lubrication two Eaton oilpumps Engine oil see bellow Engine oil guantity appr 2 1 liters including frame Primary ratio straight geared spur wheels 30 81 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratio Ist 14 35 2nd 15 24 3rd 18 21 4th 20 19 5th 22 18 Ignition system contactless DC CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to max 38 BTDC at 6000 rpm Generator 12V 200W Spark plug NGK DR8EA Spark plug gap 0 7 mm Cooling system liquid cooled permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid lliter 40 antifreeze 60 water at least 25 C 13 F Starting equipment electric starter
23. E IS DOES NOT CRANK WHEN YOU ACTUATE THE STAR TER TIP SWITCH the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignition is on the headlight is on ignition lock in position If this is not the case the battery is discharged If the lights are on proceed as described in the Trouble shooting section or contact a KTM dealer ENGLISH kl kl IF THE ENGINE CRANKS BUT DOES NOT START WHEN YOU ACTUATE THE STARTER TIP SWITCH Check if the fuel tap is open Check if the choke lever has been operated Check if sufficient fuel is in the tank If this is not the case refill the tank if sufficient fuel is in the tank proceed as described in the Trouble shooting section or contact a KTM dealer NOTE THIS MOTORCYCLE IS EQUIPPED WITH A SAFETY STARTER SYSTEM THE ENGINE CAN ONLY BE STARTED WHEN THE TRANSMISSION IS SWITCHED TO IDLE OR THE CLUTCH LEVER IS PULLED RESPECTIVELY Starting when the engine is warm or hot O pen the fuel tap O Switch on ignition turn ignition key into position O Switch on emergency OFF switch symbol must be visible Switch transmission to idle green indicator lamp N lights up Do not accelerate operate starter button Lift motorcycle off center stand or swing up side stand respectively AUBWNE W hat to do when the engine is flooded The throttle must be fully opened when starting If necessary change ignition plug
24. E THUS DEVELOPED STEAM WOULD CONDENSE DURING THE COM BUSTION PROCESS AND CAUSE THE VALVES AND EXHAUST TO RUST RE INITIATION AFTER TIME OF STORAGE Mount the charged battery regard polarity Fill up tank with fresh fuel Check motorcycle as before each start see driving instructions Take a short careful test ride first TECHNICAL SPECIFICATIONS CHASSIS 400 640 LC4 98 400 640 LC4 98 Frame Central chrome moly steel frame Fork WP Extreme W heel travel front rear 280 320 mm 11 12 6 in Rear suspension Central shock absorber WP IBS with PRO LEVER linkage to rear swing arm with needle bearing Front brake Disc brake with carbon steel brake disc 300 mm 11 8 in brake caliper floated Rear brake Disc brake with carbon steel brake disc 7220 mm 8 7 in brake caliper floated Tyres front Air press road driver only Air press road with passenger 90 90 21 Enduro 3 1 5 bar 22 psi 2 0 bar 29 psi Tyres rear Air press road driver only Air press road with passenger 140 80 18 Enduro 3 2 0 bar 29 psi 2 2 bar 31 psi Fuel tank capacity 12 liter 3 2 US gallons 2 5 liter 0 6 US gallons reserve Final drive ratio 400 LC4 15 45t 640 LC4 16 42t Chain O Ring 7s x74 Battery maintenance free battery 12V 8Ah Steering angle 62 5 Wheel base 1510 10 mm 59 4 0 4 in Seat high 955 mm 37 6 in Ground
25. ERATIONS TO DESIGN AND MODEL Index Page SERIAL NUM BER LOCATIONS essiri 4 Checking the front brake pads 18 Cha sis NuM DET sve s inei zbudi Pope peki aje pei videza kai 4 Changing the basic position of the foot brake pedal 18 Engine number engine type 4 Check the rear brake fluid level 19 OPERATION INSTRUMENTS nana 4 Refilling the rear brake fluid reservoir 19 Clutch levers ansteuern 4 Checking the rear brake pads 19 Hand decompression lever 4 Dismounting and mounting the front wheel 20 Choke leyeh sugestivno ri ita 5 Dismounting and mounting the rear wheel 20 Hand brake lever nsnsensensennennenennnennennnnnnnenennnnen an 5 Checking the shock absorbtion rubbers in the rear hub 21 Speedometer indicator lamps 5 Tires air pressure 21 IGNITION OCK u een 5 Checking spoke tension 21 Combination switch 6 Battery PETE A IEE RRR TE CORR TM O ET O RL V O rice 22 Starter tip switch emergency O FF switch 6 Charging the battery ccc cee eee eeeteeeteeeteeeeeneeeee 22 Filler CAPS ee a ne tienen 6 Main fUSE nana 23 Te ee eee eee 6 Fuses for individual power consuming units nn 23 Fue TaD ni san 7 Replacing the headlight bulb
26. KTM dealer Have valve clearance adjusted Check setting of the hand decompression cable Have ignition system checked Engine overheats Insufficient cooling liquid Radiator fins are extremely dirty Foam forms in cooling system Bent radiator hose Thermostat defective Blown fan fuse Defect thermosw itch Fan defective Refill cooling liquid see maintenace work check cooling system for leaks Clean radiator with water jet Replace cooling liquid use antifreezer with brand name Shorten or replace cooling hose Remove and check thermostat opening temperature 70 C 158 F or replace it contact aKTM dealer Replace fuse and check if fan operates properly see below Contact aKTM dealer Check if fan operates properly To do this start the engine then bypass the connections to the thermoswitch bottom right radiator contact aKTM dealer High oil consumption Buckling gear ventilation hose Engine oil level too high Engine oil too thin viscosity Readjust or replace ventilation hose Check engine oil level when the engine is warm correct if necessary Use thicker engine oil see chapter Engine oil TROUBLE All switched on lamps blown out CAUSE REM EDY Voltage regulator faulty Remove seat and check connections Have voltage regulator checked Headlight and parking light fail Blown fuse Replace fuse below the headlight mask Flasher lights brake light fan and horn
