Home

Generac 40kW LP Portable Generator User Manual

1. 69 LON E 69 Putting into operation after storage 69 TECHNICAL DATA ENGINE siii gs Bes Vh 70 Capacity Oll Gat a 70 Capacity A 70 TECHNICAL ENGINE TIGHTENING TORQUES 71 TECHNICAL DATA 73 TECHNICAL DATA CHASSIS 74 Capacity on 75 TECHNICAL DATA 76 Olll TE 76 TECHNICAL DATA SHOCK ABSORBER 77 TECHNICAL DATA CHASSIS TIGHTENING TORQUES 78 WIRING DIAGRAM 80 Wine CaS ales ite arent ands 80 SED S TANGES 220 82 AUXILIARY eire paene t ee 84 MEANS OF REPRESENTATION Symbols used The symbols used are explained in the following Indicates expected reaction e g of a work step or function X Indicates an unexpected reaction e g of a work step or a function All work marked with this symbol requires specialist knowledge and technical understanding In the interest of your own Safety have these jobs done an authorized KT
2. 44 2 0110 EE 21 Checking rear brake linings 44 Adjusting the low speed compression damping of the Removing rear brake linings 45 SMOCK A 20 DB 22 Installing the rear brake linings A5 Adjusting rebound damping of the shock absorber 22 Changing the rear brake linings M 46 MCASUFINE rear WHEEL Sag 23 Removing front wheel 46 Fitting front wheel 47 Check the riding sag of the shock absorber 23 Removing rear wheel 48 preload of the shock absorber k oe Fitting rear wheel 48 riding sag sss Tire condition CHECKING e ira rete e 49 REMOVINE the shock absorber amp 25 Checking tire air a nad 49 Installing shock absorber 29 Checking spoke TENSION vs 50 Checking basic setting Of 25 Removing the battery
3. 10 Accessories adjusting basic position 59 Air filter Compression damping eee 59 val arin ah once BO ed eee 25 fitting Zw ox oni ds Atia Caf a a Sat a al 04 ORI ae ee De 59 Compression damping high speed FEMOVING ee rrr 98 of shock absorber adjusting 21 Air filter box lid Compression damping low speed enn 98 of shock absorber adjusting 22 22 50 4 do Seo tete dr Ka rate RC SCR e pe eed 58 Antifreeze eo A Seat 56 TD MORET UTE TRES 56 B Coolant level Basic chassis setting aos Wises Steuer fofi em dira te A deg rinde 55 checking with riders weight 21 Cooling system 55 Battery D e tes quud uns sd e etg 2 Dust boots i arging diac ee Cleaning of fork legs 26 Odo VII qs at AER bestes An Yos e Se a d 50 Brake calipers 38 Brake discs Starter button 10 CHECKING m 3g Engine OPIUM SUN zee sae at ate hide nee Be 14 Brak
4. 50 CONTENTS 3 Installing the battery BO STANDARD Se schismatis 86 Recharging the battery WIDE ie ME LEE 87 Removing 52 Replacing d He TESe 52 Ignition curve plug 52 Changing the ignition curve 52 Removing the sedb eser bi desea edes 53 Mounting the seat ccececececececeeeceeeeeeeeeaeeeeeeeaeeeaeeeees 53 Dismounting the fuel tank M 53 Installing the fuel tank 4 54 S ato 55 Checking antifreeze and coolant level 55 Checking the coolant 55 Draining coolant 4 25 56 Refilling 20014 ien ut to dto sea tet sons 56 Removing main Silencer 57 Fitting the main silencer 57 Glass fiber yarn filling of main 57 Removing glass fiber yarn filling of main silencer 5 Fitting glass fiber yarn filling of main silencer
5. 78 ENGNG beni aka de Ie Mowe RA de dedi da 70 Engine tightening torques 71 72 Set ate by ce 76 850108 ive qb fece Mea 77 Tire air pressure sacre dj a Boe a Rial ee Os What a ee a 49 Tire condition male A cT 49 Uri Amm 5 Troubleshooting 66 67 2254 Se Seale SORA A RS MORE oe Pe 9 2 akin as a 5 Wiring diagram 80 81 3211243en JONEGISHIIA 01044 1002 6 KTM Sportmotorcycle AG 5230 Mattighofen Austria http www ktm com
6. 15 Rear sprocket engine sprocket checking for wear INDEX 88 Rear wheel 48 2222 14425 a eat 48 Rebound damping fork we cite oe 26 of shock absorber adjusting 22 Riding sag eU 24 Seat Queda Vc 53 FOTHOVITIEE die dete ett 53 SIE IG BE Co GP E A a a a 12 Shock absorber checking riding Sag 23 Checking static Sag 21407 ee ert at c uto 23 HODE centi Som BU 25 care 25 Short circuit button 10 NECEM tae 3 5 Spoke tension eig APP 50 Spring preload of shock absorber adjusting 24 Start number plate GISMOUNUNS 45 42 22457224 SEN osea 32 manc PF 32 cup PPM 15 Steering head bearing BIBOSIIB edt Gn rie SSA A ee ae eRe 31 Steering head bearing play a 28 I D ME arse eg d Aa ie GOA 2 SIOTABB ux s rg DU aie card cau eed MR 69 Technical data GEO dede ai let nici dir UG aee ee 73 4551 CIT CIT 74 75 Chassis tightening torques
7. Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info The service life of the chain depends largely on its maintenance Clean the chain regularly and then treat with chain spray Chain cleaner 9 P 84 Offroad chain spray P 84 Checking the chain tension Warning Danger of accidents Danger caused by incorrect chain tension Ifthe chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary lim 500192 10 Jack up the motorcycle P 21 Push the chain at the end of the chain sliding component upwards to measure the chain tension Q e Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Ifthe chain tension does not meet speci
8. Add brake fluid to level Brake fluid DOT 5 1 P 82 Check parts for damage and wear Replace damaged or worn parts 400233 10 Mount the screw cap with the membrane and the O ring e Info Clean up overflowed or spilt brake fluid immediately with water Removing front wheel Jack up the motorcycle 9 P 21 Remove screw Loosen screw 500209 10 Remove screws with washers and take off the brake caliper e Info Do not pull the handbrake lever when the brake claiper is removed MAINTENANCE WORK ON CHASSIS AND ENGINE 41 Holding the front wheel withdraw the wheel spindle Take the front wheel out of the fork e Info Always lay the wheel down in such a way that the brake disc is not dam aged Remove the spacing sleeves Fitting front wheel Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check parts for damage and wear Replace damaged or worn parts Clean and grease shaft seal rings and bearing surface Q of the spacing sleeves Long life grease 9 P 84 Fit the spacing sleeves Lift the front wheel into the fork position it and insert the wheel spindle Mount and tighten screw Specification Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft Position the br
9. 58 Changing glass fiber yarn filling of main silencer 58 Dismounting the air filter box 58 Installing the air filter box Td eene es 58 Removing the air filter 58 Installing the air filter 59 air ONE T TT 59 Adjusting basic position of clutch 59 Checking fluid level of hydraulic clutch 60 Changing fluid level of hydraulic clutch 60 Carburetor Adile aaeain E rer tt 61 Carburetor adjusting idle 61 Emptying the carburetor float chamber 62 Checking engine oil level eem 62 Changing engine oil and oil filter cleaning oil screen 63 Draining engine oil M 63 Cleaning the oil screen 63 Removing theoil 22 50 55 an ean 64 Mounting oil filter Wire omi rtt er e ucc een 64 Filling up with engine oil 64 Topping up engine eaaet eid qe 65 TROUBLESHOOTING nde Eoi pa i Oe 66 CUEANIN Or in EO eru Civi Er SA EAE 68 Cleaning 10 01 A PRA 68 STORAGE
10. Engine oil too thin low viscosity Change the engine oil and oil filter and clean the oil screen 9 P 63 Battery discharged Battery is not charged by generator Check electrical system CLEANING 68 Cleaning motorcycle Note Material damage Damage and destruction of components by high pressure cleaning equipment Never clean the vehicle with high pressure cleaning equipment or a strong water jet The excessive pressure can penetrate electri cal components connects Bowden cables and bearings etc and can damage or destroy these parts Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info If you clean the motorcycle regularly its value and appearance are maintained over a long period Avoid direct sunshine on the motorcycle during cleaning Before you clean the motocycle seal the exhaust system to prevent penetration by water First remove coarse dirt particles with a gentle water spray Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush Motorcycle cleaner P 84 e Info Use warm water containing normal motorcycle cleaner and a soft sponge After rinsing the motorcycle with a gentle water spray allow it to dry thoroughly Empty the carburetor float chamber 9 P 62 Warning Danger of acciden
11. Mount the seat 9 P 53 500219 11 MAINTENANCE WORK ON CHASSIS AND ENGINE Cooling system The water pump in the engine forces the coolant to flow The pressure resulting from the warming of the cooling system Is regulated by a valve in the radiator cap The specified coolant temperature is therefore permissible with out danger of function problems 120 C 248 F Coolant 92 P 82 Cooling is effected by the air stream The lower the speed the less the cooling effect Dirty cooling fins also reduce the cool ing effect 400242 10 Checking antifreeze and coolant level Warning A Danger of scalding The coolant gets very hot when the motorcycle is driven and 15 under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under cold water immediately f Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Stand the motorcycle upright on a horizontal surface Remove the ra
12. 33 341254 Stell 12 Adjusting the gas Bowden cable play 33 GENERAL TIPS AND HINTS ON PUTTING INTO Checking a doen 34 OPERA HON EET 13 Cleaning the 34 Advice onis toa Elsa exa lone ea eda ME EI 13 Checking the chain tension s n 34 Running in dtd 14 Checking the chain tension when fitting rear wheel 35 RIDING INSTRUCHONS 15 Checking the rear sprocket engine sprocket for wear 35 Checks before putting Into 15 Checking chain Wear aser 35 starting hu I M 15 Adjusting the chain tension 36 SANE D oed do a 16 Adjusting chain tension after 37 shifting HAINE eiaa es 16 Adjusting chain tension fitting rear 37 na 16 Adjusting chain guide V 38 Stopping parking 16 Brake MUG oin 38 FS SU IG Ss 17 Brake calipers cccccccccsessesssessseseeesessssesseseevevseessesveveveeee 38 GREASING AND SERVICE TABLE 18 CHECKING brake CSCS 38 Important maintenance work to be
13. Hand brake lever 10 adjusting basic position 39 checking free play 39 Handlebar position 32 adu SENE 32 Hot start lever 10 Ignition curve vel gui oO tel eB ate tin BW 52 Plug connection Lower triple clamp fitting removing Main silencer changing glass fiber yarn filling 58 TUCO ata aoa osea ii statera menu 0 57 Fitting glass fiber yarn filling 58 ced 57 Removing glass fiber yarn filling 5 Maintenance 5 Motorcycle 0224 gh ed aee AA Nien eae te Nie 68 Oil filter CIA OWA aa caste Se a aa e anal PC 63 s eatin Gk aa Le 64 0002 22 82 ier ott ce oe wo an a 64 Oil screen a T 63 OWNER S MANUAL 6 Play in gas Bowden cable NS Gun ki coma Reece Gen Gate 33 CHECKING yeger Varie X aer RC a a Q3 UO dO 33 Plug in stand 12 Putting into operation Advice on first use 13 alter 6 mig bue dU ek St a sins 69 Checks before putting into operation
14. Remove the cover with membrane Check the fluid level Fluid level under top level of container 4 mm 0 16 in Ifthe level of the cooling liquid does not meet specifications Correct the fluid level of the hydraulic clutch Hydraulic fluid 15 P 82 Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount and tighten screws Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws Remove the cover with membrane Fill the bleeding syringe with the appropriate hydraulic fluid Bleed syringe 50329050000 Hydraulic fluid 15 P 82 On the slave cylinder remove the bleeder screw and fit the bleeding syringe Inject the liquid into the system until it escapes from the bore hole Q of the mas ter cylinder without bubbles To prevent overflow drain fluid occasionally from the master cylinder reservoir Remove the bleeding syringe Mount and tighten screws bleeder screw Correct the fluid level of the hydraulic clutch Specification Fluid level under top level of container 4 mm 0 16 in Check parts for damage and wear Replace damaged or worn parts Position the cover with the membrane Mount a
15. without kinks The choke is fitted on the left side of the carburetor Activating the choke function frees an opening through which the engine can draw ex tra fuel This gives a richer fuel air mixture which is needed for a cold start e Info If the engine is warm the choke function must be deactivated Possible states e Choke function activated The choke lever is pulled out to the stop e Choke function activated The choke lever is pushed in to the stop PERATING ELEMENT 12 Shift lever 00 The shift lever is mounted on the left side of the engine The gear positions can be seen in the photograph The neutral or idle position is between the first and second gears The foot brake pedal is located in front of the right footrest and operates the rear wheel brake Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface To stand the motorcycle plug the plug in stand into the left side of the wheel spin dle e Info 500180 10 Before riding remove the plug in stand ENERAL TIPS AND HINTS ON PUTTING INTO OPERATION i Advice on first use Danger 7 Danger of accidents Danger from inadequate traffic experience Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs Warning Risk of injury Risk of injury by missing inadequate protective clothing Wear protective clothing
16. Info If you want to garage the motorcycle for a longer period take the following actions Before storing the motorcycle check all parts for function and wear If service repairs or replacements are necessary yOu Should do this during the storage period less workshop overload In this way you can avoid long workshop waiting times at the Start of the new season Clean the motorcycle 2 P 68 Change the engine oil and oil filter and clean the oil screen 9 P 63 Check the antifreeze and coolant level 92 P 55 Drain the fuel from the tanks into a suitable container Empty the carburetor float chamber P 62 Checking the tire air pressure 9 P 49 Remove the battery P 50 Recharge the battery P 51 Specification Storage temperature of battery without direct sunshine 0 35 32 95 TJ The storage place should be dry and not subject to large temperature differences e Info KTM recommends jacking up the motorcycle Jack up the motorcycle P 21 Cover the motorcycle with a porous sheet or blanket Do not use non porous materials since they prevent humidity from escaping thus causing corrosion e info Avoid running the engine for a short time only Since the engine cannot warm up properly the water vapor produced during combustion condenses and causes valves and exhaust system to rust Putting into operation after storage Remove the motorcycle from the work stand 9 P 21 Install
17. RIDING INSTRUCTION Checks before putting into operation e Info Make sure that the motorcycle is in a perfect technical condition before use Info In the interests of riding safety make a habit of making a general check before you ride Check the engine oil level 9 P 62 Check the chain tension 92 P 34 Check the chain dirt accumulation 9 P 34 Check the tire condition P 49 Checking the tire air pressure P 49 Check the front brake brake fluid level 9 P 39 Check the rear brake fluid level P 43 Check the front brake linings P 40 Check the rear brake linings 9 P 44 Check brake system function Check the coolant level 9 P 55 Check that all operating elements are correctly adjusted and free to move Starting Danger 2 Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and or death When running the engine always make sure there Is sufficient ventilation and do not start or run the engine in a closed Space Note Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine Always warm up the engine at low engine speeds e Info If the motorcycle is unwilling to start the cause can be old fuel in the float chamber The flammable elements of the fuel evaporate after a long time of standing If the float chamber 15 filled with fresh f
18. helmet boots gloves pants and jacket with protectors every time you ride the vehicle Warning Danger of accidents Critical riding behavior due to inappropriate riding Adapt your riding speed to the road conditoins and your riding ability Danger of accidents Accident risk caused by presence of a passenger Your vehicle is not designed to carry passengers Do not ride with a passenger Warning Danger of accidents Brake system failure Warning A Ifthe foot brake pedal is not released the brake linings drag permanently The rear brake can fail due to overheating Take your foot off the foot brake pedal if you do not want to brake Warning Danger of accidents Unstable riding behavior gt Do not exceed the maximum permitted weight and axle loads Warning Risk of misappropriation Usage by unauthorized persons gt Never leave the vehicle while the engine is running Secure the vehicle against use by unauthorized persons e Info When using your motorcycle remember that others may feel disturbed by excessive noise Make sure that the pre delivery inspection work has been carried out by an authorized KTM workshop You receive a delivery certificate and the service record at vehicle handover Before your first trip read the entire operating instructions carefully Get to know the operating elements adjust the basic position of clutch lever 9 59 adjust the
19. rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary 500193 10 Jack up the motorcycle 92 P 21 Push the chain at the end of the chain sliding component upwards to measure chain tension Q Info e The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Loosen nut Loosen nuts Adjust the chain tension by turning the left and right adjusting screws Specification Turn the left and right adjusting screws so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel 15 then correctly aligned Tighten nuts Make sure that chain adjusters are fitted correctly on the adjusting screws Tighten nut Specification Nut rear wheel spindle M20x1 5 80 Nm 59 01 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length Chain adjusters can be turned by 180 Remove the motorcycle from the work stand 9 P 21 MAINTENANCE WORK ON CHASSIS AND ENGINE 1 Adjusting chain tension after checking Loosen nut Loosen nut
20. Chain checking basic setting 25 d CI DNE ace 34 Fork legs Chain guide bleeding scooter reU Re A E aa eee 26 ev ir fed BE ee 38 1 2 aut ate ts M LE EE 29 Chain tension MOVNO dnx acu hata E od e Be b eo en 29 ce EUR 36 28 cna Sc cte po qd 34 aene ee 29 Chain wear Fork protector CINCO KING Vr oe CR ESL A ae Ves scii 35 27 Chassis number 9 OMOVING aco Dae eRe 2 CHOKE 82 Oe ord assistito ut vibe fee i E ete tn 11 Front fender Cleaning 68 WEIS een es ake a hc eee 3 Clutch palk Be Ge Bee Ge 31 Xia WAC 60 Front wheel checking fluid level 60 atten baci werd a 47 aes soap ais 46 Fuel tank PENS unns etica don A uU CUI RE 54 OMONE ee he De sah ke he 53 uuo aie ar ao eke iw afta Pare 11 Fuel ONS 618 ee ee he at 5 Fuse Ge eet ee 52 100112 seve ont OA Weleda eam ate GENNIO ES 52 Gas Bowden cable route checking
21. and Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft 500194 10 Brake fluid reservoir Warning Danger of accidents Brake system failure Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further The brake fluid reservoirs of the front and rear brakes are dimensioned so that they do not need topping up with brake fluid even if the brake linings are worn Brake calipers The brake calipers of this series are floating which means that they are not fixed to the brake caliper support The lateral compensation ensures an optimal position of the brake pad in relation to the brake disc Checking brake discs Warning Danger of accidents Reduced braking due to worn brake discs Worn brake discs should be replaced immediately by an authorized KTM workshop Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement e Info Wear reduces the thickness of the brake disc around the area used by the brake linings Wear limit of brake discs 4 5 mm 0 18 in 400388 10 3 5mm 145 brake disc thickness is less than the specified value Replace the brake disc MAINTENANCE WORK ON CHASSIS AND ENGINE AJ Danger of accidents Brake system failure lf there is no
22. attachments from damage by covering them Do not bend the cables and lines Remove o ring Remove protector ring Remove the lower triple clamp with the steering stem Remove the upper steering head bearing Clean the bearing and sealing elements check for damage and grease Replace damaged or worn parts Long life grease P 84 Insert the lower triple clamp with the steering stem Mount the upper steering head bearing e Info Check whether the top steering head seal is correctly positioned Push up protective ring and o ring 500098 10 MAINTENANCE WORK ON CHASSIS AND ENGINE th Position the upper triple clamp with the steering Mount and tighten screw Specification Screw top steering head M20x1 5 10 Nm 7 38 Ibf ft Position the clutch line wiring harness and CDI control unit Mount and tighten screws Q Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Install front fender P 31 Fit the start number plate P 32 Install the fork legs P 29 Mount and tighten screw Q Specification Screw top steering stem M8 17 Nm Loctite 243 12 54 Ibf ft Check the cable harness cable brake and clutch line for free movement and free laying Check play of steering head bearing 9 P 27 3238 500103 10 Greasing the steering head bearing 4 Remove the lower triple clamp 9 P 30 Inst
23. basic position of handbrake lever 9 P 39 Adjust the basic position of the footbrake lever 43 Get used to handling the motorcycle on a suitable piece of land before making a longer trip e Info Your motorcycle is not licensed for use on public roads Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle Do not make any trips that over stress your ability and experience Hold the handlebar firmly with both hands and keep your feet on the footrests when riding Do not make any changes to the motorcycle and use only KTM approved parts Do not carry any baggage e Info Motorcycles react sensitively to any changes of weight distribution Do not exceed the overall maximum permitted weight and the axle loads Specification Maximum permissible overall weight 335 kg 738 54 Ib Maximum permissible front axle load 145 kg 319 67 Ib Maximum permissible rear axle load 190 kg 418 87 Ib Run the engine in ENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 14 Running in the engine During the running in phase do not exceed the specified engine speed and engine performance Specification Maximum engine speed During the first 3 service hours 7000 rpm Maximum engine performance during the running in period During the first 3 service hours lt 50 During the next 12 service hours lt 5 Avoid fully opening the throttle
24. brake fluid batteries etc according to regulations Place a suitable container under the engine Remove screws Remove oil filter cover with O ring Pull the oil filter insert out of the oil filter casing Circlip pliers reverse 51012011000 Completely drain the engine oil Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts Lay the motorcycle on its side and fill the oil filter housing to about 75 full with en gine oil Fill the oil filter with engine oil and place it in the oil filter container Oil the O ring of the oil filter cover and assemble it with the oil filter cover Mount and tighten screws Specification Screw oil filter cover M6 10 Nm 7 38 Ibf ft Stand the motorcycle up Filling up with engine oil 4 e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the screw cap on the clutch cover and fill up with engine oil 1 351 1 43 qt Engine oil SAE 10W 50 9 P 82 Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there Is sufficient ventila 400265 10 tion and do not start or run the engine in a closed space Start the engine and check that it is oil tight MAINTENANCE WORK O
25. differs from the specified measurement Adjust the riding sag 9 24 R 4 Zr 4 q S E Rr NN 36 400384 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 2 A Adjusting spring preload of the shock absorber A Danger Danger of accidents The shock absorber is under high pressure shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on It yourself e Info Before changing the spring preload make a note of the present setting e g by measuring the length of the spring Remove shock absorber 9 P 25 After removing the shock absorber clean it thoroughly Loosen screw Turn adjusting ring until the spring is no longer under tension Combination wrench 50329080000 Hook wrench 11065 Measure the overall spring length when not under tension Tighten the spring by turning adjusting ring to measurement Specification Spring preload 11 mm 0 43 in Tighten screw Specification Screw shock absorber adjusting ring 5 Nm 3 69 Ibf ft Installing shock absorber 9 P 25 400216 10 Adjusting riding sag Remove shock absorber P 25 After removing the shock absorber clean it thoroughly Choose and fit a suitable spring Specification Spring rate Weight
26. e Info The low speed setting can be seen during the slow to normal compression of the shock absorber Turn the adjusting screw clockwise with a screwdriver until it stops e Info Do not loosen nut Turn back counterclockwise the number of clicks corresponding to the shock ab sorber type Specification Compression damping low speed 2 18421 Standard 10 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Adjusting rebound damping of the shock absorber A Danger Danger of accidents The shock absorber is under high pressure he shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself Turn the adjusting screw clockwise until it stops e info Do not loosen nut Turn back counterclockwise the number of clicks corresponding to the shock ab sorber type Specification Rebound damping 500185 10 Standard 20 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Measuring rear wheel sag unloaded Jack up the motorcycle P 21 Measure the distance as vertical as possible between the rear axle and a fixed point for example a mark on the side cover Make a note of the value as measurement Remove the motorcycle fro
27. engine sprocket e info When fitting the chain joint always make sure that the closed side of the joint faces forward riding direction The engine sprocket rear sprocket and chain should always be re placed together 400227 01 Check that the chain guide 16 firmly seated and not worn Checking chain wear Jack up the motorcycle P 21 Shift to neutral and pull the upper chain length with the specified tension Specification 10 15 kg 22 05 33 07 Ib Measure distance of 18 chain links in the lower chain section e Info Chain wear is not always even so you should repeat this measurement at different chain positions Maximum distance at the longest 2 2 mm 10 71 in chain section If distance is greater than the specified measurement Replace the chain e Info When you replace the chain you should also replace the rear and engine sprockets New chains wear out faster on old worn sprockets Remove the motorcycle from the work stand 9 P 21 718 400385 10 MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the chain tension Warning Danger of accidents Danger caused by incorrect chain tension If the chain tension 15 too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can
28. increase damping turn counterclockwise to reduce sus pension damping Mount protection covers Bleeding fork legs Jack up the motorcycle 9 P 21 Remove bleeder screws briefly X excess pressure escapes from the interior of the fork Mount and tighten bleeder screws Remove the motorcycle from the work stand P 21 Cleaning dust boots of fork legs Jack up the motorcycle P 21 Remove the fork protector P 27 MAINTENANCE WORK ON CHASSIS AND ENGINE 27 Push dust boots of both fork legs downwards Info The dust boots should remove dust and coarse dirt particles from the fork tubes Over time dirt can penetrate behind the dust boots If this dirt is not removed the oil seals behind can start to leak Warning Danger of accidents Reduced braking due to oil or grease on the brake 500188 10 discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Clean and oil the dust boots and inner fork tube of both fork legs Universal oil spray 92 P 84 Press the dust boots back into their normal position Remove excess oil Install the fork protector P 27 Remove the motorcycle from the work stand 9 P 21 Removing the fork protector Remove screws and take off clamp Remove screws on left fork leg Remove the fork protector Remove the screws