27. LING LIQUID LEVEL SEE PAGE 25 DRIVING WITH THE WARNING LAMP ON WILL CAUSE ENGINE DAMAGE Ignition lock with 4 switch positions Switch positions of ignition lock X Ignition off light off engine can t be started Ignition on light off engine can be started v Ignition on light on engine can be started Ignition off light off handlebar blocked To switch the ignition to position turn the ignition key to position amp and firmly press it into the lock Turn the handlebar all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position X and A Ignition lock with 3 switch positions Switch positions of ignition lock X Ignition off light off engine can t be started C Ignition on light on engine can be started Ignition off light off handlebar blocked To switch the ignition to position R turn the ignition key to position X and firmly press it into the lock Turn the handlebar all the way to the left then turn the ignition key to the left The ignition key can be withdrawn in position X and A L a J 0 ra m 5 a a by i Combination switch The rocker switch LIGHTS actuates the high beam or low beam D High beam light SD Low beam light x The indicator switch returns to central position after actuation Press flasher switch towards switch housing to switch off the flasher b
28. MANUALE D USO MANUEL D UTILISA IM PORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COM PLETELY BEFORE GOING ON YOUR FIRST RIDE IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY IN YOUR OWN INTEREST PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLO WS A WARNING A IGNORING THESE INSTRUCTIONS CAN ENDANGER YOUR BODY AND YOUR LIFE CAUTION 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 COMSUMER INFORMATION FOR AUSTRALIA ONLY TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit a The removal or rendering inoperative by any person other than for purposes of mainten ance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use and b the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Introduction We would like to congratulate you on your purchase of aKTM motorcycle You are now owner of a sporty and modern mo
29. PERATURE 32 F 10W 40 15W 40 10W 50 15W 50 10W 60 15W 60 Adjusting the choke cable At the choke cable there must always exist a play of approx 2 mm 0 1 in To check this push choke lever fully forward and pull protective cover from the adjuster piece Now it must be possible to lift the outer covering of the cable by approx 2 mm from the adjuster piece until feeling a resistance If necessary loosen counter nut and readjust play by turning the adjuster piece Tighten counter nut and slide on protective cover Adjusting the clutch cable When the engine is cold the play at the clutch lever should be 1 3 mm 0 04 0 12 in measured at the outer edge To adjust the clutch cable turn the adjusting nut accordingly Checking the adjustment of the hand decompression cable To check set piston at compression so that the valves are closed While doing this slowly operate the kickstarter through its stroke until the clicking sound disengaging of the automatic decompression can be heard Now the decompression lever must be operated 25 mm 1 in until resistance is felt the exhaust valves begin to open To adjust move back the protective cover loosen the counter nut and correct the adjusting screw accordingly Tighten counter nut and push back protective cover CAUTION IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER THIS CAN RESULT IN ENGINE DAMAGE NOTE No adjustment need be made
30. SULT Baggage carrier The baggage carrier may be loaded with up to 10 kg The two lateral hoops serve as handles for the passenger at a J 0 ra m 9 DRIVING INSTRUCTIONS Check the following before each start When you start off the motorcycle must be in a perfect tech nical condition For safety reasons you should make a habit of performing an overall check of your motorcycle before each start The following checks should be performed 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and conseguently to engine damage 2 FUEL Check that there is sufficient fuel in the tank when closing the filler cap 3 CHAIN A loose chain can fall off an extremely worn chain can tear and insufficient lubrication can result in unnecessary wear to the chain and rear sprockets 4 TIRES Check for damaged tires Tires showing cuts or dents must be replaced The tread depth must comply with the legal regulations Also check the air pressure Insufficient tread and incorrect air pressure reduce the driving performance 5 BRAKES Check correct functioning of the braking system Check for sufficient brake fluid in the reservoir The reservoirs have been designed in such a way that brake fluid does not need to be refilled even when the brake pads are worn If the level of brake fluid falls below the minimum value this indi cates a leak in the braking system or completely worn out brake pads Arrange for the br
31. T IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Fuses for individual power consuming units Additional fuses separately protecting different power consuming units are mounted under the headlight mask For instructions to remove and mount the headlight mask please refer to Exchanging the headlight lamp Fuse 10 Ampere protects the following power consuming units headlight parking light Fuse 10 Ampere protects the following power consuming units flasher lights brake light horn radiator fan motor Fuse 10 Ampere protects the following power consuming units ignition starter system 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 CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED AN INEXPERT TREATMENT COULD DAMAGE THE WHOLE ELECTRICAL INSTALLATION Exchanging the headlight lamp Remove the headlight mask Remove screws on the left and on the right side Depress the front section of the fender pull the headlight mask upwards unhook it from the lower part of the fender then swing it forwards Exchanging the headlight lamp Disconnect plug from the bulb Remove the rubber cap Unhook the retaining bracket then remove the
32. TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE Instructions for initial operation Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs see Customer Service M anual Read the entire manual carefully before your first drive Familiarize yourself with the operating elements Adjust the hand brake lever and the foot brake pedal to the most comfortable positions for you Get used to handling the motorcycle on an empty car park before starting on a longer drive Also try to drive as slowly as possible and in standing position to improve your feeling for the vehicle Do not drive along off road tracks which go beyond your ability and experience Hold the handlebar with both hands and leave your feet on the foot rests while driving Remove your foot from the foot brake pedal when you are not braking If the foot brake pedal is not released the brake pads rub continuously and the braking system is overheated You may only be accompanied by a passenger if your motorcycle is fitted and registered for such purposes The passenger must hold tight to the brackets or hold on to the driver during the drive with his feet on the passenger foot rests Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS Spare parts from other manufacturers can impair the safety of the motorcycle Motorcycles are sensitive to alterations in the distribution of weight If you are taking