29. inspection and maintenance intervals If you observe these exactly you will ensure a much longer service life for your motorcycle The maintenance work prescribed in the greasing and service table must be carried out an authorized KTM workshop and confirmed in the customer s service record since otherwise no warranty claims will be recognized No warranty claims can be considered for damage resulting from manipulations and alterations to the motorcycle You should use the fuels oils and greases according to specifications as listed in the owner s manual For your own safety use only spare parts and accessories approved by KTM KTM accepts no liability for other products and any re sulting damage loss Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine 16 running Do not place the vehicle where there are flammable or explosive substances switch off engine Turn the handle of the fuel tap to the OFF position Use straps or other suitable devices to secure the motorcycle against accidents or falling over Offroad motorcycling is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest However it is a poten tial problem for the environment and can lead to conflicts with other persons But
30. of rider 65 75 kg 143 3 165 34 Ib 76 N mm 433 97 b in Weight of rider 75 85 kg 165 34 187 39 Ib 80 N mm 456 81 Ib in Weight of rider 85 95 kg 187 39 209 44 Ib 84 N mm 479 65 e Info The spring rate is shown on the outside of the spring Installing shock absorber P 25 Check the static sag of the shock absorber 9 P 23 Adjust the rebound damping of the shock absorber 9 P 22 MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Removing the shock absorber 4 Jack up the motorcycle P 21 Remove screw and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel Fix the rear wheel in this position Remove screw push splash protector to the side and remove the shock ab sorber Check parts for damage and wear Replace damaged or worn parts Push splash protector to the side and position the shock absorber Mount and tighten screw Specification Screw top shock absorber M12 80 Nm Loctite 243 59 01 Ibf ft Mount and tighten screw Specification Screw bottom shock ab M12 80 Nm Loctite 243 sorber 59 01 Ibf ft e Info The heim joint for the shock absorber at the swing arm is Teflon coated It must not be greased with grease or with other lubricants Lubricants dis solve the Teflon coating thereby drastically reducing the service life Remove the motorcycle from the work sta
31. resting locations should be noticeable gt f click positions are noticeable Adjust play of the steering head bearing 9 28 Check the steering head bearing and replace if required Remove the motorcycle from the work stand 9 21 Jack up the motorcycle 92 P 21 Loosen screw Q9 Remove screw Loosen and retighten screw Specification Screw top steering head M20x1 5 10 Nm 7 38 Ibf ft Using a plastic hammer tap lightly on the upper triple clamp to avoid strains Fully tighten screw Specification Screw top triple clamp M8 17 Nm 12 54 Ibf ft Mount and tighten screw Specification Screw top steering stem M8 17 Nm Loctite 243 12 54 Ibf ft Check play of steering head bearing P 27 You can see the currently set offset if you remove screw The fork offset Q has an impact on the handling of the vehicle It is calculated from the center of the fork leg to the center of the steering head bearing The fork offset can optionally be adjusted Marking to the front gives greater stability on fast racetracks Fork offset Front marking 14 mm 0 55 in Marking to the rear gives better handling in bends Fork offset 16 mm 0 63 in MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Setting the fork offset 4 Remove the lower triple clamp 9 30 Remove screw Remove the steering stem Clean the parts and check for damage Rotate the
32. service plan in an authorized KTM workshop Move the brake fluid reservoir mounted on the handlebar to a horizontal position Check the brake fluid level in the brake fluid reservoir Ifthe brake fluid is below the MIN mark up the brake fluid of the front brake 9 P 40 500195 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Topping the front brake fluid Warning Danger of accidents Brake system failure Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further f Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info KTM recommends DOT 5 1 brake fluid from Motorex This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high de
33. the battery P 50 Fill up with fuel 2 P 17 Checks before putting into operation P 15 Make a test ride m m I gt m P a zz m Design 1 4 stroke engine water cooled 449 3 cm 27 42 cu in 60 8 mm 2 39 in 97 mm 3 82 in 12 5 1 1600 1650 rpm 4 valves controlled by cam levers ad 2 camshafts driven by heli cal gear pair and tooth wheel chain 40 4 mm 1 59 in 31 7 mm 1 25 in 0 07 0 13 mm 0 0028 0 01 in 0 12 0 18 mm 0 0047 0 01 in 2 cylinder roller bearing Displacement Stroke Bore Compression ratio Idle speed Control Valve diameter intake Valve diameter exhaust Valve clearance cold intake Valve clearance cold exhaust Crankshaft bearing Conrod bearing Needle bearing Piston pin bearing Bronze bush Pistons Forged light alloy Piston rings 1 compression ring 1 oil scraper ring Engine lubrication Pressure circulation lubrication with 3 rotor pumps Primary transmission 29 74 Transmission ratio 18 31 20 29 22 27 24 25 26 23 12V 42 W Contactless controlled fully electronic ignition with digital igni lst gear 2 gear 3rd gear Ath gear 5th gear Generator Ignition tion adjustment type Kokusan NGK CR 9 EKB Spark plug 0 7 mm 0 03 Water cooling permanent circulation of coolant by water pump spark plug electrode gap Cooling Starting aid Electric starter Capacity engine oi
34. 100 6061 Within the meaning of the international quality management standard ISO 9001 KTM uses quality assurance processes that lead to the maximum possible quality of the products Issued by T V Management Service 12 4 Li KTM Sportmotorcycle AG 5230 Mattighofen Austria CONTENTS 2 MEANS OF REPRESEN ATION 2 58 4 Adjusting compression damping of 25 IMPORTANT NOTES 5 Adjusting rebound damping of fork eene 26 NEW Ol ai 7 sic modice 26 View of vehicle front left side su s sere toc reste tee 7 Cleaning dust boots of fork legs 26 View of vehicle rear right 5 8 Removing the fork 27 LOCATION OF SERIAL NUMBERS cccccccccccceccececcececeeveueuees 9 Installing the fork protector icc eii i roc v Ee exa at 27 Chassis 001 9 Checking play of steering head bearing 27 e DN RN RNC 9 Adjusting play of steering head bearing 28 PAE 9 FOKON Elen dU E Ea OD P enews 28 Fork part o sos nba AU are ca ted 9 Setting the fork offset V 29 shock absorber part number sessi nh race
35. Clean or dry dirty or wet brakes by riding and braking gently On sandy wet or slippery surfaces use the rear brake Braking should always be completed before you go into a bend Change down to a lower gear appropriate to your road speed long downhill stretches use the braking effect of the engine Change down one or two gears but do not overstress the engine In this way you have to brake far less and the brakes do not overheat Stopping parking Warning Danger of burns Some vehicle components get very hot when the machine Is driven Do not touch hot components such as exhaust system radiator engine shock absorber and brakes Allow these compo nents to cool down before starting work on them Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface RIDING INSTRUCTION 17 Note Fire hazard Some components engine radiator and exhaust system get very hot when the engine Is running Do not place the vehicle where there are flammable or explosive substances Brake the motorcycle Shift gear to neutral Press the short circuit button amp when the engine is idling until the engine stops Turn the handle Q of the fuel tap to the OFF position Figure 500178 10 P 11 Stand the motorcycle on a hard surface Refueling Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle
36. Front fender Front wheel Fork part number Oil filter cover Plug in stand Shift lever Choke button Air filter Filler cap Wl 001 41 03 011 Bl GW PMI Clutch lever VIEW OF VEHICLE 8 View of vehicle rear right side 500183 10 Main silencer Shock absorber Brake caliper of rear wheel brake Rear wheel Foot brake pedal Manifold Chassis number type label CO N oy 01 441 GW Throttle grip LOCATION OF SERIAL NUMBERS 9 a The chassis number is stamped on the steering head on the right 400193 10 The type label is fixed to the front of the steering head The engine number is stamped on the left side of the engine under the engine Sprocket The fork part number is stamped on the inner side of the fork stub The shock absorber part number is stamped on the top of the shock absorber above the adjusting ring on the engine side 500083 10 OPERATING ELEMENTS 10 The clutch lever is fitted on the left side of the handlebar The clutch 16 hydraulically operated and self adjusting The hot start lever is fitted on the left side of the handlebar If you pull the hot start lever to the handlebar during the start procedure a bore 15 opened in the carburetor through which the engine can draw in extra air This gives a leaner fuel air mixture which is needed for a hot start Possible states e Hot start function activated Hot st
37. LESHOOTING 67 Fouts Engine has no idle Ignition system defective Have ignition system checked Engine does not speed up Carburetor running over because float Have carburetor checked needle dirty or worn Loose carburetor jets Have carburetor checked Electronic ignition adjustment defective Have ignition system checked Fuel feed interrupted Check tank vent Engine has too little power Clean fuel tap Clean carburetor Exhaust system leaky deformed or too lit Check exhaust system for damage tle glass fiber yarn filling in main silencer Change glass fiber yarn filling of main Silencer 92 P 58 Valve clearance too little Have valve clearance adjusted Electronic ignition adjustment defective Have ignition system checked Engine stalls or is popping into the carbu Lack of fuel Clean and check the fuel system and retor carburetor Engine takes in bad air Check rubber sleeves and carburetor for tightness Engine overheats Too little coolant in cooling system Check the cooling system for leakage Check the coolant level 9 P 55 Foam formation in cooling system Drain the coolant 9 P 56 Refill the coolant 9 56 Bent radiator hose Replace the radiator hose High oil consumption Engine vent hose bent Route the vent hose without bends or replace it if necessary Engine oil level too high Check the engine oil level 9 P 62
38. M workshop There your motorcycle will be serviced optimally by specially trained experts using the specialist tools required Q7 Identifies a page reference more information is provided on the specified page Formats used The typographical and other formats used are explained in the following Specific name Identifies a specific name Identifies a protected name Brand Identifies a brand in merchandise traffic IMPORTANT NOTES 5 Use definition KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use The motorcycles com ply with currently valid regulations and categories of the top international motorsport organizations e Info The motorcycle must be used only on secluded property remote from public road traffic A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described in the owner s manual are properly carried out Poor adjustment and tuning of the engine and chassis can lead to damage and break age of components Using the motorcycle in extreme conditions such as very muddy or wet terrain can lead to above average wear of components such as the transmission train or the brakes For this reason it may be necessary to service or replace worn parts before the limit specified in the greasing and service table 15 reached Pay careful attention to the prescribed running in period
39. N CHASSIS AND ENGINE Check the engine oil level 9 62 Topping up engine oil e Info Too little engine oil or poor quality engine oil results in premature wear to the engine Remove the screw cap on the clutch cover and fill up with engine oil Engine oil SAE 10W 50 P 82 Mount and tighten screw cap Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engine always make sure there is sufficient ventila 400265 10 tion and do not start or run the engine in a closed space Start the engine and check that it is oil tight TROUBLESHOOTING 66 The engine cannot be cranked electric Battery discharged Recharge the Fuse blown Remove the fuse 92 P 52 Replace the fuse 92 P 52 Low external temperature Use the battery supplied in the acces 501165 package 4Ah battery YTX5L BS 9 P 74 Engine turns but does not start Operating error Carry out the instructions for starting P 15 Motorcycle was out of use for a long time Empty the carburetor float chamber and there is old fuel in the float chamber P 62 Fuel feed interrupted Check tank vent Clean fuel tap Clean carburetor Engine flooded Clean and dry spark plug or replace if necessary Spark plug oily or wet Clean and dry spark plug or replace if necessary Electrode distance plug gap of spa
40. NGINE 4 Changing the rear brake linings 4 Warning Skin irritations Brake fluid can cause skin Irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends brake fluid DOT 5 1 from Motorex This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Remove the rear brake linings 9 P 45 Stand the vehicle upright Remove screw cap with membrane and the O ring Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir Install the rear brake linings 9 P 45