33. aking system to be checked by a KTM specialist garage as complete failure of the braking system can be expected Also check the state of the brake hoses and the thickness of the brake linings Check free travel at hand brake lever and foot brake pedal 6 CABLES Check correct setting and easy running of all control cables 7 COOLING LIOUID Check the level of cooling liguid when the engine is cold 8 ELECTRICAL SYSTEM Check headlight parking light tail light brake light flashers indicator lamps and horn for faultless operation 9 LUGGAGE If you are taking luggage with you check that this is securely fastened A WARNING A WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE CLEVER KTM DRIVERS ALWAYS WEAR A HELMET BOOTS GLOVES AND A JACKET REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLOURED SO THAT OTHER USERS OF THE ROADS CAN SEE YOU AS EARLY AS POSSIBLE YOUR PASSENGER OF COURSE WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIVERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM For EXAM PLE FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE CASES EXTRA TANKS ETC CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLE S DRIVING PROPERTIES THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE
34. an oil filter wrench you will be able to unscrew it the rest of the way with your bare hand Let engine oil flow out of the front pipe of the frame Clean sealing surfaces on the front pipe fill new fine screen filter with engine oil and oil rubber gasket Replace fine screen filter and screw it back in place your bare hand will do Start motor bleed oil system see Changing the engine oil and make sure that the fine screen filter does not leak CAUTION USE ONLY ORIGINAL KTM FINE SCREEN FILTERS USING ANOTHER FILTER BRAND CAN RESULT IN DAMAGE TO THE ENGINE IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME YOU MUST BLEED THE OIL SYSTEM Changing oil filter Replace the oil filter when changing the engine oil Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible Remove banjo bolt and the three screws Remove oil filter cover and oil filter Clean filter housing oil filter cover and sealing surfaces Check oil duct in oil filter cover if clogged Check the O ring for damage O rings need not be replaced unless damaged Press the O ring into the groove of the filter cover Fit new oil filter with rubber gasket on the fitting in oil filter cover and mount cover with filter Mount three screws and tighten with 5 Nm 4 ft lb Mount hollow screw with seal rings and tighten with 15 Nm 11 ft l
35. b Start engine and check oil system for leakage TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out disturbances can hardly be expected Should an error occur nevertheless we advise you to use the trouble shooting chart in order to find the cause of error We would like to point out that many operations cannot be performed by oneself In case of uncertainty please contact a KTM dealer TRO UBLE CAUSE REM EDY Engine doesn t crank O perating errror Turn on the ignition switch the gear to neutral and switch the emergency OFF switch on Discharged battery Recharge the battery and investigate the causes for dischar ging contact a KTM dealer Defect ignition lock or emergency Check ignition lock and emergency OFF switch contact a OFF switch KTM dealer The engine doesn t crank Blown fuse safe starting system Replace fuse below the headlight mask The neutral indicator lamp doesn t light up Blown main fuse Remove seat and replace the main fuse If fuse blows again contact a KTM dealer The engine cranks only with Defect safe starting system Contact a KTM dealer pulled clutch lever Engine cranks with gear Defect safe starting system Contact a KTM dealer engaged Engine cranks but doesn t O perating error O pen fuel tap tank fuel you did not use choke i e the warm start start device Pay attention to starting off information see driving instructions
36. bulb When inserting the new bulb make sure that the wider of the 3 tongues is located in the corresponding groove in the socket g CAUTION NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE HEAT WILL OTHERWISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR Hook in the retaining bracket mount the rubber cap and connect the plug to the bulb M ounting the headlight mask Appropriately position the headlight mask The headlight must be located below the cockpit Depress the front part of the fender pull the headlight mask upwards and insert the retaining pins into the corresponding bores of the fender M ount the screws 9 Replacing the parking light bulb Disassemble the headlight as described above and simply pull the bulb socket out of the reflector N w ENGLISH Exchanging the brake light and tail light bulb Remove the cap 0 on the underside of the license plate retainer Turn the lamp socket approximately 30 counterclockwise and pull it out of the tail light housing Slightly depress the bulb turn it approx 30 counterclockwise and pull it out of the socket To mount the lamp reverse the worksteps indicated above Cooling system Coolant is circulated by a water pump located in the engine When the engine is cold the cooling liquid circulates only through
37. easure the voltage between the battery poles off load voltage Accurate results can only be obtained if the battery has neither been char ged nor discharged during a period of 30 minutes preceding the measuring off load voltage charging level charging time charging voltage Volt 0 8A gt 12 7 100 za 12 5 75 4h 123 50 7h max 12 0 25 11h liv 11 8 0 14h STD 0 0A 8 10h or GUICK A DA 1 0 YY YUASA If the battery is empty it can be recharged for a maximum period of 10 hours at 0 3 A and a maximum of 14 4 V CAUTION TO AVOID DAMAGE DO NOT REMOVE THE LOCKING BAR ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTI LATION EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES O THERW ISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES AVOID QUICK CHARGING IF POSSIBLE Main fuse Located near the battery under the seat the main fuse protects all power consumers 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 20 Ampere CAUTION UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SE
38. ecking and adjusting steering head bearing 15 Changing oil filter 28 Changing the spring preload of the shock absorber 15 TROUBLE SHOOTIN Gini a 29 Lubricate shock absorber linkage 15 CLEANING ae Rinne 32 Checking rubber ring on the rear shock absorber 16 Checking chain tension 16 CONSERVATION FOR WINTER OPERATION 32 Correct chain tension 16 STORAGE ae Rain 32 Chain maintenance 16 Re initation after time of storage 32 Chain wear a AE 17 TECHNICAL SPECIFICATIONS CHASSIS 33 General information on KTM disc brakes 17 a TECHNICAL SPECIFICATIONS ENGINE 34 Adjisting of free travel at the hand brake lever 17 Checking of brake fluid level front brake 18 WIRING DIAGRAM APPENDIX Refilling the front brake fluid reservoir 18 3 SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube Write this number into the relevant area on page 1 Engine number engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket Write this number into the relevant area on page 1 OPERATION INSTRUMENTS Clutch lever The clutch lever is fi
39. ew never should be changed Adjust idling speed 640 LC4 Use the adjusting screw to adjust the basic position of the throttle valve and thus the idle speed Turning in clockwise direction will increase the idling speed turning in counterclockwise direction will reduce the idling speed Normal idling speed 1400 1500 rpm Adjusting the throttle cable 400 LC4 There must always be a 3 5 mm 0 1 0 2 in play in the throttle cable To check this move back the protective cover on the throttle grip You must be able to lift the outer covering of the cable 3 5 mm from the adjusting screw 9 until resistance is felt To adjust loosen the counter nut and turn the adjusting screw accor dingly Finally tighten counter nut and slide the protective cover back on Adjusting the throttle cable 640 LC4 A play of 3 5 mm must at any time be left in the throttle cables To check the play of the throttle cables first push back the protective cap on the throttle twist grip Now it should be possible to lift the outer sleeve of one of the two cables 3 5 mm off the adjusting screw before resistance is felt The play of the throttle cables can be adjusted if necessary using the two adjusting screws For this purpose undo counter nut and turn the adjusting screw until the desired play is achieved Then tighten the counter nut and replace the protective cap API SF SG SH TEM
40. ing approximately 75 kg 165 Ib If you want to take a passenger with you of if you weigh considerably more or less than 75 kg 165 Ib you should change the spring preload accordingly This is easily done NOTE Before changing the spring preload note down the basic setting e g how many threads are visible above the adjusting ring One rotation of the adjusting ring changes the spring preload by approximately 1 75 mm 0 07 in Loosen the locking ring with the hook wrench from the tool set Change the spring preload with the adjusting ring and retighten the locking ring BASIC SETTING SPRING PRELOAD A 23 mm 0 9 in Lubricating the shock absorber linkage The bearings in the rocker arm must be greased Shell Advance Grease in regular intervals For this purpose a grease nipple 9 is mounted on the rocker arm CAUTION AFTER EACH TIME THE MOTORCYCLE IS WASHED IT IS ESPECIALLY IMPORTANT TO GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS L a J 0 ra m pal u s HSIIDNI3 16 38 16 40 16 42 A 0mm Checking rubber ring on the WP rear shock absorber A rubber ring mounted on the rear shock absorber serves as a vibration damper This ring gets pressed together with time and loses its shock absorbing quality M easure the distance between the two discs at various points around their circumferences The space should be at least 2 5 mm 0 1
41. instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Loosen bleeder screws at fork legs overpressure Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance adjust Clean and grease steering head bearings and its seals Check adjustment and funktion of shock absorber Check O ring of the shock absorber for wear Service the shock absorber Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check shock absorber rubbers on the rear hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check battery holder battery and connections Check adjustment of headlight Spray ignition lock emergency off switch and light switch with contact spray Check all screws nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points after washing 1st service after 500 km 300 miles after 5000 km 3000 miles or once a year at least once a year before each start
42. ket and carefully take the rear wheel out of the swingarm CAUTION l DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DISMOUNTED F THE AXLE IS DISMOUNTED CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE SHELL ADVANCE GREASE TO PREVENT THE THREAD FROM JAMMING The rear wheel is remounted in reverse order Before tightening the collar nut to 80 Nm 60 ft lb push the rear wheel forwards so that the chain tensioners lie on the tension screws A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE REAR WHEEL KEEP OPERATING THE FOOTBRAKE UNTIL THE PRESSURE POINT RETURNS T IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE OTHER WISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED TIRES AIR PRESSURE front rear Road driver only 1 5 bar 22 psi 2 0 bar 29 psi Road w passenger 2 0 bar 29 psi 2 2 bar 31 psi Checking the shock absorption rubbers in the rear hub LC4 models have a damped rear wheel hub For this purpose the engine power is conveyed from the rear sprocket via 6 shock absorption rubbers to the rear wheel These 6 absorption rubbers wear with increasing operation time and sho