41. OWNER S MANUAL 2008 450 SMR ART NO 3211243en DEAR KIM TOMER i Congratulations on your decision to purchase a KTM motorcycle You are now the owner of a state of the art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly We wish you great pleasure riding the vehicle Enter the serial numbers of your vehicle below Chassis number P 9 Dealer s stamp Engine number 2 P 9 The owner s manual corresponded to the latest state of this series at the time of printing Slight deviations resulting from continuing development and design of our motorcycles can however not be completely excluded All specifications are not binding KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica tions prices colors forms materials services designs equipment etc without prior notice and without specifying reasons to adapt these to local conditions as well as to stop prudction of a particular model without prior notice KTM accepts no liability for delivery options deviations from illustrations and descriptions as well as printing and other errors The models portrayed partly contain special equipment that does not belong to the regular scope of delivery 2007 by KTM Sportmotorcycle AG Mattighofen Austria All rights reserved Reproduction even in part is permitted only with the express written permission of the copyright owner ISO 9001 12
42. P 82 cartridge TECHNICAL DATA SHOCK ABSORBER 11 Shock absorber part number 12 18 7D 15 Shock absorber WP PDS 5018 DCC Compression damping low speed Compression damping high speed Spring preload 11 mm 0 43 in Weight of rider 65 75 kg 143 3 165 34 Ib Weight of rider 75 85 kg 165 34 187 39 Ib Weight of rider 85 95 kg 187 39 209 44 Ib TECHNICAL DATA CHASSIS TIGHTENING TORQUE 18 Spoke nipple M48 Spoke nipple earwhes e 8 MN brake cylinder 10 Nm 7 38 Ibf ft M 30 Nm 22 13 Ibf ft M Screw fork stub 15 Nm 11 06 Ibf ft 24 25 Nm 18 44 Ibf ft 17 Nm 12 54 Ibf ft Loctite 243 Screw handlebar clamp 20 Nm 14 75 Ibf ft 0 Engine carving screw omamo SSS O ite 24 Nut seat fing ma Nus pat oO ooo Nut rear spinde Mais oo Screw top sternere woas o Screw front wheel spindle M24x1 5 40 Nm 29 5 Ibf ft 2 2 WIRING DIAGRAM Wiring diagram 000 CEN 6 ELL SSOUIEY QD 000 870 LL 62 ellow black Kg UMOJq c c 28 The Q U99JD red white red white grey black blue 1 black black SSOUJEU 148615 ss uley brown V S 216 SI W
43. Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Check parts for damage and wear Replace damaged or worn parts Clean and grease shaft seal rings and bearing surface Q of the spacing sleeves Long life grease P 84 Fit the spacing sleeves MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Lift the rear wheel into the swing arm position it and insert the wheel spindle Put the chain on Ad S s 1 ti 1 Position the chain adjuster Fit nut but do not tighten it yet Check the chain tension when fitting rear wheel 92 P 35 Make sure that the chain adjusters are fitted correctly on the adjusting screws Q Tighten nut Specification Nut rear wheel spindle M20x1 5 80 Nm 59 01 Ibf ft e Info The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters can be turned by 180 Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there 16 a tight spot Remove the motorcycle from the work stand 9 21 Tire condition checking e Info Fit only tires approved by KTM Other tires could have a negative effect on riding behavior The type condition and air pressure of the tires all have an im
44. UMOdq black red white ellow 1 400277 10 WIRING DIAGRAM i Components 1 Battery 2 Generator 3 Ignition coll 4 Pulse generator 5 Voltage regulator rectifier 6 Starter button 7 Starter relay 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller Cable colors black black black white black white brown brown brown white brown white blue blue blue white blue white green green grey gray grey black gray black red red red white red white white white yellow yellow yellow black yellow black SUBSTANCES 82 Super unleaded ROZ95 RON95 PON91 00 according to DIN EN 228 ROZ 95 95 PON 91 according to DOT Specification Use only brake fluid that complies with the specified standards see specifications on the container and that possesses the corre sponding properties KTM recommends Motorex products Supplier Motorex Motorex Brake Fluid DOT 5 1 Specification Use only suitable coolant even in countries with high temperatures Using inferior antifreeze can result in corrosion and foaming KTM recommends Motorex products Mixture ratio Antifreeze 25 45 C 13 49 F 50 Anti corrosion antifreeze 50 distilled water Antifreeze 40 C 40 F Supplier Motorex Motorex Anti Freeze according to 150 VG 15 Specification Use onl
45. a big engine speed rise reduce the idle speed to a normal level and repeat the above steps The extreme sport motocyclist will set the mixture about 1 4 of a turn back from this ideal value leaner in a clockwise direction since the engine be comes hotter in sporting use If the procedure described here does not lead to satisfactory results the cause may be a wrongly dimensioned Idling jet If you can turn the Idle adjusting screw to the end without any change of engine speed you have to fit a smaller idling jet The idle adjusting screw must not be opened more than two turns If more than two turns are necessary rich mixture use a larger idling jet After changing the idling jet start from the beginning with the adjusting steps Adjust the idle speed with the adjusting screw Specification Choke function activated The choke lever is pushed in to the stop P 11 Idle speed 1600 1650 rpm e Info Following extreme air temperature or altitude changes adjust the idle speed again MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Emptying the carburetor float chamber 4 Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank Is overfilled See spec
46. ake caliper Fit and tighten screws with washers Specification Screw front brake caliper M10x1 25 40 Nm Loctite 243 29 5 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there 16 a tight spot Remove the motorcycle from the work stand 9 21 Pull the front wheel brake and push down hard on the fork several times to align the fork legs Fully tighten screw Specification 500209 11 11 06 Ibf ft Jack up the motorcycle 9 P 21 Press the brake caliper by hand on to the brake disc in order to press back the brake piston e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove nut Remove chain adjuster Withdraw the wheel spindle only enough to allow the rear wheel to be pushed forward Push the rear wheel forward as far as possible Remove the chain from the rear Sprocket Holding the rear wheel withdraw the wheel spindle Take the rear wheel out of the Swing arm e Info i Do not operate the foot brake when the rear wheel is removed Always lay the wheel down in such a way that the brake disc is not dam aged 4 J yI F 8 4 D 5 4 T E WE i i is i i Es Remove the spacing sleeves 498 500214 11 Warning 4 Danger of accidents
47. all the lower triple clamp P 30 Dismounting the front fender Remove screws Remove the front fender Make sure that the distance bushings remain in place Check parts for damage and wear Replace damaged or worn parts Make sure that the spacing sleeves are mounted in the fender Position the front fender Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft e Info 500190 10 Take care with the contact of the holding lugs to the start number plate MAINTENANCE WORK ON CHASSIS AND ENGINE Dismount the start number plate 400271 10 Remove screw and take off clamp Remove screw Remove the start number plate Check parts for damage and wear Replace damaged or worn parts Position the start number plate Mount and tighten screw Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft e Info Take care with the contact of the holding lug at the fender Position brake line Put the clamp on mount and tighten screw On the upper triple clamp there are 2 holes at a distance of to each other Drilling distance A 15 mm 0 59 in The holes on the handlebar support are placed at a distance of from the center Drilling distance B 3 5 mm 0 14 in The handlebar can be mounted in 4 different positions This enables you to mount the handlebar in the position most suitable for the rider Remove the four screws R
48. art lever is pulled out to the stop e Hot start function deactivated Hot start lever is pushed back to the stop The hand brake lever is located on the right side of the handlebar and operates the front wheel brake The short circuit button is fitted on the left side of the handlebar Possible states Short circuit button amp in basic position In this position the ignition circuit is closed and the engine can be started Short circuit button amp pressed In this position the ignition circuit is interrupted a running engine stops and a non running engine will not start The electric starter button is fitted on the right side of the handlebar Possible states Electric starter button in basic position Electric starter button pressed In this position the electric starter is actuated 500177 10 PERATING ELEMENT T Fuel tap With the tap handle on the fuel tap you can open or close the supply of fuel to the carburetor Possible states e Fuel supply closed OFF No fuel can flow from the tank to the carburetor e Fuel supply open ON Fuel can flow from the tank to the carburetor The fuel tank empties completely 500178 10 Opening filler cap EH Press release button turn filler cap counterclockwise and lift it free Replace the filler cap and turn clockwise until the release button locks in place e Info Run the fuel tank breather hose
49. carried out by an Checking free play of hand brake 39 authorized KTM workshop een Hm 18 mur ER Adjusting basic position of handbrake lever 39 Mane Mane SEE pyran Checking front brake fluid 39 authorized KTM workshop as additional order 19 Instant eee ke and miainienanceavork to be caned Topping up the front brake fluid 40 OUE DY 19 Checking the front brake linings esse 40 MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Removing front brake linings 41 Jacking up the 21 Mounting front brake linings 41 Removing the motorcycle from the work stand 21 Changing the front brake linings 42 Checking the basic chassis setting with the rider s Checking free play of foot brake 43 Weight 21 Adjusting basic position of footbrake lever 43 Compression damping of shock absorber 21 Checking the rear brake fluid 43 Adjusting high speed compression damping of the shock Adding rear brake fluid
50. cification recommends Motorex products Supplier Motorex Motorex Air Filter Oil Spray 655 Specification KTM recommends Motorex products Supplier Motorex Motorex Moto Clean 900 Specification recommends Motorex products Supplier Motorex Motorex Protect amp Shine 645 AUXILIARY SUBSTANCE High luster polish for paint Specification KTM recommends Motorex products Supplier Motorex Motorex Moto Polish Specification KTM recommends Motorex products Supplier Motorex Accu Contact STANDARDS 86 Different technical development directions required a new specification for 4 stroke motorcycles the JASO T903 MA Standard Ear lier engine 0116 from the automobile industry were used for 4 stroke motorcycles because there was no separate motorcycle specifi cation Whereas long service intervals are demanded for automobile engines high performance at high engine speeds are in the fore ground for motorcycle engines With most motorcycles the gearbox and the clutch are lubricated with the oil as the engine The JASO MA Standard meets these special requirements The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their vis cosity The viscosity describes only one property of oil and says nothing about quality INDEX 87 A Clutch
51. cs 4 5 mm 0 18 in 3 5 mm 0 14 in front Rear Tire air pressure front 1 6 bar 23 21 psi 1 6 bar 23 21 psi 14 48 5 8 x 1 4 38 40 42 45 48 49 50 51 52 63 5 1475 10 mm 58 07 0 39 in 920 mm 36 22 in 300 mm 11 81 in 111 5 kg 245 81 Ib 145 kg 319 67 Ib 190 kg 418 87 Ib Maximum permissible overall weight 335 kg 738 54 Ib 3Ah battery YTXAL BS Battery voltage 12 V Nominal capacity 3 Ah maintenance free 4Ah battery YTX5L BS Battery voltage 12 V Nominal capacity 4 Ah maintenance free Rear Rear wheel gearing Chain Rear sprockets available Steering head angle Wheelbase Seat height unloaded Ground clearance unloaded Weight without fuel Maximum permissible front axle load Maximum permissible rear axle load 125 80 R 420 TL 170 55 R 17 TL Dunlop KR106 Dunlop KR108 For further information see http www ktm com TECHNICAL DATA CHASSI 1 Capacity fuel Tank capacity 8 21 2 17 US gal Super unleaded ROZ 95 RON 95 PON 91 P 82 TECHNICAL DATA FORK 16 Spring length with preload 482 mm 18 98 in Weight of rider 65 75 kg 143 3 165 34 Ib Weight of rider 75 85 kg 165 34 187 39 Ib Weight of rider 85 95 kg 187 39 209 44 Ib Capacity fork oil Oil capacity cartridge 195 ml 6 59 fl oz Fork oil SAE 5 P 82 Oil capacity fork tube without 390 ml 13 19 fl oz Fork oil SAE 5
52. d and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Stand the vehicle upright Remove screw cap with membrane and the O ring Add brake fluid to level Q Brake fluid DOT 5 1 P 82 Check parts for damage and wear Replace damaged or worn parts Mount the screw cap with the membrane and the O ring e info 400233 10 Clean up overflowed or spilt brake fluid immediately with water Checking rear brake linings A Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Check the brake linings for minimum thickness Minimum thickness gt 1 mm gt 0 04 in If the minimum thickness 15 less than specified Change the rear brake linings P 46 500206 11 Removing rear brake linings 4 Warning Danger of accidents Improper brake maintenance and repair Always have your brake system maintained and repaired in an authorized KTM workshop Press the brake caliper by hand on to the brake disc in order to press back the brake piston e Info Make sure when pushing back the brake piston that you do not press the brake caliper against the spokes Remove the locking split pins withdraw the bolt and take out the brake pads Clean brake caliper and brake caliper suppor
53. di cation of different spoke tensions Removing the battery 4 Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Switch off all power consuming components and switch off the engine Remove the seat P 53 Disconnect the negative minus cable of the battery Pull back the plus pole cover and disconnect the positive plus cable of the bat tery Hang the rubber band out to the bottom Lift the battery up 500069 10 Check parts for damage and wear Replace damaged or worn parts Place the battery in the battery holder Condition Outdoor temperature gt 10 C gt 50 F 3Ah battery YTX4L BS _ 74 Condition Outdoor temperature lt 10 C lt 50 F 4Ah battery YTX5L BS 9 P 74 Reconnect the rubber band 500069 11 Attach the plus cable and replace the plus pole cover Attach the minus cable MAINTENANCE WORK ON CHASSIS AND ENGINE i Mount the seat 9 P 53 Rechargi
54. diator cap Check antifreeze of coolant 25 45 C 13 49 F Ifthe antifreeze of the cooling liquid does not meet specifications Correct antifreeze of coolant Check the coolant level in the radiator Coolant level above radiator fins 10 mm 0 39 in 400243 10 Ifthe level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant P 82 Alternative 2 Coolant mixed ready to use P 82 Refit the radiator cap Checking the coolant level Warning Danger of scalding The coolant gets very hot when the motorcycle is driven and 15 under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine is hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children MAINTENANCE WORK ON CHASSIS AND ENGINE Stand the motorcycle upright on a horizontal surface Remove the radiator cap Check
55. e always make sure there Is sufficient ventila tion and do not start or run the engine in a closed space Start the engine and let it run idle Move the handlebar to and fro over the entire steering range The idle speed must not change If the idle speed changes Adjust the gas Bowden cable play 9 P 33 Dismount the fuel tank 9 P 53 Check gas Bowden cable route P 33 Move the handlebar to the straight ahead position Push back bellows Loosen nut Turn adjusting screw in as far as possible Loosen nut Turn adjusting screw so that there is play in the gas Bowden ble at the throttle grip Specification Play in gas Bowden cable 3 5 0 12 0 2 in Tighten nut Press and hold the throttle grip in the closed setting Turn adjusting screw out until there is no play in the Bowden cable Tighten nut Push bellows on Check the throttle grip for smooth operation Install the fuel tank P 54 Check play in the gas Bowden cable 92 P 33 MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Checking chain dirt Check the chain for coarse dirt accumulation If the chain is very dirty Clean the chain 9 P 34 Cleaning the chain Warning Danger of accidents Oil or grease on the tires reduces their grip Remove oil and grease with a suitable cleaning material Warning Danger of accidents Reduced braking due to oil or grease on the brake discs
56. e fluid of rear brake adding AA Engine fumer Us atat at db siege d eu doi ode 9 Topping up brake fluid of front brake 40 Engine on CT 63 Brake fluid level 23 wt as ee oe neri 63 Checking the front brake brake fluid level 39 filli 64 OMINO aie oT i Ni CE E 4230 56 65 Brake linings 23 Engine oil level Changing the front brake linings 42 Pul CHOC KIS ce mc Noel Uia cer uet d tet 62 Mounting front brake linings 41 of front brake checking AO Environment de ORE ee 5 of rear brake changing 46 F of rear brake checking 44 Filler cap of rear brake Installing 45 leri UD 11 of reat brake removing 45 ISI MENOR 11 Removing front brake liningS 41 Filling up C as oe Stats cae ghee Be ete ar se 17 Carburetor Foot brake pedal 12 adjusting EUER 61 adjusting basic position 43 emptying the float chamber zone ea 62 checking free play 43 61 Fork
57. e tire air pressure 9 P 49 Check the chain wear 2 P 35 Check the chain tension P 34 Clean the chain P 34 Check wheel bearing for play Wheels Clean and grease adjusting screws of chain adjuster S3N After 3 service hours corresponds to about 21 liters of fuel S10A Every 10 service hours corresponds to about 70 liters of fuel after every race 530 Every 30 service hours corresponds to about 210 liters of fuel GREASING AND SERVICE TABLE 19 Important maintenance work to be carried out by an authorized KTM workshop as additional order stn EA Gary outa Grease the steering head bearing 3 Glean and adhustcamueto ws Treat electric contacts wih rare yrat 1 1 _ check clutch slave cyinderfordenis E Gheck outer clutch hubfordenis check camshait wear visene 1041 11 20 Uwcewarchaespsa Gheckwearcfavegudes 1141 21 20 Gheck he timingchaintensionerfunction Gheck crankshaft and Ghange the crankshaft main bearing E Check wear of all transmission components including and bearings check he spri
58. e while simulta neously pulling the clutch lever shift into the next gear release the clutch and open the throttle Ifthe choke function was activated deactivate it after the engine has warmed When you reach maximum speed after fully opening the throttle turn back the throttle to about 3 4 of its range the speed hardly drops but the fuel consumption falls considerably Always open the throttle only as much as the engine can handle abrupt throttle opening increases fuel consumption shift down brake if necessary and close the throttle at the same time Pull the clutch lever and shift into a lower gear release the clutch lever slowly and open the throttle or shift again Switch off the engine if you expect to be standing for a long time Specification gt 2 min Avoid frequent and longer slipping of the clutch This heats the engine oil the engine and the cooling system Ride with a lower engine speed instead of with a high engine speed and a slipping clutch Braking Warning Danger of accidents f you brake too hard the wheels can lock Adapt your braking to the traffic situation and the road conditions Warning A Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake Have the brake system checked in an authorized KTM workshop and do not ride any further Warning Danger of accidents Reduced braking due to wet or dirty brakes
59. ehicle upright Check the brake fluid level in the viewer When in the viewer an air bubble is visible Add rear brake fluid 9 P 44 Adding rear brake fluid Warning Danger of accidents Brake system failure Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked an authorized KTM workshop and do not ride any further Warning Skin irritations Brake fluid can cause skin irritation on contact Avoid contact with skin and eyes and keep out of the reach of children If brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends brake fluid DOT 5 1 from Motorex9 This brake fluid has a higher wet boiling point than brake fluid DOT 4 and offers more protection under high load Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake flui
60. emove the handlebar clamp Remove the handlebar and lay it to one side e Info Protect the motorcycle and its attachments from damage by covering them Do not bend the cables and lines Remove the two screws Remove the handlebar support Place the handlebar support in the required position Fit and tighten the two screws Screw handlebar support MIO 40 Nm Loctite 243 29 5 Ibf ft e Info Specification Position the left and right handlebar supports evenly Position the handlebar e Info Make sure cables and wiring are positioned correctly Position the handlebar clamp Fit and evenly tighten the four screws Specification Screw handlebar clamp M8 20 Nm 14 75 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE Checking gas Bowden cable route 400192 10 Adjusting the gas Bowden cable play The two gas Bowden cables must run parallel behind the handlebar down to the frame They must be routed directly on the frame above the tank bearing to the car buretor Move the handlebar to the straight ahead position Move the throttle grip back and forth slightly to ascertain the play in the gas Bowden cable Play in gas Bowden cable 3 5 0 12 0 2 in Ifthe gas Bowden cable play does not meet specifications Adjust the gas Bowden cable play 9 P 33 Danger Danger of poisoning Exhaust gases are poisonous and can result in uncon sciousness and or death When running the engin
61. ents MAINTENANCE WORK ON CHASSIS AND ENGINE 21 Jacking up the motorcycle Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Jack up the motorcycle underneath the engine The wheels must no longer touch the ground Work stand 59229055000 Secure the motorcycle against falling over 500181 01 Removing the motorcycle from the work stand Note Danger of damage Danger of damage by the vehicle running away or falling over Always place the vehicle on a firm and even surface Remove the motorcycle from the work stand Remove the work stand Checking the basic chassis setting with the rider s weight e Info When adjusting the basic chassis setting first adjust the shock absorber and then the fork For optimal motorcycle riding characteristics and to avoid damage to forks shock absorbers swing arm and frame the basic settings of the suspension components must match your body weight As delivered KTM motorcycles are adjusted for a standard rider weight with full protective clothing Standard rider weight 75 85 kg 165 34 187 39 Ib If your weight is above or below the standard range you have to adjust the basic setting of the suspension components accordingly Small weight differences can be compensated by adjusting the spring preload but in the case of large weight differences the springs must be
62. er of the springs must be positioned upwards Fit the locking splint pins Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there 16 a tight spot wm Changing the front brake linings 4 Warning Skin irritations Brake fluid can cause skin Irritation on contact Avoid contact with skin and eyes and keep out of the reach of children f brake fluid gets into your eyes rinse thoroughly with water and contact a doctor immediately Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info KTM recommends DOT 5 1 brake fluid from Motorex This has a higher wet boiling point than DOT 4 brake fluid and provides greater safety for high demands Never user DOT 5 brake fluid This is based on silicone oil and is colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Remove the front brake linings P 41 Move the brake fluid reservoir mounted on the handlebar to a horizon
63. ewer When the engine oil does not reach the top of the viewer Top up the engine oil 9 P 65 Condition Engine Is cold 400212 10 Check the engine oil level The engine oil reaches the bottom of the viewer Q When the engine oil does not reach the bottom of the viewer Top up the engine oil 9 P 65 MAINTENANCE WORK ON CHASSIS AND ENGINE Drain the engine oil 9 P 63 Remove the oil filter 64 Mount the oil filter 9 P 64 Fill up with engine oil 64 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately sig Warning 7 Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info Drain the engine oil only when the engine is warm Stand the motorcycle on its side stand on a horizontal surface Place a suitable container under the engine Remove the oil drain plug with the seal ring Completely drain the engine oil Thoroughly clean the oil drain plug with a magnet Clean the sealing area on the engine Check parts for damage and wear Replace damaged or worn parts Refit oil drain plug with seal ring and tighten it S
64. fications Adjusting chain tension after checking P 37 Remove the motorcycle from the work stand 9 P 21 MAINTENANCE WORK ON CHASSIS AND ENGINE Checking the chain tension when fitting rear wheel Warning Danger of accidents Danger caused by incorrect chain tension Ifthe chain tension is too high the components of the secondary power train chain engine sprocket rear sprocket bear ings in transmission and rear wheel are under additional load Apart from premature wear in extreme cases the chain can rupture or the countershaft of the transmission can break On the other hand if the chain is loose it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine Check for correct chain tension and adjust if necessary Make sure that the chain adjusters are fitted correctly on the adjusting screws Push the chain at the end of the chain sliding component upwards to measure chain tension Q e Info The upper chain section must be taut Chain wear is not always even so you should repeat this measurement at different chain positions Ifthe chain tension does not meet specifications Adjust the chain tension when fitting rear wheel 9 P 37 Checking the rear sprocket engine sprocket for wear Check the rear sprocket engine sprocket for wear n Ifthe rear sprocket engine sprocket are worn COCO Replace rear sprocket
65. free travel on the hand brake lever pressure builds up on the front brake in the brake system The front brake can fail due to overheating Adjust free travel on hand brake lever according to specifications Push the hand brake lever forwards and check free play Free play of hand brake lever gt gt 0 12 in If the free travel does not meet specifications adjust the basic position of handbrake lever 9 P 39 Adjust the basic setting of the handbrake lever to your hand size by turning adjust ing screw e Info f If you turn the adjusting screw clockwise as seen in the direction of travel the handbrake lever moves nearer to the handlebar If you turn the adjusting screw counterclockwise as seen in the direction of travel the handbrake lever moves away from the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding Check the free play of the hand brake lever 9 P 39 Warning 4X Danger of accidents Brake system failure Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked in an authorized KTM workshop and do not ride any further A Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the