43. low the MIN marking when the vehicle is in an upright position A WARNING A IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HASA LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN IN THIS CASE CONSULT AN AUTHORIZED KTM DEALER IM M EDIATELY Refilling the rear brake fluid reservoir W hen the brake fluid level has dropped to the M IN mark you need to refill the brake fluid reservoir For easier access to the brake fluid reservoir it is recommended to remove the hexagon screw Then move the container outwards as indicated in the illustration Remove plug with rubber boot and add brake fluid DOT 5 1 Shell Advance Brake DOT 5 1 up to the MAX mark Replace rubber boot and plug O verflown or spilled brake liquid must be rinsed off with water Mount the screw and fix the brake fluid reservoir to the frame always making sure to prevent kinks in the connecting hose A WARNING A NEVER use DOTS BRAKE FLUID IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT STORE BRAKE FLUID OUT OF REACH OF CHILDREN BRAKE FLUID CAN CAUSE SKIN IRRITATION AVOID CONTACT WITH SKIN AND EYES IF YOU GET BRAKE FLUID IN YOUR EYES RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR CAUTION DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT IT IS AN EFFECTIVE PAINT REM OVER USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER Checking the rea
44. luggage with you this should be secured as close as possible to the middle of the vehicle distribute the weight evenly between the front and rear wheel Never exceed the maximum permissible laden weight and the axle weights The maximum permissible laden weight is made up of the following components Motorcycle ready for operation and tank full Luggage Driver and passenger with protective clothing and helmet Pay attention to running in instructions Running in the LC4 models Even finely machined surfaces of engine parts have rougher surfaces than parts that slide on each other for a long time Therefore every engine must be run in For this reason do not demand maximum performance from the engine for the first 100 kilometers The vehicle must be run in at low changing performance level for the first 1000 KM 620 miles The engine speed of 4800 r p m must not be exceeded during the first 1000 kilometers 620 miles During this break in time you should ride your motorcycle in different conditions The following table shows you the maximum velocity values in the different gears at 4800 r p m as based on the rear wheel transmission ratio of your motorcycle Exceeding the above listed rotations as well as pushing high rpm when the engine is cold will have an adverse effect on the life of your engine 400 LC4 640 LC4 15 45t 16 40t 30 20 35 20 30 50 30 0 70 40 90 55 45 55 105 65
45. n counter nuts and turn right and left adjusting screws equally far Tighten counter nuts 8 Before tightening the wheel spindle verify that the chain adjusters are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel Tighten collar nut with 80 Nm 60 ft Ib A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE Chain maintenance For long chain life good maintenance is very important O ring chains require only modest maintenance The best way is to use lots of water but never use brushes or solvents After letting the chain dry you can use a special O ring chain spray Shell Advance Bio Chain A WARNING A No LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL CAUTION WHEN MOUNTING THE CHAIN JOINT THE CLOSED SIDE OF THE SAFETY DEVICE MUST POINT IN RUNNING DIRECTION Also check sprockets and chain guides for wear and replace if necessary max 272 mm N Ji G DA R k o A O o NU o O LSe DOT 5 1 5
46. not need to brake so much and the brakes will not overheat A WARNING A WHEN YOU BRAKE THE BRAKE DISCS BRAKE PADS BRAKE CALIPER AND BRAKE FLUID HEAT UP THE HOTTER THESE PARTS GET THE WEAKER THE BRAKING EFFECT IN EXTREME CASES THE ENTIRE BRAKING SYSTEM CAN FAIL Stopping and parking Apply the brakes fully and put the engine into neutral To stop the engine switch off the ignition Turn the fuel tap to the OFF position park on an area where the ground is firm and lock the motorcycle A WARNING A NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUNNING THE ENGINE RADIATORS EXHAUST EXHAUST SYSTEM BRAKE DISCS AND SHOCK ABSORBERS CAN BECOME VERY HOT DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS CAUTION CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE O THERWISE THE CARBURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS NOTE REGARDING THE CENTER STAND We advise the following procedure to place the motorcycle on the center stand as effortlessly as possible a press main stand to gr
47. o The horn is sounded with button 8 D The light signal high beam is actuated with button Starter tip switch emergency O FF switch Use the starter tip switch to operate the electric starter CAUTION MAXIMUM PERIOD FOR CONTINUOUS STARTING 5 SECONDS WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN The emergency OFF switch is mainly a safety and emergency switch and should normally be ON X If this symbol is visible on the switch the engine can be started i e the ignition circuit and the starter circuit are switched on If this symbol is visible on the switch the engine can not be started i e the ignition circuit and the starter circuit are interrupted Filler cap The filler cap can be locked and is provided with a fuel evaporation con trol system To open the cap insert the ignition key turn it 90 counterclockwise then lift off the filler cap To close the tank insert the filler cap turn the ignition key 90 clockwise and take out the key Fuel The LC4 engine needs premium gasoline with an octane number of 95 or higher CAUTION USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE 95 OCTANES NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE F YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER ALWAYS KEEP IN MIND THAT LEADED FUEL WILL DESTROY THE CATALYTIC CONVERTER WHETHER OR NOT YOUR MOTORCYCLE IS EQUIPPED WITH A CATALYTIC CONVERTER IS INDICATED