66. fuel tank lower the rear of the seat and simultaneously push it forwards Make sure that the seat 15 correctly locked in Mount and tighten the screw of the seat fixing Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Remove the seat 92 P 53 Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt espe cially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel 500219 10 A Warning mE mE Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change cloth ing that has come into contact with fuel Store fuel in a suitable canister according to regulations and keep it out of the reach of children Turn off the fuel tap and pull off the fuel hose Remove screws with collar sleeve Remove screw with collar sleeve Remove the tube from the fuel tank vent line ig 500066 10 MAINTENANCE WORK ON CHASSIS AND ENGINE rs Pu
67. h into the air and the silencer burns out Not only is the noise level higher the performance characteristic changes Warning Danger of burns exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Remove the main silencer 9 P 57 Remove screws of end cap Remove the end cap Remove screws of insert Remove insert Remove screws of cap Remove Remove inner tube Remove glass fiber yarn filling from insert and inner tube Clean parts to be refitted 500226 10 MAINTENANCE WORK ON CHASSIS AND ENGINE SE Check parts for damage and wear Replace damaged or worn parts Attach the glass fiber yarn filling to inner tube Fit the inner tube into the outer tube Insert cap Mount and tighten screws Attach the glass fiber yarn filling to insert Fit the insert into the outer tube Mount and tighten screws Insert end cap Mount and tighten screws Fit the main silencer 9 P 57 500226 11 Remove glass fiber yarn filling of main silencer 92 P 57 Fit the glass fiber yarn filling of the main silencer 9 P 58 Pull off the air filter box lid in area Q to the side and remove to the front Check parts for damage and wear Replace damaged or worn parts Insert the air filter box lid into the rear area and clip i
68. if you use your motorcycle responsibly you can en sure that such problems and conflicts do not have to occur To protect the future of motorcycle sport make sure that you use your mo torcycle legally display environmental consciousness and respect the rights of others In your own interest read the specified warning notes e Info Various warning labels are attached to your vehicle Do not remove any warning labels If they are missing you or others may not recognize dangers and may therefore be injured IMPORTANT NOTES 6 Grades of risks 00 Danger Danger that leads immediately and certainly to severe and permanent injury or death A Warning Danger that will probably lead to severe and permanent injury or death Note Danger of serious damage to machine or material Warning Ae Risk of environmental damage Read this owner s manual carefully and completely before making your first trip It contains a lot of Information and tips to help you operate and handle your motorcycle Only then will you find out how to customize the motorcycle ideally for your own use and how you can protect yourself from injury The owner s manual also contains important information on servicing the motorcycle The owner s manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is sold VIEW OF VEHICLE 1 View of vehicle front left side 500182 10 Hand brake lever Start number plate
69. ifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ac cording to regulations and keep it out of the reach of children Warning Ae Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system e Info Carry out this work with a cold engine Turn the handle Q of the fuel tap to the OFF position Figure 500178 10 2 P 11 v more fuel flows from the tank to the carburetor Guide the hose coming down behind the engine into a suitable container e Info Water in the float chamber results in malfunctioning Undo the screw turn it counterclockwise few turns and drain the fuel from the float chamber Tighten screw Checking engine oil level e Info The engine oil level can be checked on a cold or hot engine Stand the motorcycle upright on a horizontal surface Condition The engine is at operating temperature Check the engine oil level The engine oil reaches the top of the vi
70. l Engine oil SAE 10 50 9 P 82 Engine oil 1 35 1 1 43 qt Capacity coolant Coolant 1 21 1 27 qt Coolant P 82 Coolant mixed ready to use P 82 TECHNICAL DATA ENGINE TIGHTENING TORQUE 1 ed Screw camshaft bearing retaining M5 6 Nm 4 43 Ibf ft Loctite 243 bracket Screw timing train axle retaining M5 6 Nm 4 43 Ibf ft Loctite 243 bracket Screw ignition pulse generator 5 6 Nm 4 43 Ibf ft Loctite 243 Screw ignition pulse generator adapter M5 6 Nm 4 43 Ibf ft Loctite 243 Screw stator cable holder M5 6 Nm 4 43 Ibf ft Loctite 243 Screw bearing bolt of oil pump idler 6 Nm 4 43 Ibf ft Loctite 243 shaft v6 omga Oooo S Screw ignition pulse generator cable M6 10 Nm 7 38 Ibf ft Loctite 243 holder Screw clutch cover M6 10 Nm 7 38 Ibf ft Screw clutch spring M6 10 Nm 7 38 Ibf ft 0 Screw clutch slave cylinder M6 10 Nm 7 38 Ibf ft O1 gt lt I v6 8 908 v6 HONnUGB Me 03801020 o O o o o o ooo o o NI NIN gt lt gt lt gt lt Plug crankshaft location M8 20 Nm 14 75 Ibf ft Screw unlocking of timing chain ten 10 1 10 Nm 7 38 Ibf ft RN sioner Nut cylinder head M10x1 25 Tightening sequence Engine oil any Tighten in diagonal sequence Tightening stage 1 10 Nm 7 38 Ibf ft Tightening
71. ll both spoilers to the side of the radiator bracket and take the fuel tank away upwards 500220 10 Installing the fuel tank Danger Fire hazard Fuel can easily catch fire Never fill up the vehicle near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank Is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Check parts for damage and wear Replace damaged or worn parts Position the fuel tank and fit the two spoilers to the side of the radiator fixing Make sure that no cables or Bowden cables are trapped or damaged 500220 01 Mount the fuel tank vent hose Fit and tighten screw with collar sleeve Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Fit and tighten screws with collar sleeve Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Connect fuel hose
72. m the work stand 9 P 21 Sa NS 400389 10 Checking static sag of the shock absorber Measure distance Q of rear wheel unloaded P 23 Ask someone to help you by holding the motorcycle upright Measure the distance between the rear axle and the fixed point again Make a note of the value as measurement e Info The static sag is the difference between measurements and le Check the static sag UU Static sag 15 20 mm 0 59 0 79 in Ifthe static sag is less or more than the specified value Adjust the spring preload of the shock absorber 9 24 400383 10 Check the riding sag of the shock absorber Measure distance of rear wheel unloaded 9 23 With another person holding the motorcycle sit on the saddle with full protective clothing in a normal sitting position feet on footrests and bounce up and down a few times until the rear suspension levels out The other person now has to measure the distance between the rear axle and a fixed point v Make a note of the value as measurement e Info The riding sag is the difference between measurements Q and ANANAS ANN Check the riding sag Riding sag 80 90 mm 3 15 3 54 in Ifthe riding sag
73. mands Never user DOT 5 brake fluid This is based on silicone oil and 16 colored purple Oil seals and brake lines are not designed for DOT 5 brake fluid Avoid contact between brake fluid and painted parts Brake fluid attacks paint Use only clean brake fluid from a sealed container Move the brake fluid reservoir mounted on the handlebar to a horizontal position Remove screw cap Remove the plastic ring with membrane Top up the brake fluid to level MAX Brake fluid DOT 5 1 9 P 82 Check parts for damage and wear Replace damaged or worn parts Fit the membrane and the plastic ring Mount and tighten the screw cap 500196 10 e Info Clean up overflowed or spilt brake fluid immediately with water Checking the front brake linings Warning Danger of accidents Reduced braking due to worn brake linings Worn brake linings should be replaced immediately in an authorized KTM workshop Check the brake linings for minimum thickness Q Minimum thickness gt 1 mm gt 0 04 in If the minimum thickness is less than specified Change the front brake linings P 42 MAINTENANCE WORK ON CHASSIS AND ENGINE Removing front brake linings Warning Danger of accidents Always have your brake system maintained and repaired in an authorized KTM workshop Improper brake maintenance and repair Remove locking split pins Press the spring hanger of the
74. n be overloaded by the use of incorrect fuses Use only fuses with the prescribed amperage Never by pass or repair fuses Check parts for damage and wear Replace damaged or worn parts e Info A reserve fuse is located in the starter relay Replace a burned out fuse only by an equivalent fuse Refit the fuse Fuse 58011109110 e info If the new fuse burns out contact an authorized KTM workshop 400273 10 Replace the protection cover Install the air filter box lid 2 P 58 Ignition curve plug connection The plug connection is located in front of the fuel tank on the left of the frame Possible states Soft If the plug connection is separated riding is more flexible e Performance If the plug connection is connected higher performance 15 achieved Changing the ignition curve Changing the ignition curve from Performance to Soft Separate plug connection Figure 500218 10 P 52 w Soft Greater flexibility Changing the ignition curve from Soft to Performance Connect plug connection Figure 500218 10 P 52 v Performance Higher performance MAINTENANCE WORK ON CHASSIS AND ENGINE Removing the seat Remove screw Lift up the seat at the rear pull it back and then remove from above he 1 500080 10 Check parts for damage and wear Replace damaged or worn parts Hook the front of the seat into the flange adapter of the
75. n the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications Disconnect spring Loosen nut and with push rod turn it back until you have maximum free play To adjust the basic position of the footbrake lever individually lossen nut and turn screw accordingly e Info The range of adjustment is limited Turn push rod accordingly until you have free play If necessary adjust the 400232 10 basic position of the footbrake lever Specification Free play at foot brake lever 3 5 mm 0 12 0 2 in Hold screw and tighten nut Specification Remaining nuts chassis M8 30 Nm 22 13 Ibf ft Hold push rod and tighten nut 0 Specification Remaining nuts chassis M6 15 Nm 11 06 Ibf ft Reconnect spring Checking the rear brake fluid level Warning Danger of accidents Brake system failure Ifthe brake fluid level falls below the MIN mark this indicates a leakage in the brake system or worn out brake linings Have the brake system checked an authorized KTM workshop and do not ride any further Warning Danger of accidents Reduced braking due to old brake fluid Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop MAINTENANCE WORK ON CHASSIS AND ENGINE 44 Stand the v
76. nd 9 21 Checking basic setting of fork e Info For various reasons no exact riding sag can be determined for the forks As with the shock absorber smaller weight differences can be compensated by the spring preload However if your fork is often overloaded hard end stop on compression you must fit harder springs to avoid damage to the fork and frame Adjusting compression damping of fork e Info The hydraulic compression damping determines the fork suspension behavior MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the top end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise the number of clicks corresponding to the fork type Specification Compression damping Standard 15 clicks e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Adjusting rebound damping of fork e Info The hydraulic rebound damping determines the fork suspension behavior Remove protection covers Turn adjusting screws clockwise until they stop e Info The adjusting screws are located at the bottom end of the fork legs Make the same adjustment on both fork legs Turn back counterclockwise the number of clicks corresponding to the fork type Specification Rebound damping Standard 15 clicks e Info Turn clockwise to
77. nd tighten screws MAINTENANCE WORK ON CHASSIS AND ENGINE th Carburetor idle The idle setting of the carburetor has a big influence on the starting behavior stable idling and the response to throttle opening That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly r Info 1 15 The carburetor and its components are subject to increased wear caused by en 4 A gine vibration Wear can result in malfunctioning t The idle speed is adjusted with the adjustment screw The idle mixture is adjusted with the idle mixture adjustment screw Screw in the idle adjusting screw until it stops and then to the prescribed basic setting Specification A Idle mixture adjusting screw Open 1 5 turns E Adjustment tool for mixture control screw 77329034000 Run the engine until warm Specification gt 5 min Warm up time Adjust the idle speed with the adjusting screw Specification Choke function activated The choke lever is pushed in to the stop 9 P 11 Idle speed 1600 1650 rpm Turn the idle adjusting screw slowly until the idle speed begins to fall Note the position and turn the idle adjusting screw slowly counterclockwise until the idle speed falls Adjust to the point between these two positions with the highest idle speed e Info If there is
78. near open flames or burning cigarettes and always switch off the engine first Be careful that no fuel is spilt especially on hot vehicle components Clean up spilt fuel immediately Fuel in the fuel tank expands when warm and can escape if the tank is overfilled See specifications on filling up with fuel Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel xt Warning Environmental hazard Improper handling of fuel is a danger to the environment Do not allow fuel to get into the ground water the ground or the sewage system Open the filler 9 P 11 Fill the fuel tank with fuel up to measurement Specification Measurement of 35 mm 1 38 in Tank capacity 8 2 Super unleaded ROZ 95 RON 95 2 17 US gal PON 91 P 82 Close the filler cap 9 11 M 400382 10 REASING AND SERVICE TABLE Important maintenance work to be carried out by an authorized KTM workshop Engine Change the engine oil and oil filter and clean the oil screen 9 63 Replace spark plug Check and adjust valve clearance Check engine mounting scre
79. ng length ofthe oi pressureregulatorvave J Ghange ass fiber yar Replace fot brake 1010 check S10A Every 10 service hours corresponds to about 70 liters of fuel after every race S20N After 20 service hours corresponds to about 140 liters of fuel S40N After 40 service hours corresponds to about 280 liters of fuel J1A annually J2A every 2 years Important checks and maintenance work to be carried out by the rider Check ie front brake bake uia we Check tne rear bake fua Check the front brake linings Bleed fork legs 9 P 26 Clean dust boots of fork legs P 26 Clean the chain P 34 Check the chain wear 92 35 Check the rear sprocket engine sprocket for wear P 35 Clean the air filter P 59 Checking the tire air pressure 9 49 Check the tire condition P 49 NM Clean the chain Check the chain tension 7 34 ELE GREASING AND SERVICE TABLE 20 Check the coolant level 92 P 55 Empty the carburetor float chamber 9 P 62 ELE Check that all operating elements for smooth operation Check braking EN Check all screws nuts and hose clamps regularly for tightness pe NB1A Depending on conditions of use according to requirem
80. ng the battery 4 A Warning Risk of injury Battery acid and battery gases cause serious cauterization Keep batteries out of the reach of children Wear suitable protective clothing and goggles Avoid contact with battery acid and battery gases Keep the battery away from sparks or open fire Charge only in well ventilated rooms Inthe event of skin contact rinse with large amounts of water If battery acid gets in the eyes rinse with water for at least 15 minutes and contact a doctor Warning Environmental hazard Components and battery acid are a danger to the environment Do not dispose of batteries in normal household waste Take defective or used batteries to a battery recycling operator Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Info Even if there is no load on the battery it loses power every day The charge state and the type of charge are very important for the service life of the battery Fast recharging with a high charge current shortens the battery s service life If the charge current the charge voltage and the charge time are exceeded electrolyte escapes through the breathing holes The battery capacity is then reduced If the battery is discharged from starting it must be recharged immediately If it stands for a long time in a discha
81. oisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Make sure that the screw is tightened Stand the vehicle upright Pour coolant in up to measurement above the radiator fins Specification 10 mm 0 39 in Coolant 1 21 1 27 qt Coolant Coolant 7 P 82 P 82 EGIT mixed ready to use 82 Refit the radiator cap Make a short test ride Check the coolant level 9 P 55 MAINTENANCE WORK ON CHASSIS AND ENGINE Removing main silencer 0000 Warning Danger of burns exhaust system gets very hot when the vehicle is driven Allow the exhaust system to cool down Do not touch hot components Disconnect spring Remove screws and take off main silencer Check parts for damage and wear Replace damaged or worn parts Mount the main silencer Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Reconnect spring The main silencer is filled with glass fiber yarn Over a period the fibers of the insulating material vanis
82. on the right fork leg Remove the fork protector Check parts for damage and wear Replace damaged or worn parts Position the fork protection on the left fork leg Mount and tighten screws Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Position the brake line Put the clamp on mount and tighten screws Position the fork protection on the right fork leg Mount and tighten screws Specification 900187 10 Remaining screws chassis M6 10 Nm 7 38 Ibf ft Checking play of steering head bearing Warning Danger of accidents Unsafe riding behavior due to incorrect steering head bearing play steering head bearing play should be adjusted immediately in an authorized KTM workshop e Info If the bike is driven for a longer time with play the steering head bearing the bearing and the bearing seats the frame be damaged after time Jack up the motorcycle P 21 MAINTENANCE WORK ON CHASSIS AND ENGINE 2 400387 10 Fork offset 400188 10 Move the handlebar to the straight ahead position Move the fork legs to and fro In the direction of travel No play should be noticeable in the steering head bearing Y If there is noticeable play present Adjust play of the steering head bearing P 28 Move the handlebar to and fro over the entire steering range The handlebar must be able to move easily over the entire steering range No
83. pecification Oil drain plug with magnet M12x1 5 20 Nm 14 75 Ibf ft Clean the oil screen 9 63 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage 4 A 2 Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Place a suitable container under the engine Loosen the plug with a few light hammer blows Remove plug with oil screen and O rings Completely drain the remaining engine oll Thoroughly clean parts and sealing area Check parts for damage and wear Replace damaged or worn parts Fit and tighten plug with oil screen and O rings Specification Plug oil screen M32x1 5 30 Nm 400261 11 22 13 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE A Removing the oil filter 2 Warning Danger of scalding Engine oil and gear oil get very hot when the motocycle is driven Wear suitable protective clothing and gloves If you scald yourself hold the affected area under cold water immediately Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances
84. portant impact on the riding behavior of the motorcycle The front and rear wheels must be fitted with tires with similar profiles Worn tires have a negative effect on riding behavior especially on wet surfaces Examine the tires for cuts foreign bodies and other damage Checking tire air pressure e Info Low tire air pressure leads to abnormal wear and overheating of the tire Correct tire air pressure ensures optimal riding comfort and maximum tire service life Remove dust cap Check tire air pressure when tires are cold If the tire pressure does not meet specifications Correct tire pressure Mount dust cap 500216 01 MAINTENANCE WORK ON CHASSIS AND ENGINE Checking spoke tension Warning Danger of accidents Unstable riding behavior due to loose spokes f you ride with loose spokes the spokes can break Have the spoke tension corrected in an authorized KTM workshop e Iinfo A loose spoke can cause wheel imbalance which leads to more loose spokes in a short time If the spokes are too tight they can break due to local overload Check the spoke tension regularly especially on a new motorcycle check spoke tension tap each spoke with a screwdriver Specification You should hear a high note Spoke nipple front wheel 5 Nm 3 69 Ibf ft Spoke nipple rear wheel 5 Nm 3 69 Ibf ft e Info If you hear different tone frequencies from different spokes this is an in
85. r ker e e X Fe Fa c 9 Removing the fork legs 29 OPERATING ELEMENT eee 10 Installing the fork legs 29 amp ire Sc c 10 Removing the lower triple clamp 5 30 PIOUS enaA ce cet etd 10 Installing the lower triple clamp 30 Hand brake lever sss nean tede DR Ub 10 Greasing the steering head bearing 31 Short circuit DUTTON inerea a bon to 10 Dismounting the front 31 BICCIIC Starter DUTTON 10 Installing the front feHdel 31 oce 11 Dismount the start number 32 esque bed 11 Fitting the start number plate eeeeennee 32 11 01155 6 RS Co e dr 32 a on 11 Adjusting handlebar position amp 32 winner 12 Checking gas Bowden cable 33 Foot Drake PCG ali e ce tec atr a 12 Checking play in the gas Bowden cable
86. replaced Compression damping of shock absorber The shock absorber can regulate compression damping in low and high speed range separately Dual Compression Control The term low and high speed refers to the movement of the shock absorber during compression and not the riding speed of the motor cycle The low and high speed technology works non specifically Adjusting high speed compression damping of the shock absorber VN Danger Danger of accidents shock absorber is under high pressure he shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself e Info The high speed setting can be seen during the fast compression of the shock absorber Turn the adjusting screw clockwise with a ring wrench until it stops e Info Do not loosen nut 500184 10 MAINTENANCE WORK ON CHASSIS AND ENGINE 22 Turn back counterclockwise the number of turns corresponding to the shock ab sorber type Specification Compression damping high speed e Info Turn clockwise to increase damping turn counterclockwise to reduce sus pension damping Adjusting the low speed compression damping of the shock absorber VW Danger Danger of accidents The shock absorber is under high pressure he shock absorber is filled with highly compressed nitrogen so never dismantle the shock absorber or carry out any main tenance on it yourself
87. rged state the battery becomes over discharged and sulfated and then it is destroyed The battery is maintenance free i e the acid level does not have to be checked Switch off all power consuming components and switch off the engine Remove the seat 9 P 53 Disconnect the minus negative cable of the battery to avoid damage to the motor 5 electronics Connect the battery charger to the battery Switch on the battery charger Battery charger 58429074000 You can also use the battery charger to test rest potential and start potential of the battery and to test the generator With this device you cannot overcharge the bat tery e Info Never remove the lid 400240 10 Charge the battery according to the instructions on the battery casing Switch off the charger after charging Disconnect the battery Specification The charge current charge voltage and charge time must not be exceeded Charge the battery regularly when the 3 months motorcycle is not in use Mount the seat 9 P 53 MAINTENANCE WORK ON CHASSIS AND ENGINE 2 Removing a fuse Switch off all power consuming components and switch off the engine Dismount the air filter box lid 9 P 58 Remove the protection cover e Info The fuse is located in the starter relay under the filter box cover Remove the fuse O F 400270 10 Replacing the fuse f Warning Fire hazard The electrical system ca
88. rk Adjust plug gap plug too wide Specification spark plug electrode gap 7 mm 0 03 in Spark plug connector or spark plug defec Warning Risk of injury The ignition system is under high voltage Do not touch parts of the ig nition system Have work on the ignition system carried out in an authorized KTM workshop Remove spark plug connect ignition cable hold spark plug to ground bare metal area on engine and try to start the engine Specification You should see a strong spark on the spark plug there is no spark change the spark plug If there is still no spark remove the spark plug cap from the ignition cable hold it at the specified distance from the ground contact and try to start the engine Specification 5 mm 0 2 in f you now have a spark replace the spark plug connector f there is no spark have the ignition system checked Short circuit cable in wiring harness Check wiring harness visual check chafed short circuit button defective Check electrical system Socket connector of CDI control device Clean socket connector and treat it pulse generator or ignition coil oxidized with contact spray Water in carburetor or jets blocked Clean carburetor Engine has no idle Idling jet blocked Clean carburetor Adjusting screws on carburetor distorted Have the carburetor adjusted Spark plug defective Change spark plug TROUB
89. s Adjust the chain tension by turning the adjusting screws left and right Specification Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks Q The rear wheel is then correctly aligned Tighten nuts Make sure that the chain adjusters O are fitted correctly on the adjusting screws Q Tighten nut Specification Nut rear wheel spindle M20x1 5 80 Nm 59 01 Ibf ft e Info l The wide adjustment range of the chain adjusters 32 mm enables different secondary transmissions with the same chain length The chain adjusters can be turned by 180 Loosen nuts Adjust the chain tension by turning the adjusting screws left and right Specification Turn the adjusting screws left and right so that the markings on the left and right chain adjusters are in the same position relative to the reference marks The rear wheel 15 then correctly aligned Tighten nuts MAINTENANCE WORK ON CHASSIS AND ENGINE Remove screws and Take off the chain guide Conditions Number of teeth lt 44 teeth Insert nut O in hole Position the chain guide Mount and tighten screws and Specification Remaining screws chassis M6 10 Nm 7 38 Ibf ft Conditions Number of teeth gt 45 teeth Insert nut O in hole Position the chain guide Mount and tighten screws
90. spring forwards and withdraw the bolt Take off the springs Remove the brake linings am am 3 Remove screws with washers and take off the brake caliper Clean the brake caliper Mounting front brake linings 4 Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary A Warning Danger of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty 16 no longer valid Check the brake discs 9 P 38 Check parts for damage and wear Replace damaged or worn parts Position the brake caliper Fit and tighten screws with washers Specification 41 Screw front brake caliper 10 1 25 40 Nm Loctite 243 29 5 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE 42 Fit the brake linings Position the springs and mount the bolts e Info The spring hang