48. oling liquid How ever the anti freeze protection must be at least 25 C 13 F Aside from antifreezing protection this mixture also provides great corrosion protection which is why it must not be replaced by pure water CAUTION FOR THE COOLING SYSTEM USE ONLY HIGH GRADE ANTIFREEZER SHELL ADVANCE COOLANT USING LOWERGRADE ANTIFREEZE AGENTS CAN CAUSE CORROSION AND COOLANT FOAMING Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap a water temperature rising up to 120 C 248 F is admissible without fear of problems 10 mm when engine is cold Checking the cooling liguid level The cooling liguid should be 10 mm 0 4 in above the cooling elements when the engine is cold cf diagram In the event of the cooling liguid being drained always fill the system before hand then top off while the engine is running A WARNING A IF POSSIBLE ALWAYS CHECK LEVEL OF COOLING LIOUID WHEN ENGINE IS COLD IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN ENGINE IS HOT USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE Adjust idling speed 400 LC 4 The throttle stop screw is used to adjust the basic position of the slide Turning in clockwise direction will increase the idling speed turning in counterclockwise direction will reduce the idling speed Normal idling speed 1400 1500 rpm The mixture control scr
49. onnection of the CDI Remove the seat the right side cover and the fuel tank Clean unit the pulse generator or the the plug connection and treat it with contact spray ignition coil has oxydized Water in carburetor or jets blocked Dismount and clean carburetor TROUBLE Engine fails to idle CAUSE REM EDY Glogged idling jet Oncorrect adjustment of adjusting screws on carburetor Defective spark plug Defective ignition system Disassemble carburetor and clean jets Have carburetor adjusted Replace spark plug Have ignition system checked Engine does not rev high Carburetor fuel level too high because Float needle is dirty or worn out Float leaks The cold starting system is perma nently activated due to a lack of play in the choke cable Defective membrane of slide Loose carburettor jets Electronic ignition timing faulty Dismount carburetor and check if worn out Replace float needle Replace float Adjust choke cable Replace membrane Tighten jets Have ignition system checked Engine will not reach full power Fuel supply partically interrupted or carburetor dirty Float leaks Defective membrane of slide Air filter very dirty Valve clearance to small Loss of compression because hand decompressor has no play Electronic ignition timing faulty Clean and check fuel system as well as carburetor Replace the float Replace membrane Clean or replace air filter contact a
50. ound using foot b swing out kickstarter and pull motorcycle backwards at an angle as illustrated see illustration M ake sure that the ground is solid and that your motorcycle is standing securely PERIODIC MAINTENANCE SCHEDULE e NE 400 640 LC4 98 620 LC4 Comp 98 Kit u IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING THE 5000 KM 3000 MILES SERVICE NEEDSTO BE CARRIED OUT AFTER EVERY RACE Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter screwed filter at front pipe of the frame Check oil lines for leakage and proper instalment without kinks Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers 6 200 miles Drain and clean carburetor float chamber Adjust idling Check all air supply and ventilation hoses of of the engine and of the carburetor for kinks Clean air filter and air filter box Check sprockets chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreezer Check cooling system for leaks visual check Check exhaust system for leakage Check exhaust brackets Disassemble and clean spark arrestor discs USA models Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct
51. proof solvent and compressed air in order to remove the metal abrasion After all the oil has drained through clean sealing areas and install plugs with gaskets Tighten plug with 30 Nm 23 ft lb and plugs and with 20 Nm 15 Ib ft Remove oil dipstick on the clutch cover fill with 2 0 litre engine oil and attach plug again CAUTION IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME YOU MUST BLEED THE OIL SYSTEM To allow the air to escape from the front pipe of the frame remove plug next to the steering head Start engine and let it run in idle 1 2 minutes until oil escapes at the bore As soon as oil starts to escape turn off the engine and mount plug together with the gasket l CAUTION l DO NOT REV UP THE ENGINE DURING THE BLEEDING PROCEDURE BECAUSE NOT ALL THE LUBRICATING POINTS WILL ALREADY HAVE BEEN SUPPLIED WITH SUFFICIENT AMOUNTS OF OIL Warm up engine check engine oil level and refill up to the marking M AX Finally check the oil system for leaks Note DISPOSE OF USED OIL PROPERLY UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE 1 LITER OIL CONTAMINATES 1 000 000 LITER WATER N N ENGLISH IM HSIIDN3 Changing the fine screen filter Replace the fine screen filter when changing the engine oil To do so loosen the three screws and remove the cover Loosen the fine screen filter with
52. r brake pads The brake pads can be inspected from the rear The thickness of the linings may not be less than 1 mm 0 04 in A WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC L a J 0 ra m ka Ce se uri m INVE 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 collar screw and unscrew it approx 5 turns Loosen the 4 clamping screws on the fork leg axle passage Use the collar screw to push the wheel spindle forward and remove the collar screw Hold the front wheel pull out the wheel spindle 8 NOTICE the wheel spindle may be pulled out more easily if you slide an open end wrench 17mm onto the flat portion of the wheel spindle Remove front wheel carefully from the fork and take the speedometer drive off the hub CAUTION DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISM O UNTED Prior to mounting the front wheel clean and grease sealing ring and running s
53. ront brake pads The brake pads can be inspected from below The linings must be at least 1 mm 0 04 in thick A WARNING A AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM OTHERWISE THEY COULD LEAD TO BRAKE FAILURE FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED CAUTION IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY THE STEEL COM PONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC IMPAIRING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC Changing the basic position of the foot brake pedal The basic position of the foot brake pedal can be altered by turning the stop roller The free play at the foot brake pedal must then be adjusted by means of the piston rod Measured on the outside the foot brake pedal must have 3 5 mm 0 12 0 20 in of free play before the piston rod can move the piston in the brake cylinder to be recognised from the resistance on the foot brake pedal CAUTION IF THIS FREE PLAY IS NOT PRESENT THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING CAUSING CONSTANT FRICTION OF THE BRAKE PADS THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES Checking rear brake fluid level The reservoir for the rear disc brake is located on the left hand side of the vehicle next to the carburetor carburetor connection boot The brake fluid level may not drop be
54. s sure ensures optimum driving comfort and extends the life of your tires A WARNING A DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM OTHER TIRES COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE RIDES THE FRONT AND REAR WHEEL ARE ONLY ALLOWED TO BE TIRED WITH TIRES THAT HAVE THE SAME PROFILE TYPE FOR YOUR OWN SAFETY REPLACE DAMAGED TIRES IMMEDIATELY WORN TIRES CAN HAVE A NEGATIVE EFFECT ON HOW YOUR MOTORCYCLE PERFORMS ESPECIALLY ON WET SURFACES IF AIR PRESSURE IS TOO LOW ABNORMAL WEAR AND OVERHEATING OF THE TIRE CAN RESULT Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety A loose spoke causes the wheel to become unba lanced and before long other spokes will have come loose Check spoke tension especially on a new motorcycle in regular intervals For checking tap on each spoke with the blade of a screw driver see illustration A clear tone must be the result Dull tones indicate loose spokes If necessary have the spokes retightened and the wheel centered by a KTM dealer A WARNING A SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE N ENGLISH Pam mu Gi mi Battery The battery is mounted under the seat remove the seat see page 14 The battery has a closed system and therefore reguires no maintenance It is not
55. ted on the left side of the engine The position of the gears is shown in the illustration Neutral or the idle speed is located between first and second gear Kickstarter The kickstarter is mounted on the left side of the engine Its upper part can be swivelled A WARNING A WHEN STARTING THE ENGINE PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES YOU MAY SLIP OFF THE KICKSTARTER OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT VEHEMENTLY ENOUGH m ra N N L 8 Foot brake pedal The foot brake pedal is located in front of the right footrest Its basic position can be adjusted to your seat position see maintenance work A WARNING A IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS SPONGY TOO MUCH GIVE THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM DON T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER Compression damping of fork The compression damping mechanism is built into the left fork tube It only regulates the degree of damping during compression By using the knob 0 COM the degree of damping of the compression can be adjusted Turn the knob clockwise to increase damping turn it counterclockwise to reduce damping during compression BASIC SETTING turn rotary knob clockwise as far as it will go turn it back counter clockwise by as many clicks as are specified for
56. the relevant type of fork 918S757 12 clicks Rebound damping of fork The rebound damping mechanism is built into the right fork tube It only regulates the degree of damping during rebounding By using the knob REB the degree of damping of the rebound can be adjusted Turn the knob clockwise to increase damping turn it counter clockwise to reduce damping during rebounding BASIC SETTING turn rotary knob clockwise as far as it will go turn it back counter clockwise by as many clicks as are specified for the relevant type of fork 918S 57 12 clicks Compression damping of shock absorber With the knob the degree of damping of the compression can be adjus ted to 7 positions Turn the knob counterclockwise to increase damping turn it clockwise to reduce damping during compression BASIC SETTING 1185701 position 3 Rebound damping of shock absorber With the setting wheel the degree of damping of the rebound can be adjusted to 11 positions Turn the knob to the left side to increase damping turn it to the right side to reduce damping during rebounding BASIC SETTING 1185701 position 5 A WARNING A NEVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COMPRESSED NITROGEN NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF SEVERE INJURIES COULD BE THE RE
57. the front pipe of the frame 9 where the engine oil is cooled down Afterwards the engine oil runs through the fine screen filter O which filters out even the finest impurities The cleaned engine oil is pumped through the oil line and the clutch cover into the crankshaft to the conrod bearing and drips into the crankcase An additional oil pump sucks the engine oil out of the crankcase and pumps it through the oil line to the gear wheels of the 4th and 5th gear Via the gear wheels the engine oil reaches the oil sump The timing chain runs through the oil sump and transports the engine oil upwards to the cylinder head Through the bore hole the oil reaches the camshaft and the valves Oil change and bleeding of the oil system NOTE FOR IMPROVED COOLING OF THE ENGINE OIL THE FRONT PIPE OF THE FRAME IS INTEGRATED INTO THE OIL CIRCUIT WHEN CHANGING THE OIL THE ENGINE OIL MUST BE DRAINED FROM THE FRONT PIPE The engine oil change is to be carried out when the engine is still warm A WARNING A AN ENGINE HAVING BEEN RUN WARM AND THE ENGINE OIL IN IT ARE VERY HOT DO NOT BURN YOURSELF Place the motorcycle on a horizontal surface Remove the two plugs and and drain oil into a container M odels with integrated font pipe Remove cover unscrew plug at the lower end of the front pipe and drain oil CAUTION H PLUG MUST NOT BE REMOVED THIS IS PART OF THE BY PASS VALVE Clean all 3 plugs thoroughly with a fire
58. to the automatic decompressor Engine oil Only use high quality oils Shell Advance Ultra 4 meeting or surpassing the quality requirements of API classes SF SG or SH for specifications see containers You may use either mineral oils or synthetic oils fulfilling the above criteria CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE Checking engine oil level Allow the engine to run at idle speed for about 4 minutes Turn off the engine and place the motorcycle on a flat level surface main stand Take out the oil dipstick and wipe it off with a cloth TWIST THE OIL DIPSTICK ALL THE WAY IN AND THEN RETRIEVE IT The oil level should be between the two marks on the dipstick Add engine oil if necessary CAUTION INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL DO NOT OVERFILL THE ENGINE CASE DO NOT UNDERFILL THE ENGINE CASE Check the engine for leaks Oil circuit The oil pump 0 pumps the engine oil past the by pass valve through the oil filter After the oil filter an oil line branches off to a jet which sprays engine oil onto the piston pin bearing and piston head The second oil line takes the main flow of oil into
59. torcycle which you are bound to have a great time with provided you care for it properly This manual will furnish you with important information on how to operate and maintain your new KTM motorcycle At the time of printing the handbook covered the most up to date models in this series It is however possible that we may have made slight modi fications in the meantime due to development in our motorcycle design M any motorcyclists have a good working knowledge of motorcycle mechanics if this is true in your case you will be able to use this manual to carry out most of the maintenance steps yourself If on the other hand you are not very familiar with motorcycles it might be better to have a professional KTM dealer perform those steps marked x described in the chapter entitled Maintenance Work on Chassis and Engine of this manual Take special care to follow the recommended run in inspection and maintenance intervals Heeding these guidelines will significantly increase the life of your motorcycle Have services carried out by a KTM dealer so that your warranty claim remains intact We wish you a lot of fun when driving a FOR QUALITY SYSTEM ISO 9001 REG NO 12 100 606 1 KTM Austria s certificate of achievement for its Quality System ISO 9001 is the beginning of an on going total re engineering quality plan for a brighter tomorrow KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN AUSTRIA ALL RIGHTS RESERVED TO MAKE ALT
60. tted on the left hand side of the handle bar When engine is cold there should allways be a play of 1 3 mm 0 04 0 1 in at this lever measured at outer edge CAUTION IF THERE IS NO PLAY ON THE CLUTCH LEVER THE CLUTCH WILL START TO SLIP THE CLUTCH WILL THEN OVERHEAT DESTROYING THE CLUTCH LININGS Hand decompression lever The hand decompression lever is only used in two special cases a When the engine stalled It is possible that the starter motor is not able to crank the engine on the next attempt This is due to the fact that the automatic decompressor doesn t work properly If this happens pull the manual decompression lever and start again Afterwards normal starting will be possible b When you want to push the motorcycle While pushing pull the hand decompression lever to make it easier to get the engine going CAUTION THE SETTING OF THE HAND DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED SEE MAINTENANCE WORK A LACK OF PLAY IN THE HAND DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE Choke lever If the choke lever is pulled backwards a bore will be opened in the carburetor through which the engine may draw in additional fuel This produces a rich fuel air mixture necessary for cold start If the choke lever is pushed forward up to the stop the bore will be closed again In this position the choke cable must have a play of approx 2 mm
61. uld be checked for wear whenever the rear wheel is dismounted For this purpose lie the rear wheel on a work bench with the rear sprocket upwards and put the wheel spindle in the hub Now hold the rear wheel firmly and try to turn the rear sprocket The rear sprocket may not turn more than maximum 5 mm 0 2 in measured on the outside If the play in the chain wheel is larger all 6 shock absorption rubbers are to be replaced Check the shock absorption rubbers for signs of damage and dirt CAUTION IF THE SHOCK ABSORPTION RUBBERS ARE NOT REPLACED IN GOOD TIME THE REAR SPROCKET CARRIER AND THE REAR HUB WILL BE DAMAGED ALLWAYS REPLACE ALL 6 ABSORPTION RUBBERS NEVER SINGLE RUBBERS Tires air pressure Tire type tire condition and how much air pressure the tires have in them affect the way your motorcycle rides and they must therefore be checked whenever you re getting ready to go anywhere on your motorcycle Tire type and size can be found in the technical specifications and in the homologation certificate Tire condition has to be checked every time you want to ride your motorcycle Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire Refer to the specific regulations in your country for minimum tire tread requirements We recommend replacing tires at the latest when the tread is down to 2 mm Tire pressure should be checked regularly on a cold tire Proper pre
62. urface at the speedometer drive To mount the front wheel lift it into the fork Insert speedometer drive into the hub M ake sure that the driving tabs engage with the slots of the drive Position front wheel and speedometer drive and mount wheel spindle Mount collar screw turn speedometer drive in a way that the flexible speedometer shaft will curve upwards in a slight bow and tighten collar screw to 40 Nm 30 ft lb Take the motorcycle off the stand and bounce the fork hard a few times to align the fork legs Then tighten clamping screws 9 to a max torque of 10 Nm 7 ft lbs A WARNING A IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE AFTER MOUNTING THE FRONT WHEEL KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED Dismounting and mounting the rear wheel Park the motorcycle on the center stand The rear wheel must not touch the ground Loosen the collar nut remove chain tensioner hold the rear wheel and pull out the wheel spindle until the rear wheel is free but the brake caliper support is still held Push the rear wheel as far forward as possible take the chain from the rear sproc

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