91. stage 2 30 Nm 22 13 Ibf ft Tightening stage 3 50 TECHNICAL DATA ENGINE TIGHTENING TORQUE 12 Stud cylinder head M10x1 25 20 Nm 14 75 Ibf ft Screw engine sprocket 60 Nm 44 26 Ibf ft Loctite 243 Spark plug M10 10 12 Nm 7 38 8 85 Ibf ft Screw in studs for clutch cover M12x1 5 20 Nm 14 75 Ibf ft es Oi drain plugwith magnet _ Fase guide rail for timing chain o o Fase tension fortiming Oi pressure regulator vae pug o Pg timing chain tensioner oo Nut compensating sprocket M14x1 20 Nm 14 75 Ibf ft Loctite 243 TECHNICAL DATA CARBURETOR 13 Carburetor identfication number Diameter of bore in carburetor body Idling jet Main air jet Cold start jet BU 185 42 200 100 85 15 TECHNICAL DATA CHASSI 1 Frame Fork Suspension travel Central tube frame made of chrome molybdenum steel tubing WP 4860 MXMA CC 280 mm 11 02 in 310 mm 12 2 in front Rear Fork offset Front marking 14 mm 0 55 in 16 mm 0 63 in WP PDS 5018 DCC Rear marking Shock absorber Brake system front single disc brake with radially screwed four piston fixed caliper floating brake disc Rear single disc brake with single piston floating caliper fixed brake disc Diameter of brake discs 310 mm 12 2 in 220 mm 8 66 in front Rear Wear limit of brake dis
92. steering stem 180 and insert into the triple clamp Mount and tighten screw Specification Screw bottom steering M20x1 5 60 Nm Loctite 243 head 44 26 Ibf ft Install the lower triple clamp P 30 500104 10 Remove front wheel P 46 Remove screws and take off clamp Hang the brake caliper and the brake line loosely to the side Loosen screw Remove the fork leg on the left Loosen screw Remove the fork leg on the right Check parts for damage and wear Replace damaged or worn parts Position the fork legs Info e The topmost sunk nut in the fork leg must be flush to the upper edge of the upper triple clamp Position the bleeder screw to the front oh Fully tighten screw Specification Screw top triple clamp M8 17 Nm 12 54 Ibf ft Fully tighten screw Specification Screw bottom triple clamp M8 12 Nm 8 85 Ibf ft MAINTENANCE WORK ON CHASSIS AND ENGINE Position the brake line Put the clamp on mount and tighten screws Fit front wheel P 47 Remove the fork legs 9 29 Dismount the start number plate 32 Dismount the front fender 2 P 31 Remove screws and hang the CDI control unit to the side e Info Do not unplug the CDI control unit Remove screw Remove screw take off top triple clamp with the handlebar and place it on one side e Info Protect the motorcycle and its
93. t Installing the rear brake linings 4 f Warning Danger of accidents Reduced braking due to oil or grease on the brake discs Always keep the brake discs free of oil and grease and clean them with brake cleaner when necessary Warning Danger of accidents Reduced braking due to use of non approved brake linings Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles The construc tion and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake linings If brake linings are used that differ from the originals there is no guarantee that they comply with the origi nal license The vehicle no longer corresponds to the condition at delivery and the warranty is no longer valid Check the brake discs P 38 Check parts for damage and wear Replace damaged or worn parts Check that leaf spring in the brake caliper and sliding plate in the brake caliper support are seated correctly e Info The arrow on the leaf spring points in the rotation direction of the brake disc Fit the brake linings insert bolt and mount locking split pins O e Info Make sure that the decoupling plate is mounted on the piston side of the brake pad Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot MAINTENANCE WORK ON CHASSIS AND E
94. t into the front area Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations Dismount the air filter box lid 9 P 58 Undo the hose clip Remove the air filter 5 500223 10 MAINTENANCE WORK ON CHASSIS AND ENGINE Installing the air filter OOKt lt _ lt Cleaning air filter 4 Check parts for damage and wear Replace damaged or worn parts Fit a clean air filter e Info If the air filter is not correctly mounted dust and dirt can penetrate into the engine and can cause damage Position and tighten the hose clip Install the air filter box lid P 58 Warning Environmental hazard Problem materials cause environmental damage Dispose of oil grease filters fuel cleaning substances brake fluid batteries etc according to regulations e Info Do not use fuel or kerosene for cleaning the air filter 500225 01 Adjusting basic position of clutch lever Remove the air filter P 58 Remove large pieces of dirt by shaking Use a soft brush to clean the air filter Spray on the cleaner and le
95. t it penetrate for 1O minutes Air filter cleaner P 84 Rinse the air filter from the inside with a soft Jet of water shake off remaining water Allow the air filter to dry e Info Do not use compressed air for drying Spray the dry air filter carefully with filter oil Air filter oil P 84 Allow the filter oil to penetrate for 20 minutes Clean the air filter box Check the distribution of the filter oil unoiled areas are visible the air filter again Wipe off excess filter oil e Info Do not over oil the air filter Check carburetor connection boot for damage and tightness Install the air filter 2 P 59 Adjust the basic setting of the clutch lever to your hand size by turning adjusting screw e info Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar The range of adjustment is limited Turn the adjusting screw by hand only and do not apply any force Do not make any adjustments while riding MAINTENANCE WORK ON CHASSIS AND ENGINE Checking fluid level of hydraulic clutch e Info The fluid level rises with increasing wear of the clutch lining disc Do not use brake fluid Changing fluid level of hydraulic clutch Move the clutch fluid reservoir mounted on the handlebar to a horizontal position Remove screws
96. tal position Remove screw Remove the plastic ring with membrane Press the brake piston back to its basic position and make sure that no brake fluid overflows from the reservoir Mount the front brake linings 9 P 41 Top up the brake fluid to level MAX 500196 10 Brake fluid DOT 5 1 2 P 82 Check parts for damage and wear Replace damaged or worn parts Fit the membrane and the plastic ring Mount and tighten the screw e Info Clean up overflowed or spilt brake fluid immediately with water MAINTENANCE WORK ON CHASSIS AND ENGINE 4 Checking free play of foot brake lever Warning Danger of accidents Brake system failure lf there is no free travel on the foot brake pedal pressure builds up on the rear brake in the brake system The rear brake can fail due to overheating Adjust free travel on foot brake pedal according to specifications Disconnect spring Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play Specification Free play at foot brake lever 3 5 0 12 0 2 in If the free travel does not meet specifications Adjust the basic position of the footbrake lever 9 43 Reconnect spring 400205 11 Adjusting basic position of footbrake lever Warning Danger of accidents Brake system failure lf there is no free travel o
97. the coolant level in the radiator Coolant level above radiator fins 10 mm 0 39 in Ifthe level of the cooling liquid does not meet specifications Correct the coolant level Alternative 1 Coolant P 82 400243 10 Alternative 2 Coolant mixed ready to use P 82 Refit the radiator cap Draining coolant 4 Warning A Danger of scalding The coolant gets very hot when the motorcycle is driven and is under high pressure Do not open the radiator radiator hoses or other cooling system components when the engine 15 hot Allow the engine and cooling system to cool down If you scald yourself hold the affected area under cold water immediately Warning Danger of poisoning Coolants are poisonous and a health hazard Avoid contact between coolants and skin eyes and clothing If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas immediately with soap and water If coolant is swallowed contact a doctor im mediately Change clothes that have come into contact with coolants Keep coolants out of the reach of children Stand the vehicle upright Place a suitable container under the water pump cover Remove screw Remove the radiator Completely drain the coolant Fit screw with a new seal and tighten it Specification Screw water pump cover M6 10 Nm 7 38 Ibf ft Refilling coolant Warning Danger of p
98. ts Reduced braking due to wet or dirty brakes Clean or dry dirty or wet brakes by riding and braking gently After cleaning ride the vehicle a short distance until the engine warms up and then apply the brakes e Info The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate Push back the protection covers on the handlebar instruments to allow water to evaporate After the motorcycle has cooled off oil or grease all moving parts and bearings Clean the chain P 34 Treat bare metal parts except for brake discs and exhaust system with anti corrosion materials Cleaning and polishing materials for metal rubber and plastic P 84 reat all painted parts with a mild paint polish High luster polish for paint P 85 To prevent electrical problems treat electric contacts and switches with contact spray Contact spray P 85 STORAGE Storage Warning Danger of poisoning Fuel is poisonous and a health hazard Avoid contact between fuel and skin eyes and clothing Do not inhale fuel vapors If fuel gets into your eyes rinse imme diately with water and contact a doctor Wash affected skin areas immediately with soap and water If fuel is swallowed contact a doctor immediately Change clothing that has come into contact with fuel Store fuel in a suitable canister ac cording to regulations and keep it out of the reach of children
99. uel the engine starts immediately Press the starter for a maximum of 5 seconds Wait for a least 5 seconds until trying again Conditions Motorcycle standing still gt 1 week Empty the carburetor float chamber 9 P 62 Turn the handle Q of the fuel tap to the ON position Figure 500178 10 9 P 11 4 Fuel can flow from the tank to the carburetor Remove the motorcycle from the stand Shift gear to neutral Conditions Engine cold Pull choke lever out as far as possible Conditions Engine warm Pull the hot start lever out to the stop Press the electric starter button e Info Don t open the throttle Conditions Engine hot and running Push back the hot start lever to the stop with the engine running RIDING INSTRUCTION i Starting up Pull the clutch lever engage 161 gear release the clutch lever slowly and simultaneously open the throttle carefully Shifting riding Warning Danger of accidents f you change down at high engine speed the rear wheel can lock up Do not change into a low gear at high engine speed The engine races and the rear wheel can block e Info If you hear unusual noises while riding stop immediately switch off the engine and contact an authorized KTM workshop First gear is used for starting off or for steep inclines When conditions allow incline road situation etc you can shift into a higher gear To do so release the throttl
100. ws for tightness Clean spark plug connectors and check for tightness Check screw of shift lever for tightness Carburetor Check carburetor connection boots for cracks and leakage Check vent hoses for damage and routing without sharp bends Check idle Attachments Check the cooling system for leakage Check the antifreeze and coolant level 9 P 55 Check the exhaust system for leakage and looseness Check Bowden cables for damage smooth operation and routing without sharp bends Check the fluid level of the hydraulic clutch 9 60 Clean the air filter P 59 Check cables for damage and routing without sharp bends Check the front brake linings 7 P 40 Check the rear brake linings P 44 Check the brake discs P 38 Check the front brake brake fluid level 7 P 39 Check the rear brake fluid level P 43 Check brake lines for damage and leakage Check the free play of the hand brake lever 9 P 39 Check the free play of the foot brake lever P 43 Check brake system function Brakes Check screws and guide bolts of brake system for tightness Chassis Check shock absorber and fork for leakage and functioning Clean dust boots of fork legs 2 P 26 Bleed fork legs 9 P 26 Check swingarm bearing Check play of steering head bearing P 27 Check all screws to see if they are tight Check the spoke tension P 50 Check rim run out Check the tire condition P 49 Checking th
101. y hydraulic fluid that complies with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products Supplier Motorex Motorex Hydraulic Fluid 75 according to JASO T903 MA P 86 SAE 9 P 86 SAE 10W 5O Specification Use only engine oils that comply with the specified standards see specifications on the container and that possess the corre sponding properties KTM recommends Motorex products Synthetic engine oil Supplier Motorex Motorex Cross Power 4T according to SAE SAE 5 Specification Use only oils that comply with the specified standards see specifications on the container and that possesses the corresponding properties KTM recommends Motorex products SUBSTANCES 83 Supplier Motorex Motorex Racing Fork Oil AUXILIARY SUBSTANCE Specification KTM recommends Motorex products Supplier Motorex Motorex Joker 440 Universal Specification KTM recommends Motorex products Supplier Motorex Motorex Long Therm 2000 Specification KTM recommends Motorex products Supplier Motorex Motorex Chain Clean 611 Specification recommends Motorex products Supplier Motorex Motorex Chain Lube 622 Specification recommends Motorex products Supplier Motorex Motorex Twin Air Dirt Bio Remover Spe

Generac 40kW LP Portable Generator User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents