KTM 450XC-W Users Manual

0Whk'8 MAhAL 2009
400 X0
400 X0 A8
400 X0-W 8A
450 X0
450 X0 A8
450 X0 8IX 0AY8
450 X0-W 8A
450 X0-W ZA
530 X0
530 X0 A8
530 X0 8IX 0AY8
530 X0-W 8A
530 X0-W ZA
AkT. h0. 3211355en
0Ak kTM 08T0Mk 1
DEAR KTM CUSTOMER
0ongraLuaLons on your decson Lo purchase a KTM moLorcyce. You are now Lhe owner of a sLaLe-of-Lhe-arL sporLs moLorcyce LhaL w
gve you enormous peasure f you servce and manLan L accordngy.
we wsh you greaL peasure rdng Lhe vehce!
EnLer Lhe sera numbers of your vehce beow.
0hasss number ( p. 9) Deaer's sLamp
Engne number ( p. 9)
Key number (a EX0 modes) ( p. 9)
The owner's manua corresponded Lo Lhe aLesL sLaLe of Lhs seres aL Lhe Lme of prnLng. SghL devaLons resuLng from conLnung
deveopmenL and desgn of our moLorcyces can however noL be compeLey excuded.
A specfcaLons are noL bndng. KTM SporLmoLorcyce A0 specfcay reserves Lhe rghL Lo modfy or deeLe Lechnca specfca-
Lons, prces, coors, forms, maLeras, servces, desgns, equpmenL, eLc., wLhouL pror noLce and wLhouL specfyng reasons, Lo adapL
Lhese Lo oca condLons, as we as Lo sLop producLon of a parLcuar mode wLhouL pror noLce. KTM accepLs no abLy for devery
opLons, devaLons from usLraLons and descrpLons, as we as prnLng and oLher errors. The modes porLrayed parLy conLan speca
equpmenL LhaL does noL beong Lo Lhe reguar scope of devery.
2008 by KTM-SporLmoLorcyce A0, MaLLghofen AusLra
A rghLs reserved
ReproducLon, even n parL, s permLLed ony wLh Lhe express wrLLen permsson of Lhe copyrghL owner.
IS0 900T(T2 T00 606T)
wLhn Lhe meanng of Lhe nLernaLona quaLy managemenL sLandard IS0 900T, KTM uses quaLy assurance processes
LhaL ead Lo Lhe maxmum possbe quaLy of Lhe producLs.
Issued by. T\ ManagemenL Servce
KTM-SporLmoLorcyce A0
5230 MaLLghofen, AusLra
00hThT8 2
CONTENTS
MEANS 0F REPRESENTATI0N ............................................ 4
IMP0RTANT N0TES............................................................ 5
\IEw 0F \EHI0LE............................................................... 7
\ew of Lhe vehce from Lhe efL fronL (exampe) ................. 7
\ew of Lhe vehce from Lhe rghL rear (exampe) ................ 8
L00ATI0N 0F SERIAL NUMBERS........................................ 9
0hasss number............................................................... 9
Type abe....................................................................... 9
Key number (a EX0 modes) ........................................... 9
Engne number................................................................ 9
Fork parL number............................................................. 9
Shock absorber parL number........................................... T0
0PERATIN0 ELEMENTS.................................................... TT
0uLch ever .................................................................. TT
Hand brake ever ........................................................... TT
ShorL crcuL buLLon (a X0-w modes)............................. TT
ShorL crcuL buLLon (a EX0 modes)............................... TT
Emergency 0FF swLch (EX0 AUS) .................................. TT
EecLrc sLarLer buLLon (EX0 EU, EX0 SIX DAYS, X0-w) ..... T2
EecLrc sLarLer buLLon (EX0 AUS).................................... T2
LghL swLch (a EX0 modes) ......................................... T2
LghL swLch (a X0-w modes) ....................................... T2
Horn buLLon (a EX0 modes) ......................................... T2
Fasher swLch (a EX0 modes) ...................................... T3
0vervew of ndcaLor amps (a EX0 modes) ................... T3
SpeedomeLer................................................................. T3
SpeedomeLer acLvaLon and LesL ..................................... T3
TrpmasLer swLch.......................................................... T4
SeLLng komeLers or mes ............................................. T4
SeLLng Lhe cock ........................................................... T4
Ad|usLng Lhe speedomeLer funcLons............................... T5
0ueryng Lhe ap Lme .................................................... T5
SPEED dspay mode (speed).......................................... T6
SPEED/H dspay mode (servce hours) ............................ T6
SPEED/0LK dspay mode (Lme)..................................... T6
SPEED/LAP dspay mode (ap Lme)................................ T6
SPEED/0D0 dspay mode (odomeLer) ............................. T7
SPEED/TRT dspay mode (Lrp masLer T)......................... T7
SPEED/TR2 dspay mode (Lrp masLer 2)......................... T7
SPEED/AT dspay mode (average speed T) ...................... T8
SPEED/A2 dspay mode (average speed 2) ...................... T8
SPEED/ST dspay mode (sLop waLch T)........................... T8
SPEED/S2 dspay mode (sLop waLch 2)........................... T8
Fue Lap........................................................................ 20
0penng fer cap.......................................................... 20
0osng fer cap ........................................................... 20
0hoke (EX0 AUS, X0-w)................................................. 20
0hoke (EX0 EU, EX0 SIX DAYS) ..................................... 2T
ShfL ever..................................................................... 2T
FooL brake peda ........................................................... 2T
KcksLarLer .................................................................... 2T
Sde sLand .................................................................... 22
SLeerng ock (a EX0 modes) ........................................ 22
Lockng Lhe sLeerng (a EX0 modes).............................. 22
Unockng Lhe sLeerng (a EX0 modes) .......................... 23
0ENERAL TIPS AND HINTS 0N PUTTIN0 INT0
0PERATI0N...................................................................... 24
Advce on frsL use......................................................... 24
Runnng n Lhe engne.................................................... 25
RIDIN0 INSTRU0TI0NS.................................................... 26
0hecks before puLLng nLo operaLon ............................... 26
SLarLng ........................................................................ 26
SLarLng up ................................................................... 27
ShfLng, rdng.............................................................. 27
Brakng ........................................................................ 27
SLoppng, parkng .......................................................... 28
Refueng...................................................................... 28
SER\I0E S0HEDULE......................................................... 30
ImporLanL manLenance work Lo be carred ouL by an
auLhorzed KTM workshop. ............................................. 30
ImporLanL manLenance work Lo be carred ouL by an
auLhorzed KTM workshop. (as addLona order)................ 3T
ImporLanL checks and manLenance work Lo be carred
ouL by Lhe rder. ............................................................ 3T
MAINTENAN0E w0RK 0N 0HASSIS AND EN0INE.............. 33
Jackng up Lhe moLorcyce.............................................. 33
Removng Lhe moLorcyce from Lhe work sLand.................. 33
0heckng Lhe basc chasss seLLng wLh Lhe rder's
weghL .......................................................................... 33
0ompresson dampng of shock absorber.......................... 33
Ad|usLng hgh-speed compresson dampng of Lhe shock
absorber ....................................................................... 33
Ad|usLng Lhe ow-speed compresson dampng of Lhe
shock absorber .............................................................. 34
Ad|usLng rebound dampng of Lhe shock absorber ............ 34
Measurng rear whee sag unoaded ................................. 35
0heckng sLaLc sag of Lhe shock absorber ........................ 35
0heckng Lhe rdng sag of Lhe shock absorber .................. 36
Ad|usLng sprng preoad of Lhe shock absorber ............ 36
Ad|usLng rdng sag .................................................. 37
Removng Lhe shock absorber ..................................... 37
InsLang Lhe shock absorber ..................................... 37
0heckng basc seLLng of fork......................................... 38
Ad|usLng compresson dampng of fork ........................... 38
Ad|usLng rebound dampng of fork.................................. 38
Ad|usLng sprng preoad of Lhe fork................................. 39
Beedng fork egs.......................................................... 39
0eanng dusL booLs of fork egs ...................................... 39
Loosenng Lhe fork proLecLon.......................................... 40
PosLonng Lhe fork proLecLon ........................................ 40
0heckng pay of sLeerng head bearng............................ 40
Ad|usLng pay of sLeerng head bearng (EX0 EU,
EX0 AUS, X0-w ZA)....................................................... 4T
Ad|usLng pay of sLeerng head bearng
(EX0 SIX DAYS, X0-w USA) ........................................... 4T
Removng Lhe fork egs................................................... 42
InsLang Lhe fork egs ............................................... 42
Removng Lhe fork proLecLor ....................................... 43
InsLang Lhe fork proLecLor ....................................... 43
Removng Lhe ower Lrpe camp (EX0 SIX DAYS,
X0-w USA) ................................................................... 43
Removng Lhe ower Lrpe camp (EX0 EU, EX0 AUS,
X0-w ZA)...................................................................... 44
InsLang Lhe ower Lrpe camp (EX0 SIX DAYS,
X0-w USA) ................................................................... 45
InsLang Lhe ower Lrpe camp (EX0 EU, EX0 AUS,
X0-w ZA)...................................................................... 46
0reasng Lhe sLeerng head bearng ............................. 46
DsmounLng Lhe fronL fender .......................................... 47
InsLang Lhe fronL fender............................................... 47
Removng headghL mask wLh headghL (EX0,
EX0 SIX DAYS, X0-w ZA) ............................................... 47
RefLLng Lhe headghL mask wLh Lhe headghL (EX0,
EX0 SIX DAYS, X0-w ZA) ............................................... 47
00hThT8 3
DsmounL Lhe sLarL number paLe (X0-w USA)................... 48
InsLang Lhe sLarL number paLe (X0-w USA) ................... 48
Handebar posLon ........................................................ 48
Ad|usLng handebar posLon ...................................... 48
0heckng gas Bowden cabe rouLe ................................... 50
0heckng pay n Lhe gas Bowden cabe ........................... 50
Ad|usLng Lhe gas Bowden cabe pay .......................... 50
0heckng for chan drL accumuaLon .............................. 5T
0eanng Lhe chan......................................................... 5T
0heckng Lhe chan Lenson ............................................ 52
0heckng Lhe chan Lenson when fLLng rear whee........... 52
0heckng Lhe rear sprockeL / engne sprockeL for wear ....... 52
0heckng chan wear ...................................................... 53
Ad|usLng Lhe chan Lenson ............................................ 53
Ad|usLng chan Lenson - afLer checkng .......................... 54
Ad|usLng chan Lenson - fLLng rear whee ...................... 55
Ad|usLng chan gude ............................................... 55
0heckng Lhe brake dscs................................................ 55
0heckng free Lrave of hand brake ever........................... 56
Ad|usLng basc posLon of handbrake ever (a X0-w
modes) ........................................................................ 56
Ad|usLng free Lrave of handbrake ever (a EX0
modes) ........................................................................ 57
0heckng Lhe fronL brake fud eve ................................. 57
Addng fronL brake fud ............................................ 57
0heckng Lhe fronL brake nngs...................................... 58
Removng fronL brake nngs ..................................... 58
MounLng fronL brake nngs ...................................... 59
0hangng Lhe fronL brake nngs ................................. 59
0heckng free Lrave of fooL brake ever ............................ 60
Ad|usLng basc posLon of fooLbrake ever ................... 60
0heckng Lhe rear brake fud eve .................................. 6T
Addng brake fud for Lhe rear brake .......................... 6T
0heckng Lhe rear brake nngs....................................... 62
Removng rear brake nngs ....................................... 62
InsLang Lhe rear brake nngs .................................. 62
0hangng Lhe rear brake nngs .................................. 63
Removng Lhe fronL whee .......................................... 64
InsLang Lhe fronL whee ........................................... 64
Removng rear whee ................................................. 65
InsLang Lhe rear whee ............................................ 65
Tre condLon checkng.................................................. 66
0heckng Lre ar pressure............................................... 67
0heckng spoke Lenson.................................................. 67
Removng Lhe baLLery ................................................ 67
InsLang Lhe baLLery ................................................. 68
Rechargng Lhe baLLery .............................................. 68
Removng a fuse............................................................ 69
InsLang Lhe fuse ......................................................... 69
Removng Lhe seaL ......................................................... 69
MounLng Lhe seaL ......................................................... 70
DsmounLng Lhe fue Lank ......................................... 70
InsLang Lhe fue Lank .............................................. 7T
0oong sysLem.............................................................. 7T
0heckng anLfreeze and cooanL eve .............................. 72
0heckng Lhe cooanL eve.............................................. 72
Dranng cooanL ....................................................... 73
Refng cooanL ....................................................... 73
0ass fber yarn fng of man sencer ............................ 73
Removng man sencer ................................................. 74
InsLang Lhe man sencer ............................................ 74
DsmounLng Lhe ar fLer box d..................................... 74
InsLang Lhe ar fLer box d.......................................... 74
Removng Lhe ar fLer ............................................... 75
InsLang Lhe ar fLer ............................................... 75
0eanng ar fLer ...................................................... 75
Ad|usLng basc posLon of cuLch ever............................ 76
0heckng Lhe fud eve of hydrauc cuLch...................... 76
0hangng Lhe hydrauc cuLch fud ............................ 76
0arbureLor - de ............................................................ 77
0arbureLor - ad|usLng de ......................................... 78
EmpLyng Lhe carbureLor foaL chamber ....................... 79
0heckng engne o eve................................................ 79
0hangng engne o and o fLer, ceanng engne o
screen ..................................................................... 80
Dranng engne o, ceanng engne o screen ............ 80
Removng Lhe o fLer ............................................... 80
MounLng o fLer ..................................................... 8T
Fng up wLh engne o ........................................... 8T
Toppng up engne o .................................................... 82
0heckng gear o eve ................................................... 82
0hangng gear o, ceanng gear o screen .................. 82
Dranng gear o, ceanng gear o screen ................... 82
Fng up wLh gear o .............................................. 83
Addng gear o ......................................................... 83
TR0UBLESH00TIN0......................................................... 85
0LEANIN0........................................................................ 87
0eanng moLorcyce ...................................................... 87
ST0RA0E......................................................................... 88
SLorage......................................................................... 88
PuLLng nLo operaLon afLer sLorage ................................. 88
TE0HNI0AL DATA - EN0INE.............................................. 89
0apacLy- engne o ....................................................... 89
0apacLy - gear o.......................................................... 90
0apacLy - cooanL.......................................................... 90
TE0HNI0AL DATA - EN0INE TI0HTENIN0 T0R0UES.......... 9T
TE0HNI0AL DATA - 0ARBURET0R..................................... 93
400 EX0....................................................................... 93
400 X0-w USA ............................................................. 93
450 EX0, 450 EX0 SIX DAYS......................................... 93
450 X0-w..................................................................... 94
530 EX0, 530 EX0 SIX DAYS......................................... 94
530 X0-w..................................................................... 94
TE0HNI0AL DATA - 0HASSIS ............................................ 95
LghLng equpmenL ....................................................... 95
Tres ............................................................................ 96
0apacLy - fue............................................................... 96
TE0HNI0AL DATA - F0RK.................................................. 97
TE0HNI0AL DATA - SH00K ABS0RBER ............................. 98
TE0HNI0AL DATA - 0HASSIS TI0HTENIN0 T0R0UES ........ 99
wIRIN0 DIA0RAM .......................................................... T00
wrng dagram (a EX0 modes) ................................... T00
wrng dagram (a X0-w modes) ................................. T04
SUBSTAN0ES................................................................. T06
AUXILIARY SUBSTAN0ES................................................ T07
STANDARDS................................................................... T09
INDEX............................................................................ TT0
MAh8 0F kFk8hTATI0h 4
1MEANS OF REPRESENTATlON
8yboIs used
The symbos used are expaned n Lhe foowng.
IndcaLes an expecLed reacLon (e.g. of a work sLep or a funcLon).
IndcaLes an unexpecLed reacLon (e.g. of a work sLep or a funcLon).
A work marked wLh Lhs symbo requres specasL knowedge and Lechnca undersLandng. In Lhe nLeresL of
your own safeLy, have Lhese |obs done n an auLhorzed KTM workshop! There, your moLorcyce w be servced
opLmay by specay Lraned experLs usng Lhe specasL Loos requred.
IdenLfes a page reference (more nformaLon s provded on Lhe specfed page).
Forats used
The Lypographca and oLher formaLs used are expaned n Lhe foowng.
8pecific nae IdenLfes a specfc name.
hae
IdenLfes a proLecLed name.

8rand IdenLfes a brand n merchandse Lraffc.
IMF0kTAhT h0T8 5
2lMPORTANT NOTES
se definition (aII X0 odeIs)
KTM sporL moLorcyces are desgned and buL Lo wLhsLand Lhe norma sLresses and sLrans of compeLLve use. The moLorcyces com-
py wLh currenLy vad reguaLons and caLegores of Lhe Lop nLernaLona moLorsporL organzaLons.
Info
The moLorcyce s auLhorzed for pubc road Lraffc n Lhe homoogous (reduced) verson ony.
In Lhe deresLrcLed verson, Lhe moLorcyce musL be used ony on secuded properLy remoLe from pubc road Lraffc.
The moLorcyce s desgned for off-road sporL endurance compeLLon (Enduro) and noL for Lhe predomnanL moLocross use.
se definition (aII X0-W odeIs)
KTM sporL moLorcyces are desgned and buL Lo wLhsLand Lhe norma sLresses and sLrans of compeLLve use. The moLorcyces com-
py wLh currenLy vad reguaLons and caLegores of Lhe Lop nLernaLona moLorsporL organzaLons.
Info
The moLorcyce musL be used ony on secuded properLy remoLe from pubc road Lraffc.
The moLorcyce s desgned for off-road sporL endurance compeLLon (Enduro) and noL for Lhe predomnanL moLocross use.
Maintenance
A prerequsLe for perfecL operaLon and prevenLon of wear s LhaL Lhe engne and chasss manLenance and ad|usLmenL work descrbed
n Lhe owner's manua are propery carred ouL. Poor ad|usLmenL and Lunng of Lhe engne and chasss can ead Lo damage and break-
age of componenLs.
Usng Lhe moLorcyce n exLreme condLons such as very muddy or weL Lerran can ead Lo above-average wear of componenLs such as
Lhe Lransmsson Lran or Lhe brakes. For Lhs reason, L may be necessary Lo servce or repace worn parLs before Lhe mL specfed n
Lhe servce schedue s reached.
Pay carefu aLLenLon Lo Lhe prescrbed runnng-n perod, nspecLon and manLenance nLervas. If you observe Lhese exacLy, you w
ensure a much onger servce fe for your moLorcyce.
Warranty
The work prescrbed n Lhe servce schedue musL be carred ouL n an auLhorzed KTM workshop and confrmed n Lhe cusLomer's ser-
vce record, snce oLherwse no warranLy cams w be recognzed. No warranLy cams can be consdered for damage resuLng from
manpuaLons and/or aLeraLons Lo Lhe vehce.
FueI, oiIs, etc.
You shoud use Lhe fues, os and greases accordng Lo specfcaLons as sLed n Lhe owner's manua.
8pare parts, accessories
For your own safeLy, ony use spare parLs and accessory producLs LhaL are approved and/or recommended by KTM and have Lhem
nsLaed by an auLhorzed KTM workshop. KTM accepLs no abLy for oLher producLs and any resuLng damage or oss.
The currenL kTM FowerFarts for your vehce can be found on Lhe KTM websLe.
InLernaLona KTM websLe. hLLp.//www.kLm.com
Work ruIes
when Lhe vehce s assembed, non-reusabe parLs (e.g., sef-ockng screws and nuLs, gaskeLs, sea rngs, 0-rngs, spnLs, ock wash-
ers) musL be repaced wLh new parLs.
where Lhread ockers are used on screw connecLons (e.g., Loctite
), foow Lhe nsLrucLons for use from Lhe manufacLurer.

AfLer dsassemby, cean Lhe parLs LhaL are Lo be reused and check Lhem for damage and wear. Repace damaged or worn parLs.
AfLer you compeLe Lhe repar or manLenance work, check Lhe roadworLhness of Lhe vehce.
Transport
hote
0aner of daae Danger of damage by Lhe vehce runnng away or fang over.
Aways pace Lhe vehce on a frm and even surface.
hote
Fire hazard Some componenLs (engne, radaLor and exhausL sysLem) geL very hoL when Lhe engne s runnng.
Do noL pace Lhe vehce where Lhere are fammabe or exposve subsLances.
swLch off engne.
IMF0kTAhT h0T8 6
Turn hande O of Lhe fue Lap Lo Lhe 0FF posLon. (Fgure 500T37-T0 p. 20)
Use sLraps or oLher suLabe devces Lo secure Lhe moLorcyce agansL accdenLs or fang over.
nvironent
0ffroad moLorcycng s a wonderfu sporL and we naLuray hope LhaL you w be abe Lo en|oy L Lo Lhe fuesL. However, L s a poLen-
La probem for Lhe envronmenL and can ead Lo confcLs wLh oLher persons. BuL f you use your moLorcyce responsby, you can
ensure LhaL such probems and confcLs do noL have Lo occur. To proLecL Lhe fuLure of moLorcyce sporL, make sure LhaL you use your
moLorcyce egay, dspay envronmenLa conscousness, and respecL Lhe rghLs of oLhers.
hotes/warnins
Be sure Lo pay aLLenLon Lo Lhe noLes and warnngs gven here.
Info
\arous noLes and warnng sLckers are aLLached Lo Lhe vehce. Do noL remove any noLes and warnng sLckers. If Lhey are mss-
ng, you or oLhers may noL recognze dangers and may Lherefore be n|ured.
0rades of risks
0aner
Danger LhaL eads mmedaLey and cerLany Lo severe and permanenL n|ury or deaLh.
Warnin
Danger LhaL w probaby ead Lo severe and permanenL n|ury or deaLh.
hote
Danger of serous damage Lo machne or maLera.
Warnin
Rsk of envronmenLa damage.
0Whk'8 MAhAL
IL s mporLanL LhaL you read Lhs owner's manua carefuy and compeLey before makng your frsL Lrp. IL conLans usefu nfor-
maLon and many Lps on how Lo operaLe and hande your moLorcyce. 0ny Lhen w you fnd ouL how Lo besL cusLomze Lhe moLor-
cyce for your own use and how you can proLecL yoursef from n|ury. The owner's manua aso conLans mporLanL nformaLon on
servcng Lhe moLorcyce.
The owner's manua s an mporLanL componenL of Lhe moLorcyce and shoud be handed over Lo Lhe new owner f Lhe vehce s
sod.
VIW 0F VhI0L 7
3VlEW OF VEHlCLE
3.1 View of the vehicIe fro the Ieft front (exapIe)
8000T4-T0
T Sde sLand
2 ShfL ever
3 0han gude
4 Fue Lap
5 Ar fLer box d
6 0uLch ever
7 Hand brake ever
VIW 0F VhI0L 8
3.2 View of the vehicIe fro the riht rear (exapIe)
8000T3-T0
T Leve vewer for brake fud, rear
2 Fork compresson ad|usLmenL
3 FooL brake peda
4 KcksLarLer
5 Horn
6 Fer cap
7 Fork rebound ad|usLmenL
8 EecLrc sLarLer buLLon
9 SpeedomeLer
T0 ShorL crcuL buLLon
TT Shock absorber compresson ad|usLmenL
T2 Shock absorber rebound ad|usLmenL
L00ATI0h 0F 8kIAL hM8k8 9
4LOCATlON OF SERlAL NUMBERS
4.1 0hassis nuber
500T27-T0
The chasss number O s sLamped on Lhe sLeerng head on Lhe rghL.
4.2 Type IabeI
500T28-T0
The Lype abe O s fxed Lo Lhe fronL of Lhe sLeerng head.
4.3 key nuber (aII X0 odeIs)
500T25-T0
The key number O s sLamped on Lhe key sLrap.
4.4 nine nuber
500072-T0
The engne number O s sLamped on Lhe efL sde of Lhe engne under Lhe engne
sprockeL.
4.5 Fork part nuber
500082-T0
The fork parL number O s sLamped on Lhe nner sde of Lhe fork sLub.
L00ATI0h 0F 8kIAL hM8k8 10
4.6 8hock absorber part nuber
500T29-T0
The shock absorber parL number O s sLamped on Lhe Lop of Lhe shock absorber above
Lhe ad|usLng rng on Lhe engne sde.
0FkATIh0 LMhT8 11
5OPERATlNG ELEMENTS
5.1 0Iutch Iever
500T33-T0
The cuLch ever O s fLLed on Lhe efL sde of Lhe handebar.
The cuLch s hydraucay operaLed and sef-ad|usLng.
5.2 hand brake Iever
400T96-T0
Hand brake ever O s ocaLed on Lhe rghL sde of Lhe handebar.
The hand brake ever s used Lo acLvaLe Lhe fronL brake.
5.3 8hort circuit button (aII X0-W odeIs)
500T32-T0
The shorL crcuL buLLon O s fLLed on Lhe efL sde of Lhe handebar.
FossibIe states
ShorL crcuL buLLon n basc posLon In Lhs posLon, Lhe gnLon crcuL s
cosed, and Lhe engne can be sLarLed.
ShorL crcuL buLLon pressed In Lhs posLon, Lhe gnLon crcuL s nLerrupLed,
a runnng engne sLops, and a non-runnng engne w noL sLarL.
5.4 8hort circuit button (aII X0 odeIs)
500T34-T0
The shorL crcuL buLLon O s fLLed on Lhe efL sde of Lhe handebar.
FossibIe states
ShorL crcuL buLLon n basc posLon In Lhs posLon, Lhe gnLon crcuL s
cosed, and Lhe engne can be sLarLed.
ShorL crcuL buLLon pressed In Lhs posLon, Lhe gnLon crcuL s nLerrupLed,
a runnng engne sLops, and a non-runnng engne w noL sLarL.
5.5 erency 0FF switch (X0 A8)
500T3T-T0
The emergency 0FF swLch O s fLLed on Lhe efL sde of Lhe handebar.
FossibIe states
IgnLon off In Lhs posLon, Lhe gnLon crcuL s nLerrupLed, a run-
nng engne sLops, and a non-runnng engne w noL sLarL.
IgnLon on In Lhs posLon, Lhe gnLon crcuL s cosed, and Lhe
engne can be sLarLed.
0FkATIh0 LMhT8 12
5.6 Iectric starter button (X0 , X0 8IX 0AY8, X0-W)
400T98-T0
The eecLrc sLarLer buLLon O s fLLed on Lhe rghL sde of Lhe handebar.
FossibIe states
EecLrc sLarLer buLLon n basc posLon
EecLrc sLarLer buLLon pressed In Lhs posLon, Lhe eecLrc sLarLer s acLuaLed.
5.7 Iectric starter button (X0 A8)
500T3T-TT
The eecLrc sLarLer buLLon O s fLLed on Lhe rghL sde of Lhe handebar.
FossibIe states
EecLrc sLarLer buLLon n basc posLon
EecLrc sLarLer buLLon pressed In Lhs posLon, Lhe eecLrc sLarLer s acLuaLed.
5.8 Liht switch (aII X0 odeIs)
500T34-T2
The ghL swLch O s fLLed on Lhe efL sde of Lhe handebar.
FossibIe states
LghL off LghL swLch s Lurned Lo Lhe rghL. In Lhs posLon, Lhe ghL s
swLched off.
Low beam on LghL swLch s n Lhe cenLra posLon. In Lhs posLon,
Lhe ow beam and La ghL are swLched on.
Hgh beam on LghL swLch s Lurned Lo Lhe efL. In Lhs posLon, Lhe
hgh beam and Lhe La ghL are swLched on.
5.9 Liht switch (aII X0-W odeIs)
500T46-T0
The ghL swLch O s on Lhe rghL of Lhe speedomeLer.
FossibIe states
(X0-W ZA)
LghL off LghL swLch s pressed n up Lo Lhe sLop. In Lhs posLon, Lhe ghL
s swLched off.
LghL on LghL swLch s pued ouL Lo Lhe sLop. In Lhs posLon, Lhe ow beam
and Lhe La ghL are swLched on.
(X0-W 8A)
The ghL swLch has no funcLon when devered. IL can be used f ghLng s
fLLed aLer.
5.10 horn button (aII X0 odeIs)
500T34-TT
The horn buLLon O s fLLed on Lhe efL sde of Lhe handebar.
FossibIe states
Horn buLLon n neuLra posLon
Horn buLLon pressed The horn s operaLed n Lhs posLon.
0FkATIh0 LMhT8 13
5.11 FIasher switch (aII X0 odeIs)
500T45-T0
Fasher swLch O s fLLed on Lhe efL sde of Lhe handebar.
FossibIe states
Fasher ghL off Fasher swLch s n Lhe cenLra posLon.
Fasher ghL, efL, on Fasher swLch Lurned Lo Lhe efL.
Fasher ghL, rghL, on Fasher swLch Lurned Lo Lhe rghL.
5.12 0verview of indicator Iaps (aII X0 odeIs)
500T47-0T
FossibIe states
Hgh beam ndcaLor amp ghLs up bue Hgh beam s swLched on.
Fasher ndcaLor amp fashes green Fasher ghL s swLched on.
5.13 8peedoeter
4003T2-0T
Press Lhe key Lo change Lhe dspay mode or change Lo one of Lhe seLup menus.
Press Lhe buLLon Lo conLro dfferenL funcLons.
Press Lhe buLLon Lo conLro dfferenL funcLons.
Info
In Ls condLon aL devery, Lhe dspay mode 8F0/h and8F0/000 s acL-
vaLed.
5.14 8peedoeter activation and test
4003T3-0T
AcLvaLng Lhe speedomeLer.
The speedomeLer s acLvaLed when one of Lhe keys s pressed or an mpuse comes
from Lhe whee speed sensor.
Dspay LesL
For Lhe funcLon LesL of Lhe dspay, a dspay segmenLs ghL up brefy.
4003T4-0T
W8 (whee sze)
AfLer Lhe dspay funcLon LesL, Lhe whee sze W8 s dspayed brefy.
Info
2205 mm corresponds Lo Lhe sze of Lhe 2T" fronL whee wLh a seres produc-
Lon Lre.
The dspay Lhen changes Lo Lhe asL seecLed mode.
0FkATIh0 LMhT8 14
5.15 Tripaster switch
(0ption: Tripaster switch)
You can use Lhe Lrp masLer swLch Lo conLro Lhe funcLons of Lhe speedomeLer from Lhe handebar.
Info
The Lrp masLer s an opLona accessory.
5.16 8ettin kiIoeters or iIes
Info
If you change Lhe unL, Lhe vaue 000 s reLaned and converLed accordngy.
The vaues Tk1, Tk2, A1, A2 and 81 are ceared when Lhe unL of measure s changed.
0ondition
The moLorcyce s sLandng.
400329-0T
Press Lhe buLLon brefy and repeaLedy unL h appears aL Lhe boLLom rghL of Lhe
dspay.
Press Lhe buLLon for 3 - 5 seconds.
The SeLup menu opens and Lhe acLve funcLons are dspayed.
Press Lhe buLLon repeaLedy unL Lhe k/h/Mph dspay fashes.
k/hadjustin
Press Lhe buLLon .
Mphadjustin
Press Lhe buLLon .
The seLLngs are saved and Lhe SeLup menu cosed.
Info
If no buLLon s pressed for 20 seconds, or f no mpuse comes from Lhe
whee speed sensor, Lhe seLLngs are auLomaLcay saved and Lhe SeLup
menu cosed.
5.17 8ettin the cIock
0ondition
400330-0T
Press Lhe buLLon brefy and repeaLedy unL 0Lk appears aL Lhe boLLom rghL of
Lhe dspay.
The hour dspay fashes.
SeL Lhe hour dspay wLh Lhe buLLon and/or buLLon .
Press Lhe buLLon brefy.
The nexL segmenL of Lhe dspay fashes and can be seL.
You can seL Lhe foowng segmenLs n Lhe same way as Lhe hours by pressng
Lhe buLLon and Lhe buLLon .
Info
The seconds can ony be seL Lo zero.
Info
menu cosed.
0FkATIh0 LMhT8 15
5.18 Adjustin the speedoeter functions
Info
Upon devery, ony Lhe 8F0/h and 8F0/000 dspay modes are acLvaLed.
0ondition
4003T8-0T
dspay.
The SeLup menu opens and Lhe acLve funcLons are dspayed.
SwLch Lo Lhe funcLon you requre by brefy pressng Lhe buLLon .
The seecLed funcLon fashes.
Activatin a function
Press Lhe buLLon .
The con remans n Lhe dspay and Lhe dspay changes Lo Lhe nexL func-
Lon.
0eactivatin a function
Press Lhe buLLon .
The con dsappears from Lhe dspay and Lhe dspay changes Lo Lhe nexL
funcLon.
AcLvaLe or deacLvaLe a funcLons accordngy.
Info
menu s cosed.
5.19 0ueryin the Iap tie
Info
Ths funcLon can be caed ony f ap Lmes are measured.
0ondition
40032T-0T
Press Lhe buLLon brefy and repeaLedy unL LAF appears aL Lhe boLLom rghL of
Lhe dspay.
LAF 1 appears on Lhe efL sde of Lhe dspay.
Laps T-T0 can be dspayed by pressng Lhe buLLon .
The buLLon has no funcLon
NexL dspay mode
Info
If an mpuse s receved from Lhe whee speed sensor, Lhe efL sde of Lhe
dspay changes back Lo Lhe 8F0 mode.
0FkATIh0 LMhT8 16
5.20 8F0 dispIay ode (speed)
4003T7-02
Press Lhe buLLon brefy and repeaLedy unL 8F0 appears on Lhe efL sde of
Lhe dspay.
The currenL speed s dspayed n Lhe 8F0 dspay mode.
The currenL speed can be dspayed n k/h or Mph.
Info
Makng Lhe seLLng accordng Lo Lhe counLry.
when an mpuse comes from Lhe fronL whee, Lhe efL sde of Lhe speedomeLer
dspay changes Lo Lhe 8F0 mode and Lhe currenL speed s shown.
5.21 8F0/h dispIay ode (service hours)
4003T6-0T
0ondition
\ehce aL a sLandsL
dspay.
The number of servce hours of Lhe engne s shown n Lhe h dspay mode.
The servce hour counLer sLores Lhe LoLa Lraveng Lme.
Info
The servce hour counLer s necessary for ensurng LhaL manLenance work s car-
red ouL aL Lhe rghL nLervas.
If Lhe speedomeLer s n Lhe h dspay mode aL Lhe sLarL of Lhe Lrp, L auLomaL-
cay changes Lo Lhe 000 dspay mode.
The h dspay mode s suppressed durng Lrave.
Press Lhe buLLon . No funcLon
Press Lhe buLLon
for 3 - 5 seconds.
The dspay changes Lo Lhe SeLup menu of Lhe speedomeLer
funcLons.
Press Lhe buLLon
brefy.
nexL dspay mode
5.22 8F0/0Lk dispIay ode (tie)
4003T9-0T
Press Lhe buLLon brefy and repeaLedy unL 0Lk appears aL Lhe boLLom rghL of
Lhe dspay.
The Lme s dspayed n Lhe 0Lk dspay mode.
Press Lhe buLLon
for 3 - 5 seconds.
The dspay changes Lo Lhe SeLup menu of Lhe cock.
Press Lhe buLLon
brefy.
nexL dspay mode
5.23 8F0/LAF dispIay ode (Iap tie)
400320-0T
Press Lhe buLLon brefy and repeaLedy unL LAF appears aL Lhe boLLom rghL of
Lhe dspay.
In Lhe LAF dspay mode, up Lo Len aps can be Lmed wLh Lhe sLop waLch.
Info
If Lhe ap Lme conLnues afLer you press Lhe buLLon , 9 memory ocaLons are
aready occuped.
Lap T0 musL be Lmed wLh Lhe buLLon .
Press Lhe buLLon . SLarLs or sLops Lhe cock.
Press Lhe buLLon . SLops Lhe currenL ap Lme and saves L, and Lhe sLop waLch
sLarLs Lhe nexL ap.
Press Lhe buLLon
for 3 - 5 seconds.
The sLop waLch and Lhe ap Lme are reseL.
0FkATIh0 LMhT8 17
Press Lhe buLLon
brefy.
nexL dspay mode
5.24 8F0/000 dispIay ode (odoeter)
4003T7-0T
Press Lhe buLLon brefy and repeaLedy unL 000 appears aL Lhe boLLom rghL of
Lhe dspay.
The LoLa number of komeLers rdden s shown n Lhe 000 dspay mode.
Press Lhe buLLon
for 3 - 5 seconds.
Press Lhe buLLon

brefy.
nexL dspay mode
5.25 8F0/Tk1 dispIay ode (trip aster 1)
400323-0T
Press Lhe buLLon brefy and repeaLedy unL Tk1 appears aL Lhe Lop rghL of Lhe
dspay.
Tk1 (Lrp masLer T) runs consLanLy and counLs Lo 999.9.
You can use L Lo measure Lrps or Lhe dsLance beLween refueng sLops.
Tk1 s couped wLh A1 (average speed T) and 81 (sLop waLch T).
Info
If 999.9 s exceeded, Lhe vaues of Tk1, A1 and 81 are auLomaLcay reseL Lo
0.0.
Press Lhe buLLon
for 3 - 5 seconds.
The Tk1, A1 and 81 dspays are reseL Lo 0.0.
Press Lhe buLLon
brefy.
nexL dspay mode
5.26 8F0/Tk2 dispIay ode (trip aster 2)
400324-0T
Press Lhe buLLon brefy and repeaLedy unL Tk2 appears aL Lhe Lop rghL of Lhe
dspay.
Tk2 (Lrp masLer 2) runs consLanLy and counLs Lo 999.9.
The dspayed vaue can be seL manuay wLh Lhe buLLon and Lhe buLLon . A very
pracLca funcLon for rdes by Lhe road book.
Info
The Tk2 vaue can aso be correcLed manuay durng Lhe Lrp usng Lhe buL-
Lon and Lhe buLLon .
If 999.9 s exceeded, Tk2 s auLomaLcay reseL Lo 0.0.
Press Lhe buLLon . Increases vaue Tk2.
Press Lhe buLLon . Decreases vaue Tk2.
Press Lhe buLLon
for 3 - 5 seconds.
0ears vaue Tk2.
Press Lhe buLLon
brefy.
nexL dspay mode
0FkATIh0 LMhT8 18
5.27 8F0/A1 dispIay ode (averae speed 1)
400325-0T
Press Lhe buLLon brefy and repeaLedy unL A1 appears aL Lhe Lop rghL of Lhe
dspay.
A1 (average speed T) shows Lhe average speed cacuaLed on Lhe bass of Tk1 (Lrp mas-
Ler T) and 81 (sLop waLch T).
The cacuaLon of Lhs vaue s acLvaLed by Lhe frsL mpuse of Lhe whee speed sensor
and ends 3 seconds afLer Lhe asL mpuse.
Press Lhe buLLon
for 3 - 5 seconds.
Press Lhe buLLon
brefy.
nexL dspay mode
5.28 8F0/A2 dispIay ode (averae speed 2)
400326-0T
Press Lhe buLLon brefy and repeaLedy unL A2 appears aL Lhe Lop rghL of Lhe
dspay.
A2 (average speed 2) shows Lhe average speed on Lhe bass of Lhe currenL speed f Lhe
sLop waLch 82 (sLop waLch 2) s runnng.
Info
The dspayed vaue can dffer from Lhe acLua average speed f 82 s noL
sLopped afLer Lhe rde.
Press Lhe buLLon
for 3 - 5 seconds.
Press Lhe buLLon

brefy.
nexL dspay mode
5.29 8F0/81 dispIay ode (stop watch 1)
400327-0T
Press Lhe buLLon brefy and repeaLedy unL 81 appears aL Lhe Lop rghL of Lhe
dspay.
81 (sLop waLch T) shows Lhe Lrp Lme on Lhe bass of Tk1 and conLnues runnng when
an mpuse s receved from Lhe whee speed sensor.
The cacuaLon of Lhs vaue sLarLs wLh Lhe frsL mpuse of Lhe whee speed sensor and
ends Lhree seconds afLer Lhe asL mpuse.
Press Lhe buLLon
for 3 - 5 seconds.
Press Lhe buLLon
brefy.
nexL dspay mode
5.30 8F0/82 dispIay ode (stop watch 2)
400328-0T
Press Lhe buLLon brefy and repeaLedy unL 82 appears aL Lhe Lop rghL of Lhe
dspay.
82 (sLop waLch 2) s a manua sLop waLch.
If 82 s runnng n Lhe background, Lhe 82 dspay fashes n Lhe speedomeLer dspay.
Press Lhe buLLon . SLarLs or sLops 82.
Press Lhe buLLon
for 3 - 5 seconds.
The 82 and A2 dspays are reseL Lo 0.0.
Press Lhe buLLon
brefy.
nexL dspay mode
0FkATIh0 LMhT8 19
TabIe of functions
0ispIay Fress the button . Fress the button . Fress the button for 3 -
5 seconds.
Fress the button
briefIy.
8F0/h dspay mode
(servce hours)
No funcLon No funcLon The dspay changes Lo
Lhe SeLup menu of Lhe
speedomeLer funcLons.
nexL dspay mode
8F0/0Lk dspay mode
(Lme)
No funcLon No funcLon The dspay changes Lo
Lhe SeLup menu of Lhe
cock.
nexL dspay mode
8F0/LAF dspay mode
(ap Lme)
SLarLs or sLops Lhe
cock.
SLops Lhe currenL ap
Lme and saves L, and
Lhe sLop waLch sLarLs
Lhe nexL ap.
The sLop waLch and Lhe
ap Lme are reseL.
nexL dspay mode
8F0/000 dspay mode
(odomeLer)
No funcLon No funcLon nexL dspay mode
8F0/Tk1 dspay mode
(Lrp masLer T)
No funcLon No funcLon The Tk1, A1 and 81 ds-
pays are reseL Lo 0.0.
nexL dspay mode
8F0/Tk2 dspay mode
(Lrp masLer 2)
Increases vaue Tk2. Decreases vaue Tk2. 0ears vaue Tk2. nexL dspay mode
8F0/A1 dspay mode
(average speed T)
nexL dspay mode
8F0/A2 dspay mode
(average speed 2)
No funcLon No funcLon nexL dspay mode
8F0/81 dspay mode
(sLop waLch T)
nexL dspay mode
8F0/82 dspay mode
(sLop waLch 2)
SLarLs or sLops 82. No funcLon The 82 and A2 dspays
are reseL Lo 0.0.
nexL dspay mode
TabIe of conditions and activabiIity
0ispIay VehicIe at a stand-
stiII
Menu can be acti-
vated
8F0/h dspay mode (servce hours)
8F0/0Lk dspay mode (Lme)
8F0/LAF dspay mode (ap Lme)
8F0/Tk1 dspay mode (Lrp masLer T)
8F0/Tk2 dspay mode (Lrp masLer 2)
8F0/A1 dspay mode (average speed T)
8F0/A2 dspay mode (average speed 2)
8F0/81 dspay mode (sLop waLch T)
8F0/82 dspay mode (sLop waLch 2)
0FkATIh0 LMhT8 20
5.31 FueI tap
500T37-T0
The fue Lap s on Lhe efL of Lhe fue Lank.
wLh Lhe Lap hande O on Lhe fue Lap, you can open or cose Lhe suppy of fue Lo Lhe
carbureLor.
FossibIe states
Fue suppy cosed 0FF No fue can fow from Lhe Lank Lo Lhe carbureLor.
Fue suppy open 0h Fue can fow from Lhe Lank Lo Lhe carbureLor. The fue Lank
empLes down Lo Lhe reserve.
Reserve fue suppy open k8 Fue can fow from Lhe Lank Lo Lhe carbureLor. The
fue Lank empLes compeLey.
5.32 0penin fiIIer cap
400T99-T0
Press reease buLLon O, Lurn fer cap counLercockwse and fL L free.
5.33 0Iosin fiIIer cap
400T99-TT
Repace Lhe fer cap and Lurn cockwse unL Lhe reease buLLon O ocks n pace.
Info
Run Lhe fue Lank breaLher hose O wLhouL knks.
5.34 0hoke (X0 A8, X0-W)
500T35-T0
0hoke O s fLLed on Lhe efL sde of Lhe carbureLor.
AcLvaLng Lhe choke funcLon frees an openng Lhrough whch Lhe engne can draw
exLra fue. Ths gves a rcher fue-ar mxLure, whch s needed for a cod sLarL.
Info
If Lhe engne s warm, Lhe choke funcLon musL be deacLvaLed.
FossibIe states
0hoke funcLon acLvaLed The choke ever s pued ouL Lo Lhe sLop.
0hoke funcLon deacLvaLed The choke ever s pushed n Lo Lhe sLop.
0FkATIh0 LMhT8 21
5.35 0hoke (X0 , X0 8IX 0AY8)
500T36-T0
The fasher swLch O s fLLed on Lhe efL sde of Lhe handebar.
AcLvaLng Lhe choke funcLon frees an openng Lhrough whch Lhe engne can draw
exLra fue. Ths gves a rcher fue-ar mxLure, whch s needed for a cod sLarL.
Info
If Lhe engne s warm, Lhe choke funcLon musL be deacLvaLed.
FossibIe states
0hoke funcLon acLvaLed The choke ever s pued Lo Lhe sLop.
0hoke funcLon deacLvaLed The choke ever s pushed back Lo Lhe sLop.
5.36 8hift Iever
500T38-T0
ShfL ever O s mounLed on Lhe efL sde of Lhe engne.
500T38-TT
The gear posLons can be seen n Lhe phoLograph.
The neuLra or de posLon s beLween Lhe frsL and second gears.
5.37 Foot brake pedaI
500T39-T0
FooL brake peda O s ocaLed n fronL of Lhe rghL fooLresL.
The fooL brake peda s used Lo acLvaLe Lhe rear brake.
5.38 kickstarter
500T48-T0
KcksLarLer O s fLLed on Lhe rghL of Lhe engne.
The engne can be sLarLed wLh eLher Lhe kcksLarLer or Lhe eecLrc sLarLer.
The upper parL of Lhe kcksLarLer can be swung ouL.
Info
Before rdng, swng Lhe upper parL of Lhe kcksLarLer nward Loward Lhe engne.
0FkATIh0 LMhT8 22
5.39 8ide stand
500T40-T0
hote
hote
MateriaI daae Damage and desLrucLon of componenLs by excessve oad.
The sde sLand s desgned for Lhe weghL of Lhe moLorcyce ony. Do noL sL on Lhe
moLorcyce when L s supporLed by Lhe sde sLand ony. The sde sLand and/or Lhe
frame coud be damaged and Lhe moLorcyce coud fa over.
To park Lhe moLorcyce, press Lhe sde sLand O wLh your fooL Lo Lhe ground and ean
Lhe moLorcyce on L.
500T4T-T0
when you are rdng, Lhe sde sLand O musL be foded up and secured wLh Lhe rubber
band O.
5.40 8teerin Iock (aII X0 odeIs)
500T26-T0
SLeerng ock O s fLLed on Lhe efL sde of Lhe sLeerng head.
The sLeerng ock s used Lo ock Lhe sLeerng. SLeerng, and Lherefore rdng, s no
onger possbe.
5.41 Lockin the steerin (aII X0 odeIs)
hote
Park Lhe moLorcyce.
Turn Lhe handebar as far as possbe Lo Lhe rghL.
InserL Lhe key n Lhe sLeerng ock, Lurn L Lo Lhe efL, press L n and Lurn L Lo Lhe rghL. Remove Lhe key.
SLeerng s no onger possbe.
Info
Never eave Lhe key n Lhe sLeerng ock.
0FkATIh0 LMhT8 23
5.42 nIockin the steerin (aII X0 odeIs)
InserL Lhe key n Lhe sLeerng ock, Lurn L Lo Lhe efL, pu L ouL and Lurn L Lo Lhe rghL. Remove Lhe key.
You can now sLeer Lhe bke agan.
Info
Never eave Lhe key n Lhe sLeerng ock.
0hkAL TIF8 Ah0 hIhT8 0h FTTIh0 IhT0 0FkATI0h 24
6GENERAL TlPS AND HlNTS ON PUTTlNG lNTO OPERATlON
6.1 Advice on first use
0aner
0aner of accidents Danger from nsuffcenL Lraffc compeLence.
Do noL use Lhe vehce f you are noL fL Lo dea wLh Lraffc or f you have consumed acoho and/or medcamenLs or drugs.
Warnin
kisk of injury Rsk of n|ury by mssng/nadequaLe proLecLve coLhng.
wear proLecLve coLhng (hemeL, booLs, goves, panLs and |ackeL wLh proLecLors) every Lme you rde Lhe vehce. Aways
wear proLecLve coLhng, whch musL be n perfecL condLon and meeL ega requremenLs.
Warnin
0aner of crashin ImparmenL of rdng behavor due Lo dfferenL Lre Lread paLLerns on fronL and rear whees.
The fronL and rear whees musL be fLLed wLh Lres wLh smar Lread paLLerns Lo prevenL oss of conLro over Lhe vehce.
Warnin
0aner of accidents 0rLca rdng behavor due Lo nappropraLe rdng.
AdapL your rdng speed Lo Lhe road condLons and your rdng abLy.
Warnin
0aner of accidents AccdenL rsk caused by presence of a passenger.
Your vehce s noL desgned Lo carry passengers. Do noL rde wLh a passenger.
Warnin
0aner of accidents Brake sysLem faure.
If Lhe fooL brake peda s noL reeased, Lhe brake nngs drag permanenLy. The rear brake can fa due Lo overheaLng. Take
your fooL off Lhe fooL brake peda f you do noL wanL Lo brake.
Warnin
0aner of accidents UnsLabe rdng behavor.
Do noL exceed Lhe maxmum permLLed weghL and axe oads.
Warnin
kisk of isappropriation Usage by unauLhorzed persons.
Never eave Lhe vehce whe Lhe engne s runnng. Secure Lhe vehce agansL use by unauLhorzed persons.
Info
when usng your moLorcyce, remember LhaL oLhers may fee dsLurbed by excessve nose.
Make sure LhaL Lhe pre-devery nspecLon work has been carred ouL by an auLhorzed KTM workshop.
You receve a devery cerLfcaLe and Lhe servce record aL vehce handover.
Before your frsL Lrp, read Lhe enLre operaLng nsLrucLons carefuy.
0eL Lo know Lhe conLros.
Ad|usL Lhe basc posLon of cuLch ever. ( p. 76)
(aII X0-W odeIs)
ad|usL Lhe basc posLon of handbrake ever. ( p. 56)
(aII X0 odeIs)
Ad|usL Lhe free Lrave of Lhe handbrake ever. ( p. 57)
Ad|usL Lhe basc posLon of Lhe fooLbrake ever. ( p. 60)
0eL used Lo handng Lhe moLorcyce on a suLabe pece of and before makng a onger Lrp.
Info
0ffroad, you shoud be accompaned by anoLher person on anoLher machne so LhaL you can hep each oLher.
Try aso Lo rde as sowy as possbe and n a sLandng posLon Lo geL a beLLer feeng for Lhe vehce.
Do noL make any offroad Lrps LhaL over-sLress your abLy and experence.
Hod Lhe handebar frmy wLh boLh hands and keep your feeL on Lhe fooLresLs when rdng.
0hkAL TIF8 Ah0 hIhT8 0h FTTIh0 IhT0 0FkATI0h 25
If you carry any baggage, make sure L s fxed frmy as cose as possbe Lo Lhe cenLer of Lhe vehce and ensure even weghL ds-
LrbuLon beLween Lhe fronL and rear whees.
Info
MoLorcyces reacL sensLvey Lo any changes of weghL dsLrbuLon.
Do noL exceed Lhe overa maxmum permLLed weghL and Lhe axe oads.
0udene
Maxmum permssbe overa weghL 335 kg (739 b.)
Maxmum permssbe fronL axe oad T45 kg (320 b.)
Maxmum permssbe rear axe oad T90 kg (4T9 b.)
Run Lhe engne n.
6.2 kunnin in the enine
Durng Lhe runnng-n phase, do noL exceed Lhe specfed engne speed and engne performance.
0udene
Maxmum engne speed
Durng Lhe frsL 3 servce hours 7,000 rpm
Maxmum engne performance durng Lhe runnng-n perod
Durng Lhe frsL 3 servce hours > 50 %
Durng Lhe nexL T2 servce hours > 75 %
Avod fuy openng Lhe LhroLLe!
kI0Ih0 Ih8Tk0TI0h8 26
7RlDlNG lNSTRUCTlONS
7.1 0hecks before puttin into operation
Info
Make sure LhaL Lhe moLorcyce s n a perfecL Lechnca condLon before use.
Info
In Lhe nLeresLs of rdng safeLy, make a habL of makng a genera check before you rde.
0heck Lhe engne o eve. ( p. 79)
0heck Lhe chan Lenson. ( p. 52)
0heck for chan drL accumuaLon. ( p. 5T)
0heck Lhe Lre condLon. ( p. 66)
0heck Lhe Lre ar pressure. ( p. 67)
0heck Lhe fronL brake fud eve. ( p. 57)
0heck Lhe rear brake fud eve. ( p. 6T)
0heck Lhe fronL brake nngs. ( p. 58)
0heck Lhe rear brake nngs. ( p. 62)
0heck brake sysLem funcLon.
0heck Lhe cooanL eve. ( p. 72)
0heck LhaL a operaLng eemenLs are correcLy ad|usLed and free Lo move.
0heck Lhe funcLonng of Lhe eecLrca equpmenL.
7.2 8tartin
0aner
0aner of poisonin ExhausL gases are posonous and can resuL n unconscousness and/or deaLh.
when runnng Lhe engne, aways make sure Lhere s suffcenL venLaLon, and do noL sLarL or run Lhe engne n a cosed
space.
hote
nine faiIure Hgh engne speeds n cod engnes have a negaLve effecL on Lhe servce fe of Lhe engne.
Aways warm up Lhe engne aL ow engne speeds.
Info
If Lhe moLorcyce s unwng Lo sLarL, Lhe cause can be od fue n Lhe foaL chamber. The fammabe eemenLs of Lhe fue
evaporaLe afLer a ong Lme of sLandng.
If Lhe foaL chamber s fed wLh fresh fue, Lhe engne sLarLs mmedaLey.
Press Lhe sLarLer for a maxmum of 5 seconds. waL for a easL 5 seconds unL Lryng agan.
MotorcycIe has been out of use for ore than 1 week
EmpLy Lhe carbureLor foaL chamber. ( p. 79)
Turn hande O of Lhe fue Lap Lo Lhe 0h posLon. (Fgure 500T37-T0 p. 20)
Fue can fow from Lhe fue Lank Lo Lhe carbureLor.
Remove Lhe moLorcyce from Lhe sLand.
ShfL gear Lo neuLra.
(X0 A8)
Turn Lhe emergency 0FF swLch Lo Lhe posLon .
nine coId
(X0 A8, X0-W)
Pu Lhe choke ever ouL as far as possbe.
(X0 , X0 8IX 0AY8)
Pu Lhe choke ever Lo Lhe sLop.
Press Lhe eecLrc sLarLer buLLon or press Lhe kcksLarLer robusLy Lhrough Ls fu range.
Info
Don'L open Lhe LhroLLe.
7.3 8tartin up
Info
If your bke has ghLs, swLch Lhem on before rdng. You w Lhen be seen earer by oLher moLorsLs.
when you are rdng, Lhe sde sLand musL be foded up and secured wLh Lhe rubber band.
Pu Lhe cuLch ever, engage TsL gear, reease Lhe cuLch ever sowy and smuLaneousy open Lhe LhroLLe carefuy.
7.4 8hiftin, ridin
Warnin
0aner of accidents If you change down aL hgh engne speed, Lhe rear whee can ock up.
Do noL change nLo a ow gear aL hgh engne speed. The engne races and Lhe rear whee can bock.
Info
If you hear unusua noses whe rdng, sLop mmedaLey, swLch off Lhe engne and conLacL an auLhorzed KTM workshop.
FrsL gear s used for sLarLng off or for sLeep ncnes.
when condLons aow (ncne, road sLuaLon, eLc.), you can shfL nLo a hgher gear. To do so, reease Lhe LhroLLe whe smuLa-
neousy pung Lhe cuLch ever, shfL nLo Lhe nexL gear, reease Lhe cuLch and open Lhe LhroLLe.
If Lhe choke funcLon was acLvaLed, deacLvaLe L afLer Lhe engne has warmed up.
when you reach maxmum speed afLer fuy openng Lhe LhroLLe, Lurn back Lhe LhroLLe Lo abouL of Ls range, Lhe speed hardy
drops, buL Lhe fue consumpLon fas consderaby.
Aways open Lhe LhroLLe ony as much as Lhe engne can hande abrupL LhroLLe openng ncreases fue consumpLon.
To shfL down, brake and cose Lhe LhroLLe aL Lhe same Lme.
Pu Lhe cuLch ever and shfL nLo a ower gear, reease Lhe cuLch ever sowy and open Lhe LhroLLe or shfL agan.
SwLch off Lhe engne f you expecL Lo be sLandng for a ong Lme.
0udene
< 2 mn
Avod frequenL and onger sppng of Lhe cuLch. Ths heaLs Lhe engne o, Lhe engne and Lhe coong sysLem.
Rde wLh a ower engne speed nsLead of wLh a hgh engne speed and a sppng cuLch.
7.5 8rakin
Warnin
0aner of accidents If you brake Loo hard, Lhe whees can ock.
AdapL your brakng Lo Lhe Lraffc sLuaLon and Lhe road condLons.
Warnin
0aner of accidents Reduced brakng caused by spongy pressure ponL of fronL or rear brake.
Have Lhe brake sysLem checked n an auLhorzed KTM workshop, and do noL rde any furLher.
Warnin
0aner of accidents Reduced brakng due Lo weL or drLy brakes.
0ean or dry drLy or weL brakes by rdng and brakng genLy.
0n sandy, weL or sppery surfaces, use Lhe rear brake.
Brakng shoud aways be compeLed before you go nLo a bend. 0hange down Lo a ower gear appropraLe Lo your road speed.
0n ong downh sLreLches, use Lhe brakng effecL of Lhe engne. 0hange down one or Lwo gears, buL do noL oversLress Lhe engne.
In Lhs way, you have Lo brake far ess and Lhe brakes do noL overheaL.
7.6 8toppin, parkin
Warnin
kisk of isappropriation Usage by unauLhorzed persons.
Never eave Lhe vehce whe Lhe engne s runnng. Secure Lhe vehce agansL use by unauLhorzed persons.
Warnin
0aner of burns Some vehce componenLs geL very hoL when Lhe machne s drven.
Do noL Louch hoL componenLs such as exhausL sysLem, radaLor, engne, shock absorber and brakes. Aow Lhese compo-
nenLs Lo coo down before sLarLng work on Lhem.
hote
hote
Fire hazard Some componenLs (engne, radaLor and exhausL sysLem) geL very hoL when Lhe engne s runnng.
Do noL pace Lhe vehce where Lhere are fammabe or exposve subsLances.
hote
MateriaI daae Damage and desLrucLon of componenLs by excessve oad.
The sde sLand s desgned for Lhe weghL of Lhe moLorcyce ony. Do noL sL on Lhe moLorcyce when L s supporLed by Lhe sde
sLand ony. The sde sLand and/or Lhe frame coud be damaged and Lhe moLorcyce coud fa over.
Brake Lhe moLorcyce.
(aII X0-W odeIs)
Press and hod Lhe shorL crcuL buLLon whe Lhe engne s dng unL Lhe engne sLops.
(aII X0 odeIs)
Press and hod Lhe shorL crcuL buLLon whe Lhe engne s dng unL Lhe engne sLops.
Park Lhe moLorcyce on frm ground.
7.7 kefueIin
0aner
Fire hazard Fue can easy caLch fre.
Never f up Lhe vehce near open fames or burnng cgareLLes, and aways swLch off Lhe engne frsL. Be carefu LhaL no
fue s spL, especay on hoL vehce componenLs. 0ean up spL fue mmedaLey.
Fue n Lhe fue Lank expands when warm and can escape f Lhe Lank s overfed. See specfcaLons on fng up wLh fue.
Warnin
0aner of poisonin Fue s posonous and a heaLh hazard.
Avod conLacL beLween fue and skn, eyes and coLhng. Do noL nhae fue vapors. If fue geLs nLo your eyes, rnse mme-
daLey wLh waLer and conLacL a docLor. wash affecLed skn areas mmedaLey wLh soap and waLer. If fue s swaowed,
conLacL a docLor mmedaLey. 0hange coLhng LhaL has come nLo conLacL wLh fue.
Warnin
nvironentaI hazard Improper handng of fue s a danger Lo Lhe envronmenL.
Do noL aow fue Lo geL nLo Lhe ground waLer, Lhe ground, or Lhe sewage sysLem.
SwLch off Lhe engne.
0pen Lhe fer cap. ( p. 20)
AA
400382-T0
F Lhe fue Lank wLh fue up Lo measuremenL O.
0udene
MeasuremenL of O 35 mm (T.38 n)
ToLa fue Lank
capacLy,
approx. (EX0,
EX0 SIX DAYS,
X0-w ZA)
9.0
(2.38 US ga)
Super uneaded (R0Z 95 / R0N 95 /
P0N 9T) ( p. T06)
ToLa fue Lank
capacLy, approx.
(X0-w USA)
9.2
(2.43 US ga)
Super uneaded (R0Z 95 / R0N 95 /
P0N 9T) ( p. T06)
0ose Lhe fer cap. ( p. 20)
8kVI0 80h0L 30
8SERVlCE SCHEDULE
8.1 Iportant aintenance work to be carried out by an authorized kTM workshop.
83h 815A 830A
Engne 0hange Lhe engne o and o fLer and cean Lhe engne o screen. ( p. 80)
0hange Lhe gear o and cean Lhe gear o screen. ( p. 82)
Repace spark pug.
0heck Lhe vave cearance.
0heck engne mounLng screws for LghLness.
0ean spark pug connecLors and check for LghLness.
0heck LhaL Lhe screws n Lhe shfL ever and Lhe kcksLarLer are LghL.
0arbureLor 0heck carbureLor connecLon booLs for cracks and eakage.
0heck venL hoses for damage and rouLng wLhouL sharp bends.
0heck de.
ALLachmenLs 0heck Lhe coong sysLem for eakage.
0heck Lhe anLfreeze and cooanL eve. ( p. 72)
0heck Lhe exhausL sysLem for eakage and ooseness.
0heck Bowden cabes for damage, smooLh operaLon and rouLng wLhouL sharp
bends.

0heck Lhe fud eve of Lhe hydrauc cuLch. ( p. 76)
0ean Lhe ar fLer. ( p. 75)
0heck cabes for damage and rouLng wLhouL sharp bends.
0heck LhaL Lhe eecLrca equpmenL s funcLonng propery.
0heck Lhe headamp seLLng.
Brakes 0heck Lhe fronL brake nngs. ( p. 58)
0heck Lhe brake dscs. ( p. 55)
0heck brake nes for damage and eakage.
0heck Lhe free Lrave of Lhe hand brake ever. ( p. 56)
0heck Lhe free Lrave of Lhe fooL brake ever. ( p. 60)
0heck brake sysLem funcLon.
0heck screws and gude boLs of brake sysLem for LghLness.
0hasss 0heck shock absorber and fork for eakage and funcLonng.
0ean dusL booLs of fork egs. ( p. 39)
Beed fork egs. ( p. 39)
0heck Lhe swngarm bearng.
0heck pay of sLeerng head bearng. ( p. 40)
0heck a screws Lo see f Lhey are LghL.
whees 0heck Lhe spoke Lenson. ( p. 67)
0heck rm run-ouL.
0heck Lhe chan wear. ( p. 53)
0ean Lhe chan. ( p. 5T)
0heck Lhe whee bearng for pay.
0ean and grease ad|usLng screws of chan ad|usLer.
83h: AfLer 3 servce hours
815A: Every T5 servce hours / afLer every race
830A: Every 30 servce hours
8kVI0 80h0L 31
8.2 Iportant aintenance work to be carried out by an authorized kTM workshop. (as additionaI order)
0opetition use hobby use !1A !2A
815A 830A 845A 830A 860A 890A
0arry ouL a compeLe fork servce.
0arry ouL a compeLe shock absorber servce.
0rease Lhe sLeerng head bearng. ( p. 46)
TreaL eecLrc conLacLs wLh conLacL spray.
0hange Lhe hydrauc cuLch fud. ( p. 76)
0hange Lhe fronL brake fud.
0hange Lhe rear brake fud.
0ean Lhe spark arresLor. (X0-w USA)
0heck wear of cuLch dscs.
0heck Lhe cuLch.
0heck/measure Lhe cynder.
0hange Lhe psLon.
0heck Lhe camshafL.
0hange Lhe camshafL bearng.
0heck Lhe vave sprng seaL.
0heck Lhe cynder head.
0heck Lhe vaves.
0heck Lhe vave sprngs.
0heck Lhe rada cearance of Lhe rocker arm roers.
0heck Lhe Lmng-chan Lensoner funcLon.
0heck Lhe baancer shafL.
0heck Lhe crankshafL run-ouL aL Lhe bearng pn.
0hange Lhe conrod bearng.
0hange Lhe crankshafL man bearng.
0heck Lhe Lransmsson.
0heck Lhe shfL mechansm.
0heck Lhe sprng engLh of Lhe o pressure reguaLor
vave.

0hange gass fber yarn fng of man sencer.
Repace fooL brake cynder seas.
0heck/ad|usL Lhe carbureLor componenLs.
815A: Every T5 servce hours / afLer every race
!1A: annuay
!2A: every 2 years
8.3 Iportant checks and aintenance work to be carried out by the rider.
h81A
0heck Lhe fronL brake nngs. ( p. 58)
0heck and ad|usL Bowden cabes.
Beed fork egs. ( p. 39)
0ean dusL booLs of fork egs. ( p. 39)
8kVI0 80h0L 32
h81A
0heck Lhe chan wear. ( p. 53)
0heck Lhe rear sprockeL / engne sprockeL for wear. ( p. 52)
0ean Lhe ar fLer. ( p. 75)
0heck LhaL a operaLng eemenLs for smooLh operaLon.
0heck brakng.
0heck a screws, nuLs and hose camps reguary for LghLness.
h81A: Dependng on condLons of use accordng Lo requremenLs.
MAIhThAh0 W0kk 0h 0hA88I8 Ah0 h0Ih 33
9MAlNTENANCE WORK ON CHASSlS AND ENGlNE
9.1 !ackin up the otorcycIe
500074-0T
hote
Jack up Lhe moLorcyce underneaLh Lhe engne. The whees musL no onger Louch
Lhe ground.
work sLand (54829055000)
Secure Lhe moLorcyce agansL fang over.
9.2 keovin the otorcycIe fro the work stand
hote
Remove Lhe moLorcyce from Lhe work sLand.
Remove Lhe work sLand.
9.3 0heckin the basic chassis settin with the rider's weiht
Info
when ad|usLng Lhe basc chasss seLLng, frsL ad|usL Lhe shock absorber and Lhen Lhe fork.
For opLma moLorcyce rdng characLersLcs and Lo avod damage Lo forks, shock absorbers, swng arm and frame, Lhe basc seL-
Lngs of Lhe suspenson componenLs musL maLch your body weghL.
As devered, KTM offroad moLorcyces are ad|usLed for a sLandard rder weghL (wLh fu proLecLve coLhng).
0udene
SLandard rder weghL 75. 85 kg (T65. T87 b.)
If your weghL s above or beow Lhe sLandard range, you have Lo ad|usL Lhe basc seLLng of Lhe suspenson componenLs accord-
ngy.
Sma weghL dfferences can be compensaLed by ad|usLng Lhe sprng preoad, buL n Lhe case of arge weghL dfferences, Lhe
sprngs musL be repaced.
9.4 0opression dapin of shock absorber
The shock absorber can reguaLe compresson dampng separaLey n Lhe ow-speed and hgh-speed ranges (Dua 0ompresson 0onLro).
The Lerm ow and hgh speed refers Lo Lhe movemenL of Lhe shock absorber durng compresson and noL Lhe rdng speed of Lhe moLor-
cyce.
The ow-speed and hgh-speed Lechnoogy works non-specfcay.
9.5 Adjustin hih-speed copression dapin of the shock absorber
0aner
0aner of accidents The shock absorber s under hgh pressure.
The shock absorber s fed wLh hghy compressed nLrogen, so never dsmanLe Lhe shock absorber or carry ouL any man-
Lenance on L yoursef.
Info
The hgh-speed seLLng can be seen durng Lhe fasL compresson of Lhe shock absorber.
400208-T0
Turn Lhe ad|usLng screw O cockwse wLh a rng wrench unL L sLops.
Info
Do noL oosen nuL O!
Turn back counLercockwse Lhe number of Lurns correspondng Lo Lhe shock
absorber Lype.
0udene
0ompresson dampng, hgh-speed
0omforL 2 Lurns
SLandard T.5 Lurns
SporL T Lurn
Info
Turn cockwse Lo ncrease dampng, Lurn counLercockwse Lo reduce sus-
penson dampng.
9.6 Adjustin the Iow-speed copression dapin of the shock absorber
0aner
Info
The ow-speed seLLng can be seen durng Lhe sow Lo norma compresson of Lhe shock absorber.
400209-T0
Turn Lhe ad|usLng screw O cockwse wLh a screwdrver unL L sLops.
Info
Do noL oosen nuL O!
Turn back counLercockwse Lhe number of ccks correspondng Lo Lhe shock
absorber Lype.
0udene
0ompresson dampng, ow-speed
0omforL T8 ccks
SLandard T5 ccks
SporL T2 ccks
Info
penson dampng.
9.7 Adjustin rebound dapin of the shock absorber
0aner
0AA
00BB
0AA
4002T0-T0
Turn Lhe ad|usLng screw O cockwse unL L sLops.
Info
Do noL oosen nuL O!
Turn back counLercockwse Lhe number of ccks correspondng Lo Lhe shock
absorber Lype.
0udene
Rebound dampng
0omforL 26 ccks
SLandard 24 ccks
SporL 22 ccks
Info
penson dampng.
9.8 Measurin rear wheeI sa unIoaded
Jack up Lhe moLorcyce. ( p. 33)
400220-T0
Measure Lhe dsLance as verLca as possbe beLween Lhe rear axe and a fxed
ponL, for exampe, a mark on Lhe sde cover.
Make a noLe of Lhe vaue as measuremenL O.
Remove Lhe moLorcyce from Lhe work sLand. ( p. 33)
9.9 0heckin static sa of the shock absorber
40022T-T0
Measure dsLance O of rear whee unoaded. ( p. 35)
Ask someone Lo hep you by hodng Lhe moLorcyce uprghL.
Measure Lhe dsLance beLween Lhe rear axe and Lhe fxed ponL agan.
Info
The sLaLc sag s Lhe dfference beLween measuremenLs O and O.
0heck Lhe sLaLc sag.
SLaLc sag 35 mm (T.38 n)
If Lhe sLaLc sag s ess or more Lhan Lhe specfed vaue.
Ad|usL Lhe sprng preoad of Lhe shock absorber. ( p. 36)
CC
0AA
AA
22
11
9.10 0heckin the ridin sa of the shock absorber
400222-T0
Measure dsLance O of rear whee unoaded. ( p. 35)
wLh anoLher person hodng Lhe moLorcyce, sL on Lhe sadde wLh fu proLecLve
coLhng n a norma sLLng posLon (feeL on fooLresLs) and bounce up and down a
few Lmes unL Lhe rear suspenson eves ouL.
The oLher person now has Lo measure Lhe dsLance beLween Lhe rear axe and a
fxed ponL.
Info
The rdng sag s Lhe dfference beLween measuremenLs O and O.
0heck Lhe rdng sag.
Rdng sag T05 mm (4.T3 n)
If Lhe rdng sag dffers from Lhe specfed measuremenL.
Ad|usL Lhe rdng sag. ( p. 37)
9.11 Adjustin sprin preIoad of the shock absorber
0aner
Info
Before changng Lhe sprng preoad, make a noLe of Lhe presenL seLLng, e.g., by measurng Lhe engLh of Lhe sprng.
Remove shock absorber. ( p. 37)
AfLer removng Lhe shock absorber, cean L Lhoroughy.
4002T6-T0
Loosen screw O.
Turn ad|usLng rng O unL Lhe sprng s no onger under Lenson.
0ombnaLon wrench (50329080000)
Hook wrench (TT06S)
Measure Lhe overa sprng engLh when noL under Lenson.
TghLen Lhe sprng by Lurnng ad|usLng rng O Lo measuremenL O.
0udene
Sprng preoad 9 mm (0.35 n)
Info
Dependng on Lhe sLaLc sag and/or Lhe rdng sag, L may be necessary Lo
ncrease or decrease Lhe sprng preoad.
TghLen screw O.
0udene
Screw, shock absorber ad|usLng rng M6 5 Nm (3.7 bf fL)
InsLa Lhe shock absorber. ( p. 37)
9.12 Adjustin ridin sa
Remove shock absorber. ( p. 37)
AfLer removng Lhe shock absorber, cean L Lhoroughy.
0hoose and mounL a suLabe sprng.
0udene
Sprng raLe
weghL of rder. 65. 75 kg (T43. T65 b.) 69 N/mm (394 b/n)
weghL of rder. 75. 85 kg (T65. T87 b.) 72 N/mm (4TT b/n)
weghL of rder. 85. 95 kg (T87. 209 b.) 76 N/mm (434 b/n)
Info
The sprng raLe s shown on Lhe ouLsde of Lhe sprng.
Smaer weghL dfferences can be compensaLed by changng Lhe sprng preoad.
InsLa Lhe shock absorber. ( p. 37)
0heck Lhe sLaLc sag of Lhe shock absorber. ( p. 35)
0heck Lhe rdng sag of Lhe shock absorber. ( p. 36)
Ad|usL Lhe rebound dampng of Lhe shock absorber. ( p. 34)
9.13 keovin the shock absorber
800023-T0
Remove screw O and ower Lhe rear whee wLh Lhe swng arm as far as possbe
wLhouL bockng Lhe rear whee. Fx Lhe rear whee n Lhs posLon.
Remove screw O, push spash proLecLor O Lo Lhe sde, and remove Lhe shock
absorber.
9.14 InstaIIin the shock absorber
800023-TT
Push spash proLecLor O Lo Lhe sde and posLon Lhe shock absorber. MounL and
LghLen screw O.
0udene
Screw, Lop shock absorber MT2 80 Nm
(59 bf fL)
Loctite
243
MounL and LghLen screw O.
0udene
Screw, boLLom shock
absorber
MT2 80 Nm
(59 bf fL)
Loctite
243
Info
The hem |onL for Lhe shock absorber aL Lhe swng arm s Tefon coaLed. IL
musL noL be greased wLh grease or wLh oLher ubrcanLs. LubrcanLs ds-
sove Lhe Tefon coaLng, Lhereby drasLcay reducng Lhe servce fe.
9.15 0heckin basic settin of fork
Info
For varous reasons, no exacL rdng sag can be deLermned for Lhe forks.
400T89-0T
As wLh Lhe shock absorber, smaer weghL dfferences can be compensaLed by Lhe
sprng preoad.
However, f your fork s ofLen overoaded (hard end sLop on compresson), you musL
fL harder sprngs Lo avod damage Lo Lhe fork and frame.
9.16 Adjustin copression dapin of fork
Info
The hydrauc compresson dampng deLermnes Lhe fork suspenson behavor.
T00020-T0
Remove proLecLon covers O.
Turn ad|usLng screws O cockwse unL Lhey sLop.
Info
The ad|usLng screws O are ocaLed aL Lhe boLLom end of Lhe fork egs.
Make Lhe same ad|usLmenL on boLh fork egs.
Turn back counLercockwse Lhe number of ccks correspondng Lo Lhe fork Lype.
0udene
0ompresson dampng
0omforL 26 ccks
SLandard 22 ccks
SporL 20 ccks
Info
penson dampng.
MounL proLecLon covers O.
9.17 Adjustin rebound dapin of fork
Info
The hydrauc rebound dampng deLermnes Lhe fork suspenson behavor.
8000T7-T0
Turn ad|usLng screws O cockwse unL Lhey sLop.
Info
The ad|usLng screws O are ocaLed aL Lhe Lop end of Lhe fork egs.
Turn back counLercockwse Lhe number of ccks correspondng Lo Lhe fork Lype.
0udene
Rebound dampng
0omforL 24 ccks
SLandard 22 ccks
SporL 22 ccks
Info
penson dampng.
9.18 Adjustin sprin preIoad of the fork
8000T5-T0
Turn ad|usLng screws counLercockwse unL Lhey sLop.
Info
Turn back cockwse Lhe number of Lurns correspondng Lo Lhe fork Lype.
0udene
Sprng preoad - FreIoad Adjuster
0omforL 2 Lurns
SLandard 2 Lurns
SporL 4 Lurns
Info
Turn cockwse Lo ncrease sprng preoad, Lurn counLercockwse Lo reduce
sprng preoad.
Ad|usLng Lhe sprng preoad has no nfuence on Lhe absorpLon seLLng of
Lhe rebound dampng.
Bascay, however, you shoud seL Lhe rebound dampng hgher wLh a
hgher sprng preoad.
9.19 8Ieedin fork Ies
T0002T-T0
Remove beeder screws O brefy.
Any excess pressure escapes from Lhe nLeror of Lhe fork.
MounL and LghLen beeder screws.
9.20 0Ieanin dust boots of fork Ies
Loosen Lhe fork proLecLon. ( p. 40)
500088-T0
Push dusL booLs O of boLh fork egs downwards.
Info
The dusL booLs shoud remove dusL and coarse drL parLces from Lhe fork
Lubes. 0ver Lme, drL can peneLraLe behnd Lhe dusL booLs. If Lhs drL s noL
removed, Lhe o seas behnd can sLarL Lo eak.
Warnin
0aner of accidents Reduced brakng due Lo o or grease on Lhe brake
dscs.
Aways keep Lhe brake dscs free of o and grease, and cean Lhem wLh
brake ceaner when necessary.
0ean and o Lhe dusL booLs and nner fork Lube of boLh fork egs.
Unversa o spray ( p. T08)
Press Lhe dusL booLs back nLo Lher norma posLon.
Remove excess o.
PosLon Lhe fork proLecLon. ( p. 40)
9.21 Loosenin the fork protection
500087-TT
Remove screws O and Lake off camp.
Remove screws O on efL fork eg. Push Lhe fork proLecLon downwards.
Remove Lhe screws on Lhe rghL fork eg. Push Lhe fork proLecLon downwards.
9.22 Fositionin the fork protection
500087-T0
PosLon Lhe fork proLecLon on Lhe efL fork eg. MounL and LghLen screws O.
0udene
Remanng screws, chasss M6 T0 Nm (7.4 bf fL)
PosLon Lhe brake ne and cabe harness. PuL Lhe camp on, mounL and LghLen
screws O.
PosLon Lhe fork proLecLon on Lhe rghL fork eg. MounL and LghLen screws.
0udene
9.23 0heckin pIay of steerin head bearin
Warnin
0aner of accidents Unsafe rdng behavor due Lo ncorrecL sLeerng head bearng pay.
The sLeerng head bearng pay shoud be ad|usLed mmedaLey n an auLhorzed KTM workshop.
Info
If Lhe bke s drven for a onger Lme wLh pay n Lhe sLeerng head bearng, Lhe bearng and Lhe bearng seaLs n Lhe frame can
be damaged afLer Lme.
400387-T0
Move Lhe handebar Lo Lhe sLraghL-ahead posLon. Move Lhe fork egs Lo and fro n
Lhe drecLon of Lrave.
No pay shoud be noLceabe n Lhe sLeerng head bearng.
If Lhere s noLceabe pay presenL.
(X0 8IX 0AY8, X0-W 8A)
Ad|usL pay of Lhe sLeerng head bearng. ( p. 4T)
(X0 , X0 A8, X0-W ZA)
Move Lhe handebar Lo and fro over Lhe enLre sLeerng range.
The handebar musL be abe Lo move easy over Lhe enLre sLeerng range. No
resLng ocaLons shoud be noLceabe.
If cck posLons are noLceabe.
(X0 8IX 0AY8, X0-W 8A)
(X0 , X0 A8, X0-W ZA)
0heck Lhe sLeerng head bearng and repace f requred.
9.24 Adjustin pIay of steerin head bearin (X0 , X0 A8, X0-W ZA)
8000T6-T0
Loosen screws O and O.
Loosen and reLghLen screw O.
0udene
Screw, Lop sLeerng head M20xT.5 T0 Nm (7.4 bf fL)
Usng a pasLc hammer, Lap ghLy on Lhe upper Lrpe camp Lo avod sLrans.
Fuy LghLen screw O.
0udene
Screw, Lop Lrpe camp M8 20 Nm
(T4.8 bf fL)
TghLen screw O.
0udene
Screw, Lop sLeerng sLem M8 20 Nm
(T4.8 bf fL)
9.25 Adjustin pIay of steerin head bearin (X0 8IX 0AY8, X0-W 8A)
800022-T0
Loosen screw O. Remove screw O.
Loosen and reLghLen screw O.
0udene
Usng a pasLc hammer, Lap ghLy on Lhe upper Lrpe camp Lo avod sLrans.
Fuy LghLen screw O.
0udene
Screw, Lop Lrpe camp M8 T7 Nm
(T2.5 bf fL)
0udene
Screw, Lop sLeerng sLem M8 T7 Nm
(T2.5 bf fL)
Loctite
243
9.26 keovin the fork Ies
Remove Lhe fronL whee. ( p. 64)
500093-T0
Remove screws O and Lake off camp.
Remove cabe cp O, remove screw O and Lake off Lhe brake caper.
Hang Lhe brake caper and Lhe brake ne oosey Lo Lhe sde.
500094-T0
(X0 8IX 0AY8, X0-W 8A)
Loosen screw O. Remove Lhe fork eg on Lhe efL.
Loosen screw O. Remove Lhe fork eg on Lhe rghL.
T00023-TT
(X0 , X0 A8, X0-W ZA)
Loosen screw O. Remove Lhe fork eg on Lhe efL.
Loosen screw O. Remove Lhe fork eg on Lhe rghL.
9.27 InstaIIin the fork Ies
T0002T-T0
PosLon Lhe fork egs.
Info
The LopmosL sunk nuL n Lhe fork eg musL be fush Lo Lhe upper edge of Lhe
upper Lrpe camp.
PosLon Lhe beeder screw O Lo Lhe fronL.
500094-TT
(X0 8IX 0AY8, X0-W 8A)
Fuy LghLen screw O.
0udene
Screw, Lop Lrpe camp M8 T7 Nm
(T2.5 bf fL)
Fuy LghLen screw O.
0udene
Screw, boLLom Lrpe camp M8 T2 Nm
(8.9 bf fL)
T00023-T0
(X0 , X0 A8, X0-W ZA)
Fuy LghLen screw O.
0udene
Screw, Lop Lrpe camp M8 20 Nm
(T4.8 bf fL)
Fuy LghLen screw O.
0udene
Screw, boLLom Lrpe camp M8 T5 Nm
(TT.T bf fL)
500093-TT
PosLon brake caper, mounL and LghLen screws O.
0udene
Screw, fronL brake caper M8 25 Nm
(T8.4 bf fL)
Loctite
243
MounL cabe cp O.
screws O.
InsLa Lhe fronL whee. ( p. 64)
9.28 keovin the fork protector
Remove Lhe fork egs. ( p. 42)
500T05-T0
Remove screws O on Lhe efL fork eg. Remove Lhe fork proLecLor upwards.
Remove Lhe screws on Lhe rghL fork eg. Remove Lhe fork proLecLor upwards.
9.29 InstaIIin the fork protector
500T05-T0
PosLon Lhe fork proLecLon on Lhe efL fork eg. MounL and LghLen screws O.
0udene
PosLon Lhe fork proLecLon on Lhe rghL fork eg. MounL and LghLen Lhe screws.
0udene
InsLa Lhe fork egs. ( p. 42)
9.30 keovin the Iower tripIe cIap (X0 8IX 0AY8, X0-W 8A)
(X0-W 8A)
DsmounL Lhe sLarL number paLe. ( p. 48)
(X0 8IX 0AY8)
Remove Lhe headghL mask wLh Lhe headghL. ( p. 47)
DsmounL Lhe fronL fender. ( p. 47)
500099-T0
Remove screws O and hang Lhe 0DI conLro unL Lo Lhe sde.
Info
Do noL unpug Lhe 0DI conLro unL.
Remove screw O. Remove screw O, Lake off Lop Lrpe camp wLh Lhe handebar
and pace L on one sde.
Info
ProLecL Lhe moLorcyce and Ls aLLachmenLs from damage by coverng Lhem.
Do noL bend Lhe cabes and nes.
500T00-T0
Remove o-rng O. Remove proLecLor rng O.
Remove Lhe ower Lrpe camp wLh Lhe sLeerng sLem.
Remove Lhe upper sLeerng head bearng.
9.31 keovin the Iower tripIe cIap (X0 , X0 A8, X0-W ZA)
Remove Lhe headghL mask wLh Lhe headghL. ( p. 47)
DsmounL Lhe fronL fender. ( p. 47)
500T49-T0
Remove screws O and hang Lhe 0DI conLro unL Lo Lhe sde.
Info
Do noL unpug Lhe 0DI conLro unL.
Remove screw O. Loosen screw O. Take off Lop Lrpe camp wLh Lhe handebar
and pace L on one sde.
Info
ProLecL Lhe moLorcyce and Ls aLLachmenLs from damage by coverng Lhem.
500T50-T0
Remove proLecLor rng O.
Remove Lhe ower Lrpe camp wLh Lhe sLeerng sLem.
Remove Lhe upper sLeerng head bearng.
022
011
033
9.32 InstaIIin the Iower tripIe cIap (X0 8IX 0AY8, X0-W 8A)
500098-T0
0ean Lhe bearng and seang eemenLs, check for damage, and grease.
Long-fe grease ( p. T07)
InserL Lhe ower Lrpe camp wLh Lhe sLeerng sLem. MounL Lhe upper sLeerng head
bearng.
Info
0heck wheLher Lhe Lop sLeerng head sea O s correcLy posLoned.
Push up proLecLve rng O and o-rng O.
500099-TT
PosLon Lhe upper Lrpe camp wLh Lhe sLeerng.
0udene
PosLon Lhe cuLch ne, wrng harness and 0DI conLro unL. MounL and LghLen
screws O.
0udene
InsLa Lhe fronL fender. ( p. 47)
(X0-W 8A)
InsLa Lhe sLarL number paLe. ( p. 48)
(X0 8IX 0AY8)
RefL Lhe headghL mask wLh Lhe headghL. ( p. 47)
500T03-T0
0udene
Screw, Lop sLeerng sLem M8 T7 Nm
(T2.5 bf fL)
Loctite
243
0heck Lhe cabe harness, cabe, brake and cuLch ne for free movemenL and free
ayng.
022
011
9.33 InstaIIin the Iower tripIe cIap (X0 , X0 A8, X0-W ZA)
500T5T-T0
0ean Lhe bearng and seang eemenLs, check for damage, and grease.
InserL Lhe ower Lrpe camp wLh Lhe sLeerng sLem. MounL Lhe upper sLeerng head
bearng.
Info
0heck wheLher Lhe Lop sLeerng head sea O s correcLy posLoned.
Push on proLecLve rng O.
500T49-TT
PosLon Lhe upper Lrpe camp wLh Lhe sLeerng.
0udene
PosLon Lhe cuLch ne, wrng harness and 0DI conLro unL. MounL and LghLen
screws O.
0udene
InsLa Lhe fronL fender. ( p. 47)
RefL Lhe headghL mask wLh Lhe headghL. ( p. 47)
T00022-TT
TghLen screw O.
0udene
Screw, Lop sLeerng sLem M8 20 Nm
(T4.8 bf fL)
0heck Lhe cabe harness, cabe, brake and cuLch ne for free movemenL and free
ayng.
9.34 0reasin the steerin head bearin
8000T0-T0
(X0 8IX 0AY8, X0-W 8A)
Remove Lhe ower Lrpe camp. ( p. 43)
InsLa Lhe ower Lrpe camp. ( p. 45)
(X0 , X0 A8, X0-W ZA)
Remove Lhe ower Lrpe camp. ( p. 44)
InsLa Lhe ower Lrpe camp. ( p. 46)
9.35 0isountin the front fender
500092-T0
Remove screws O. Remove Lhe fronL fender.
Make sure LhaL Lhe dsLance bushngs reman n pace.
9.36 InstaIIin the front fender
500092-T0
Ensure LhaL Lhe spacng seeves are mounLed n Lhe fender.
PosLon Lhe fronL fender. MounL and LghLen screws O.
0udene
Info
Take care wLh Lhe conLacL beLween Lhe hodng ugs and Lhe sLarL number
paLe or headghL mask.
9.37 keovin headIiht ask with headIiht (X0, X0 8IX 0AY8, X0-W ZA)
8000T8-T0
SwLch off a eecLrca equpmenL.
Remove screw O and Lake off camp.
Loosen Lhe rubber band O. Push up Lhe headghL mask and swng L forwards.
500T56-T0
Pu ouL Lhe eecLrc pug connecLor O and remove Lhe headghL mask wLh Lhe
headghL.
9.38 kefittin the headIiht ask with the headIiht (X0, X0 8IX 0AY8, X0-W ZA)
500T56-TT
0onnecL Lhe eecLrc pug connecLor O.
0BB 0BB
0AA 0AA
022
011
0 22
011
8000T8-TT
PosLon Lhe headghL mask and fx L wLh Lhe rubber band O.
Info
Take care wLh Lhe conLacL of Lhe hodng ug aL Lhe fender.
screw O.
0heck Lhe headamp seLLng.
9.39 0isount the start nuber pIate (X0-W 8A)
500T0T-T0
Remove screw O and Lake off camp.
Remove screw O wLh dsLance bushng. Remove Lhe sLarL number paLe.
9.40 InstaIIin the start nuber pIate (X0-W 8A)
500T0T-TT
PosLon Lhe sLarL number paLe. MounL and LghLen screw O wLh Lhe dsLance
bushng.
0udene
Info
Take care wLh Lhe conLacL of Lhe hodng ug aL Lhe fender.
screw O.
9.41 handIebar position
400223-TT
0n Lhe upper Lrpe camp, Lhere are 2 hoes aL a dsLance of O Lo each oLher.
DsLance O beLween hoes T5 mm (0.59 n)
The hoes on Lhe handebar supporL are paced aL a dsLance of O from Lhe cenLer.
DsLance O beLween hoes 3.5 mm (0.T38 n)
The handebar supporLs can be mounLed n 4 dfferenL posLons.
(X0 8IX 0AY8)
The handebar supporLs can aso be mounLed aL 2 dfferenL heghLs (wLh and wLh-
ouL spacer).
Thck spacer 9 mm (0.35 n)
9.42 Adjustin handIebar position
400223-T0
(X0 , X0 A8, X0-W)
Remove Lhe four screws O. Remove Lhe handebar camp. Remove Lhe hande-
bar and ay L Lo one sde.
Info
ProLecL Lhe moLorcyce and Ls aLLachmenLs from damage by coverng
Lhem.
Remove Lhe Lwo screws O. Remove Lhe handebar supporL.
0
33
022
0
11
044
055
066
077
088
099
Pace Lhe handebar supporL n Lhe requred posLon. FL and LghLen Lhe Lwo
screws O.
0udene
Screw, handebar supporL MT0 40 Nm
(29.5 bf fL)
Loctite
243
Info
PosLon Lhe efL and rghL handebar supporLs eveny.
PosLon Lhe handebar.
Info
Make sure cabes and wrng are posLoned correcLy.
PosLon Lhe handebar camp. FL and eveny LghLen Lhe four screws O.
0udene
Screw, handebar camp M8 20 Nm
(T4.8 bf fL)
Info
Make sure Lhe gap wdLh s even.
400343-T0
(X0 8IX 0AY8)
Remove Lhe four screws O. Remove Lhe handebar camps O wLh rubber wash-
ers O and easLomers O.
Remove Lhe handebar and ay L Lo one sde.
Info
ProLecL Lhe moLorcyce and Ls aLLachmenLs from damage by coverng
Lhem.
Remove Lhe ower shes O.
Remove Lhe camp bar O wLh Lhe rubber cones O.
Remove Lhe Lwo screws O. Remove Lhe handebar supporL.
Pace Lhe handebar supporL n Lhe requred posLon. FL and LghLen Lhe Lwo
screws O.
0udene
Screw, handebar supporL MT0 40 Nm
(29.5 bf fL)
Loctite
243
0ondition
O Spacer fLLed.
Use a MT0x35 screw
0ondition
wLhouL a spacer O.
Use a MT0x25 screw
Info
PosLon Lhe efL and rghL handebar supporLs eveny.
FL Lhe rubber cones O and camp bar O.
FL Lhe ower shes O.
PosLon Lhe handebar.
Info
Make sure cabes and wrng are posLoned correcLy.
PosLon Lhe handebar camps O wLh rubber washers O and easLomers O.
EasLomer kL green - sofL quaLy (SXS05T25203)
EasLomer kL yeow - medum quaLy (sLandard) (SXS05T25204)
EasLomer kL red - hard quaLy (SXS05T25205)
Info
The easLomers are avaabe n dfferenL versons.
FL and eveny LghLen Lhe four screws O.
0udene
Screw, handebar camp M8 T6 Nm
(TT.8 bf fL)
Info
Make sure Lhe gap wdLh s even.
9.43 0heckin as 8owden cabIe route
500T52-T0
The Lwo gas Bowden cabes musL run parae behnd Lhe handebar down Lo Lhe
frame. They musL be rouLed drecLy on Lhe frame above Lhe Lank bearng Lo Lhe car-
bureLor.
9.44 0heckin pIay in the as 8owden cabIe
400T92-T0
Move Lhe handebar Lo Lhe sLraghL-ahead posLon. Move Lhe LhroLLe grp back and
forLh sghLy Lo ascerLan Lhe pay n Lhe gas Bowden cabe.
Pay n gas Bowden cabe 3. 5 mm (0.T2. 0.2 n)
If Lhe gas Bowden cabe pay does noL meeL specfcaLons.
Ad|usL Lhe gas Bowden cabe pay. ( p. 50)
0aner
0aner of poisonin ExhausL gases are posonous and can resuL n uncon-
scousness and/or deaLh.
when runnng Lhe engne, aways make sure Lhere s suffcenL venLa-
Lon, and do noL sLarL or run Lhe engne n a cosed space.
SLarL Lhe engne and eL L run de. Move Lhe handebar Lo and fro over Lhe enLre
sLeerng range.
The de speed musL noL change.
If Lhe de speed changes.
Ad|usL Lhe gas Bowden cabe pay. ( p. 50)
9.45 Adjustin the as 8owden cabIe pIay
DsmounL Lhe fue Lank. ( p. 70)
0heck gas Bowden cabe rouLe. ( p. 50)
500T53-T0
Move Lhe handebar Lo Lhe sLraghL-ahead posLon.
Push back beows O.
Loosen nuL O. Turn ad|usLng screw O n as far as possbe.
Loosen nuL O. Turn ad|usLng screw O so LhaL Lhere s pay n Lhe gas Bowden
cabe aL Lhe LhroLLe grp.
0udene
Pay n gas Bowden cabe 3. 5 mm (0.T2. 0.2 n)
TghLen nuL O.
Press and hod Lhe LhroLLe grp n Lhe cosed seLLng. Turn ad|usLng screw O ouL
unL Lhere s no pay n Lhe Bowden cabe O.
TghLen nuL O.
Push beows O on. 0heck Lhe LhroLLe grp for smooLh operaLon.
InsLa Lhe fue Lank. ( p. 7T)
0heck pay n Lhe gas Bowden cabe. ( p. 50)
9.46 0heckin for chain dirt accuuIation
8000T2-T0
0heck Lhe chan for coarse drL accumuaLon.
If Lhe chan s very drLy.
9.47 0Ieanin the chain
Warnin
0aner of accidents 0 or grease on Lhe Lres reduces Lher grp.
Remove o and grease wLh a suLabe ceanng maLera.
Warnin
0aner of accidents Reduced brakng due Lo o or grease on Lhe brake dscs.
Aways keep Lhe brake dscs free of o and grease, and cean Lhem wLh brake ceaner when necessary.
Warnin
nvironentaI hazard Probem maLeras cause envronmenLa damage.
Dspose of o, grease, fLers, fue, ceanng subsLances, brake fud, baLLeres, eLc. accordng Lo reguaLons.
Info
The servce fe of Lhe chan depends argey on Ls manLenance.
0ean Lhe chan reguary and Lhen LreaL wLh chan spray.
0han ceaner ( p. T07)
0ffroad chan spray ( p. T07)
9.48 0heckin the chain tension
Warnin
0aner of accidents Danger caused by ncorrecL chan Lenson.
If Lhe chan Lenson s Loo hgh, Lhe componenLs of Lhe secondary power Lran (chan, engne sprockeL, rear sprockeL, bear-
ngs n Lransmsson and rear whee) are under addLona oad. AparL from premaLure wear, n exLreme cases Lhe chan can
rupLure or Lhe counLershafL of Lhe Lransmsson can break. 0n Lhe oLher hand, f Lhe chan s oose, L can fa off Lhe engne
sprockeL or Lhe rear sprockeL and bock Lhe rear whee or damage Lhe engne. 0heck for correcL chan Lenson and ad|usL f
necessary.
4002T3-T0
Push Lhe chan aL Lhe end of Lhe chan sdng componenL upwards Lo measure Lhe
chan Lenson O.
Info
The upper chan secLon O musL be LauL.
0han wear s noL aways even, so you shoud repeaL Lhs measuremenL aL
dfferenL chan posLons.
0han Lenson 8. T0 mm (0.3T. 0.39 n)
If Lhe chan Lenson does noL meeL specfcaLons.
Ad|usLng chan Lenson - afLer checkng. ( p. 54)
9.49 0heckin the chain tension when fittin rear wheeI
Warnin
necessary.
4002T3-T0
Make sure LhaL Lhe chan ad|usLers are fLLed correcLy on Lhe ad|usLng screws.
Push Lhe chan aL Lhe end of Lhe chan sdng componenL upwards Lo measure
chan Lenson O.
Info
If Lhe chan Lenson does noL meeL specfcaLons.
Ad|usL Lhe chan Lenson when fLLng rear whee. ( p. 55)
9.50 0heckin the rear sprocket / enine sprocket for wear
400227-0T
0heck Lhe rear sprockeL / engne sprockeL for wear.
If Lhe rear sprockeL / engne sprockeL are worn.
Repace rear sprockeL / engne sprockeL.
Info
when fLLng Lhe chan |onL, aways make sure LhaL Lhe cosed sde
of Lhe |onL faces forward (rdng drecLon).
The engne sprockeL, rear sprockeL and chan shoud aways be
repaced LogeLher.
0heck LhaL Lhe chan gude s frmy seaLed and noL worn.
00BB
0 AA
1 2 3 16 17 18
9.51 0heckin chain wear
400226-T0
Pu Lhe upper chan secLon wLh Lhe specfed weghL O.
0udene
weghL of chan wear measuremenL T0. T5 kg (22. 33 b.)
Measure dsLance O of T8 chan nks n Lhe ower chan secLon.
Info
Maxmum dsLance O aL Lhe ongesL
chan secLon
272 mm (T0.7T n)
If Lhe dsLance O s greaLer Lhan Lhe specfed measuremenL.
Repace Lhe chan.
Info
when you repace Lhe chan, you shoud aso repace Lhe rear
sprockeL and Lhe engne sprockeL.
New chans wear ouL fasLer on od, worn sprockeLs.
9.52 Adjustin the chain tension
Warnin
necessary.
4002T3-T0
Push Lhe chan aL Lhe end of Lhe chan sdng componenL upwards Lo measure
chan Lenson O.
Info
400225-T0
Loosen nuL O.
Loosen nuLs O.
Ad|usL Lhe chan Lenson by Lurnng Lhe efL and rghL ad|usLng screws O.
0udene
Turn Lhe efL and rghL ad|usLng screws O so LhaL Lhe markngs on Lhe efL and
rghL chan ad|usLers are n Lhe same posLon reaLve Lo Lhe reference marks O.
The rear whee s Lhen correcLy agned.
TghLen nuLs O.
Make sure LhaL chan ad|usLers O are fLLed correcLy on Lhe ad|usLng screws O.
TghLen nuL O.
0udene
NuL, rear whee spnde M20xT.5 80 Nm (59 bf fL)
Info
The wde ad|usLmenL range of Lhe chan ad|usLers (32 mm) enabes dfferenL
secondary Lransmssons wLh Lhe same chan engLh.
0han ad|usLers O can be Lurned by T80.
9.53 Adjustin chain tension - after checkin
400225-T3
Loosen nuL O.
Loosen nuLs O.
Ad|usL Lhe chan Lenson by Lurnng Lhe ad|usLng screws O efL and rghL.
0udene
Turn Lhe ad|usLng screws O efL and rghL so LhaL Lhe markngs on Lhe efL and
TghLen nuLs O.
Make sure LhaL Lhe chan ad|usLers O are fLLed correcLy on Lhe ad|usLng
screws O.
TghLen nuL O.
0udene
Info
The chan ad|usLers O can be Lurned by T80.
9.54 Adjustin chain tension - fittin rear wheeI
400225-TT
Loosen nuLs O.
Ad|usL Lhe chan Lenson by Lurnng Lhe ad|usLng screws O efL and rghL.
0udene
Turn Lhe ad|usLng screws O efL and rghL so LhaL Lhe markngs on Lhe efL and
TghLen nuLs O.
9.55 Adjustin chain uide
400252-T0
Remove screws O and O. Take off Lhe chan gude.
0ondition
Number of LeeLh. > 44 LeeLh
InserL nuL O n hoe O. PosLon Lhe chan gude.
MounL and LghLen screws O and O.
0udene
Remanng screws, chasss M6 T0 Nm
(7.4 bf fL)
0ondition
Number of LeeLh. < 45 LeeLh
InserL nuL O n hoe O. PosLon Lhe chan gude.
MounL and LghLen screws O and O.
0udene
Remanng screws, chasss M6 T0 Nm
(7.4 bf fL)
9.56 0heckin the brake discs
Warnin
0aner of accidents Reduced brakng due Lo worn brake dscs.
worn brake dscs shoud be repaced mmedaLey n an auLhorzed KTM workshop.
A
400257-T0
0heck Lhe Lhckness of Lhe fronL and rear brake dscs aL severa paces on Lhe dsc
Lo see f L conforms Lo measuremenL O.
Info
wear reduces Lhe Lhckness of Lhe brake dsc around Lhe area used by Lhe
brake nngs.
wear mL of brake dscs
FronL 2.5 mm (0.098 n)
Rear 3.5 mm (0.T38 n)
If Lhe brake dsc Lhckness s ess Lhan Lhe specfed vaue.
0hange Lhe brake dsc.
9.57 0heckin free traveI of hand brake Iever
Warnin
If Lhere s no free Lrave on Lhe hand brake ever, pressure buds up on Lhe fronL brake n Lhe brake sysLem. The fronL brake
can fa due Lo overheaLng. Ad|usL free Lrave on hand brake ever accordng Lo specfcaLons.
400T96-TT
(aII X0-W odeIs)
Push Lhe hand brake ever forwards and check free Lrave O.
Free Lrave of hand brake ever < 3 mm (< 0.T2 n)
If Lhe free Lrave does noL meeL specfcaLons.
ad|usL Lhe basc posLon of handbrake ever. ( p. 56)
400T96-T3
(aII X0 odeIs)
Push Lhe hand brake Lo Lhe handebar and check free Lrave O.
Free Lrave of hand brake ever < 3 mm (< 0.T2 n)
Ad|usL Lhe free Lrave of Lhe handbrake ever. ( p. 57)
9.58 Adjustin basic position of handbrake Iever (aII X0-W odeIs)
400T96-T2
Ad|usL Lhe basc seLLng of Lhe handbrake ever Lo your hand sze by Lurnng ad|usL-
ng screw O.
Info
Turn Lhe ad|usLng screw cockwse Lo ncrease Lhe dsLance beLween Lhe
handbrake ever and Lhe handebar.
Turn Lhe ad|usLng screw counLercockwse Lo decrease Lhe dsLance beLween
Lhe handbrake ever and Lhe handebar.
The range of ad|usLmenL s mLed.
Turn Lhe ad|usLng screw by hand ony, and do noL appy any force.
Do noL make any ad|usLmenLs whe rdng!
9.59 Adjustin free traveI of handbrake Iever (aII X0 odeIs)
400T96-T2
Ad|usL Lhe free Lrave of Lhe handbrake ever wLh Lhe ad|usLmenL screw O.
Info
Turn Lhe ad|usLmenL screw cockwse Lo reduce free Lrave. The pressure
ponL moves away from Lhe handebar.
Turn Lhe ad|usLmenL screw counLercockwse Lo ncrease free Lrave. The
pressure ponL moves Lowards Lhe handebar.
9.60 0heckin the front brake fIuid IeveI
Warnin
If Lhe brake fud eve fas beow Lhe MIh mark, Lhs ndcaLes a eakage n Lhe brake sysLem or worn-ouL brake nngs.
Warnin
0aner of accidents Reduced brakng due Lo od brake fud.
Have Lhe fronL and rear brake fud repaced accordng Lo Lhe servce pan n an auLhorzed KTM workshop.
40023T-T0
Move Lhe brake fud reservor mounLed on Lhe handebar Lo a horzonLa posLon.
0heck Lhe brake fud eve n Lhe vewer O.
If Lhe brake fud s beow Lhe MIh mark.
Add fronL brake fud. ( p. 57)
9.61 Addin front brake fIuid
Warnin
Warnin
8kin irritations Brake fud can cause skn rrLaLon on conLacL.
Avod conLacL wLh skn and eyes, and keep ouL of Lhe reach of chdren.
If brake fud geLs nLo your eyes, rnse Lhoroughy wLh waLer and conLacL a docLor mmedaLey.
Warnin
Warnin
Info
Never user D0T 5 brake fud! Ths s based on scone o and s coored purpe. 0 seas and brake nes are noL desgned for
D0T 5 brake fud.
Avod conLacL beLween brake fud and panLed parLs. Brake fud aLLacks panL!
Use ony cean brake fud from a seaed conLaner!
600706-T0
Remove screws O.
Remove cover O wLh membrane O.
Add brake fud Lo eve O.
0udene
MeasuremenL of O 5 mm (0.2 n)
Brake fud D0T 4 / D0T 5.T ( p. T06)
PosLon Lhe cover wLh Lhe membrane. MounL and LghLen Lhe screws.
Info
0ean up overfowed or spL brake fud mmedaLey wLh waLer.
9.62 0heckin the front brake Iinins
Warnin
0aner of accidents Reduced brakng due Lo worn brake nngs.
worn brake nngs shoud be repaced mmedaLey n an auLhorzed KTM workshop.
400235-T0
0heck Lhe brake nngs for mnmum Lhckness O.
Mnmum Lhckness O < T mm (< 0.04 n)
If Lhe mnmum Lhckness s ess Lhan specfed.
0hange Lhe fronL brake nngs. ( p. 59)
9.63 keovin front brake Iinins
Warnin
0aner of accidents Improper brake manLenance and repar.
Aways have your brake sysLem manLaned and repared n an auLhorzed KTM workshop.
500089-TT
Press Lhe brake caper by hand on Lo Lhe brake dsc n order Lo press back Lhe
brake psLons.
Info
Make sure when pushng back Lhe brake psLons LhaL you do noL press Lhe
brake caper agansL Lhe spokes.
Remove Lhe ockng spL pns O, wLhdraw Lhe boL O, and Lake ouL Lhe brake
pads.
Remove cabe cp O. Remove screws O and Lake off brake caper.
0ean brake caper and brake caper supporL.
9.64 Mountin front brake Iinins
Warnin
Warnin
0aner of accidents Reduced brakng due Lo use of non-approved brake nngs.
Brake nngs avaabe from accessory suppers are ofLen noL LesLed and approved for use on KTM vehces. The consLruc-
Lon and frcLon facLor of Lhe brake nngs and Lherefore Lhe brake power can dffer consderaby from Lhe orgna KTM
brake nngs. If brake nngs are used LhaL dffer from Lhe orgnas, Lhere s no guaranLee LhaL Lhey compy wLh Lhe org-
na cense. The vehce no onger corresponds Lo Lhe condLon aL devery, and Lhe warranLy s no onger vad.
50009T-T0
0heck LhaL eaf sprng O n Lhe brake caper and sdng paLe O n Lhe brake
caper supporL are seaLed correcLy.
Info
The arrow on Lhe eaf sprng ponLs n Lhe roLaLon drecLon of Lhe brake
dsc.
500089-T2
InserL Lhe brake pads, nserL boL O, and mounL ockng spL pns O.
PosLon brake caper, mounL and LghLen screws O.
0udene
Screw, fronL brake caper M8 25 Nm
(T8.4 bf fL)
Loctite
243
MounL cabe cp O.
0peraLe Lhe hand brake ever repeaLedy unL Lhe brake nngs e on Lhe brake dsc
and Lhere s a LghL spoL.
9.65 0hanin the front brake Iinins
Warnin
Warnin
Warnin
Info
D0T 5 brake fud.
600706-T0
Remove Lhe fronL brake nngs. ( p. 58)
Remove screws O.
Press Lhe brake psLon back Lo Ls basc posLon and make sure LhaL no brake fud
overfows from Lhe brake fud reservor.
MounL Lhe fronL brake nngs. ( p. 59)
0udene
MeasuremenL of O 5 mm (0.2 n)
Info
9.66 0heckin free traveI of foot brake Iever
Warnin
If Lhere s no free Lrave on Lhe fooL brake peda, pressure buds up on Lhe rear brake n Lhe brake sysLem. The rear brake
can fa due Lo overheaLng. Ad|usL free Lrave on fooL brake peda accordng Lo specfcaLons.
500T39-TT
DsconnecL sprng O.
Move Lhe fooL brake ever backwards and forwards beLween Lhe end sLop and Lhe
fooL brake cynder psLon brackeL and check free Lrave O.
0udene
Free Lrave aL fooL brake ever 3. 5 mm (0.T2. 0.2 n)
Ad|usL Lhe basc posLon of Lhe fooLbrake ever. ( p. 60)
ReconnecL sprng O.
9.67 Adjustin basic position of footbrake Iever
Warnin
If Lhere s no free Lrave on Lhe fooL brake peda, pressure buds up on Lhe rear brake n Lhe brake sysLem. The rear brake
can fa due Lo overheaLng. Ad|usL free Lrave on fooL brake peda accordng Lo specfcaLons.
500T54-T0
DsconnecL sprng O.
Loosen nuL O and wLh push rod O, Lurn L back unL you have maxmum free
Lrave.
To ad|usL Lhe basc posLon of Lhe fooLbrake ever ndvduay, ossen nuL O and
Lurn screw O accordngy.
Info
Turn push rod O accordngy unL you have free Lrave O. If necessary, ad|usL Lhe
basc posLon of Lhe fooLbrake ever.
0udene
Free Lrave aL fooL brake ever 3. 5 mm (0.T2. 0.2 n)
Hod screw O and LghLen nuL O.
0udene
Remanng nuLs, chasss M8 30 Nm
(22.T bf fL)
Hod push rod O and LghLen nuL O.
0udene
Remanng nuLs, chasss M6 T5 Nm
(TT.T bf fL)
ReconnecL sprng O.
9.68 0heckin the rear brake fIuid IeveI
Warnin
Warnin
400234-T0
SLand Lhe vehce uprghL.
0heck Lhe brake fud eve n Lhe vewer O.
when n Lhe vewer O an ar bubbe s vsbe.
Add brake fud for Lhe rear brake. ( p. 6T)
9.69 Addin brake fIuid for the rear brake
Warnin
Warnin
Warnin
Warnin
Info
D0T 5 brake fud.
400233-T0
Remove screw cap O wLh membrane O and Lhe 0-rng.
MounL Lhe screw cap wLh Lhe membrane and Lhe 0-rng.
Info
9.70 0heckin the rear brake Iinins
Warnin
0aner of accidents Reduced brakng due Lo worn brake nngs.
worn brake nngs shoud be repaced mmedaLey n an auLhorzed KTM workshop.
400238-T0
0heck Lhe brake nngs for mnmum Lhckness O.
Mnmum Lhckness O < T mm (< 0.04 n)
If Lhe mnmum Lhckness s ess Lhan specfed.
0hange Lhe rear brake nngs. ( p. 63)
9.71 keovin rear brake Iinins
Warnin
0aner of accidents Improper brake manLenance and repar.
Aways have your brake sysLem manLaned and repared n an auLhorzed KTM workshop.
400236-T0
brake psLon.
Info
Make sure when pushng back Lhe brake psLon LhaL you do noL press Lhe
Remove Lhe ockng spL pns O, wLhdraw Lhe boL O, and Lake ouL Lhe brake
pads.
0ean brake caper and brake caper supporL.
9.72 InstaIIin the rear brake Iinins
Warnin
Warnin
0aner of accidents Reduced brakng due Lo use of non-approved brake nngs.
Brake nngs avaabe from accessory suppers are ofLen noL LesLed and approved for use on KTM vehces. The consLruc-
Lon and frcLon facLor of Lhe brake nngs and Lherefore Lhe brake power can dffer consderaby from Lhe orgna KTM
brake nngs. If brake nngs are used LhaL dffer from Lhe orgnas, Lhere s no guaranLee LhaL Lhey compy wLh Lhe org-
na cense. The vehce no onger corresponds Lo Lhe condLon aL devery, and Lhe warranLy s no onger vad.
500T22-T0
0heck LhaL eaf sprng O n Lhe brake caper and sdng paLe O n Lhe brake
caper supporL are seaLed correcLy.
Info
The arrow on Lhe eaf sprng ponLs n Lhe roLaLon drecLon of Lhe brake
dsc.
400237-T0
FL Lhe brake pads, nserL boL O, and mounL ockng spL pns O.
Info
Make sure LhaL Lhe decoupng paLe O s mounLed on Lhe psLon sde of Lhe
brake pad.
0peraLe Lhe fooL brake ever repeaLedy unL Lhe brake nngs e on Lhe brake dsc
9.73 0hanin the rear brake Iinins
Warnin
Warnin
Warnin
Info
D0T 5 brake fud.
400233-T0
Remove Lhe rear brake nngs. ( p. 62)
Remove screw cap O wLh membrane O and Lhe 0-rng.
Press Lhe brake psLon back Lo Ls basc posLon and make sure LhaL no brake fud
overfows from Lhe brake fud reservor.
InsLa Lhe rear brake nngs. ( p. 62)
MounL Lhe screw cap wLh Lhe membrane and Lhe 0-rng.
Info
9.74 keovin the front wheeI
500089-T0
brake psLons.
Info
Make sure when pushng back Lhe brake psLons LhaL you do noL press Lhe
500084-T0
Remove screw O.
Loosen screw O.
500085-T0
Hodng Lhe fronL whee, wLhdraw Lhe whee spnde. Take Lhe fronL whee ouL of
Lhe fork.
Info
Do noL pu Lhe hand brake ever when Lhe fronL whee s removed.
Aways ay Lhe whee down n such a way LhaL Lhe brake dsc s noL dam-
aged.
500086-T0
Remove spacng seeves O.
9.75 InstaIIin the front wheeI
Warnin
500086-TT
0ean and grease shafL sea rngs O and bearng surface O of Lhe spacng seeves.
InserL Lhe spacng seeves.
500084-TT
LfL Lhe fronL whee nLo Lhe fork, posLon L, and nserL Lhe whee spnde.
0udene
Screw, fronL whee spnde M24xT.5 45 Nm
(33.2 bf fL)
0peraLe Lhe hand brake ever severa Lmes unL Lhe brake pads are yng correcLy
on Lhe brake dsc.
Pu Lhe fronL whee brake and push down hard on Lhe fork severa Lmes Lo agn
Lhe fork egs.
Fuy LghLen screw O.
0udene
Screw, fork sLub M8 T5 Nm
(TT.T bf fL)
9.76 keovin rear wheeI
400258-T0
brake psLon.
Info
Make sure when pushng back Lhe brake psLon LhaL you do noL press Lhe
Remove nuL O.
Remove chan ad|usLer O. wLhdraw Lhe whee spnde O ony enough Lo aow Lhe
rear whee Lo be pushed forward.
Push Lhe rear whee forward as far as possbe. Remove Lhe chan from Lhe rear
sprockeL.
Hodng Lhe rear whee, wLhdraw Lhe whee spnde. Take Lhe rear whee ouL of Lhe
swng arm.
Info
Do noL operaLe Lhe fooL brake when Lhe rear whee s removed.
Aways ay Lhe whee down n such a way LhaL Lhe brake dsc s noL dam-
aged.
400260-TT
Remove Lhe spacng seeves O.
9.77 InstaIIin the rear wheeI
Warnin
400260-T0
0ean and grease shafL sea rngs O and bearng surface O of Lhe spacng seeves.
InserL Lhe spacng seeves.
400259-T0
LfL Lhe rear whee nLo Lhe swng arm, posLon L, and nserL Lhe whee spnde O.
PuL Lhe chan on.
400225-T2
PosLon Lhe chan ad|usLer O. MounL nuL O, buL do noL LghLen L yeL.
0heck Lhe chan Lenson when fLLng rear whee. ( p. 52)
Make sure LhaL Lhe chan ad|usLers O are fLLed correcLy on Lhe ad|usLng
screws O.
TghLen nuL O.
0udene
Info
The chan ad|usLers O can be Lurned by T80.
0peraLe Lhe fooL brake ever repeaLedy unL Lhe brake nngs e on Lhe brake dsc
9.78 Tire condition checkin
Info
0ny mounL Lres approved or recommended by KTM.
0Lher Lres coud have a negaLve effecL on rdng behavor.
The Lype, condLon and ar pressure of Lhe Lres a have an mporLanL mpacL on Lhe rdng behavor of Lhe moLorcyce.
The fronL and rear whees musL be mounLed wLh Lres wLh smar profes.
worn Lres have a negaLve effecL on rdng behavor, especay on weL surfaces.
Examne Lhe fronL and rear Lres for cuLs, foregn bodes and oLher damage.
If you fnd cuLs, foregn bodes or oLher damage on a Lre.
0hange Lhe Lre.
0heck Lhe depLh of Lhe Lread.
Info
NoLe oca naLona reguaLons concernng Lhe mnmum Lread depLh.
Mnmum Lread depLh < 2 mm (< 0.08 n)
If Lhe Lread depLh s ess Lhan Lhe mnmum aowabe depLh.
0hange Lhe Lre.
9.79 0heckin tire air pressure
Info
Low Lre ar pressure eads Lo abnorma wear and overheaLng of Lhe Lre.
0orrecL Lre ar pressure ensures opLma rdng comforL and maxmum Lre servce fe.
40024T-0T
Remove dusL cap.
0heck Lre ar pressure when Lres are cod.
Tre ar pressure off road
FronL T.0 bar (T5 ps)
Rear T.0 bar (T5 ps)
Road Lre pressure (a EX0 modes)
fronL T.5 bar (22 ps)
Rear 2.0 bar (29 ps)
If Lhe Lre pressure does noL meeL specfcaLons.
0orrecL Lre pressure.
MounL dusL cap.
9.80 0heckin spoke tension
Warnin
0aner of accidents UnsLabe rdng behavor due Lo oose spokes.
If you rde wLh oose spokes, Lhe spokes can break. Have Lhe spoke Lenson correcLed n an auLhorzed KTM workshop.
Info
A oose spoke can cause whee mbaance, whch eads Lo more oose spokes n a shorL Lme.
If Lhe spokes are Loo LghL, Lhey can break due Lo oca overoad.
0heck Lhe spoke Lenson reguary, especay on a new moLorcyce.
400228-0T
To check spoke Lenson, Lap each spoke wLh a screwdrver.
0udene
You shoud hear a hgh noLe.
Spoke nppe, fronL whee M4,5 5 Nm (3.7 bf fL)
Spoke nppe, rear whee M5 5 Nm (3.7 bf fL)
Info
If you hear dfferenL Lone frequences from dfferenL spokes, Lhs s an nd-
caLon of dfferenL spoke Lensons.
9.81 keovin the battery
Warnin
kisk of injury BaLLery acd and baLLery gases cause serous chemca burns.
Keep baLLeres ouL of Lhe reach of chdren.
wear suLabe proLecLve coLhng and gogges.
Avod conLacL wLh baLLery acd and baLLery gases.
Keep Lhe baLLery away from sparks or open fre. 0harge ony n we-venLaLed rooms.
In Lhe evenL of skn conLacL, rnse wLh arge amounLs of waLer. If baLLery acd geLs n Lhe eyes, rnse wLh waLer for aL easL
T5 mnuLes and conLacL a physcan.
SwLch off a power-consumng componenLs and swLch off Lhe engne.
Remove Lhe seaL. ( p. 69)
500069-T0
DsconnecL Lhe negaLve (mnus) cabe O of Lhe baLLery.
Pu back Lhe pus poe cover O and dsconnecL Lhe posLve (pus) cabe of Lhe baL-
Lery.
Hang Lhe rubber band O ouL Lo Lhe boLLom.
LfL Lhe baLLery up.
9.82 InstaIIin the battery
500069-TT
Pace Lhe baLLery n Lhe baLLery hoder.
4Ah baLLery (YTX5L-BS) ( p. 95)
ReconnecL Lhe rubber band O.
ALLach Lhe pus cabe and repace Lhe pus poe cover O.
ALLach Lhe mnus cabe O.
MounL Lhe seaL. ( p. 70)
9.83 kecharin the battery
Warnin
kisk of injury BaLLery acd and baLLery gases cause serous chemca burns.
Keep baLLeres ouL of Lhe reach of chdren.
wear suLabe proLecLve coLhng and gogges.
Avod conLacL wLh baLLery acd and baLLery gases.
Keep Lhe baLLery away from sparks or open fre. 0harge ony n we-venLaLed rooms.
In Lhe evenL of skn conLacL, rnse wLh arge amounLs of waLer. If baLLery acd geLs n Lhe eyes, rnse wLh waLer for aL easL
T5 mnuLes and conLacL a physcan.
Warnin
nvironentaI hazard 0omponenLs and baLLery acd are a danger Lo Lhe envronmenL.
Do noL dspose of baLLeres n norma househod wasLe. Take defecLve or used baLLeres Lo a baLLery recycng operaLor.
Warnin
Info
Even f Lhere s no oad on Lhe baLLery, L oses power every day.
The charge sLaLe and Lhe Lype of charge are very mporLanL for Lhe servce fe of Lhe baLLery.
FasL rechargng wLh a hgh charge currenL shorLens Lhe baLLery's servce fe.
If Lhe charge currenL, Lhe charge voLage and Lhe charge Lme are exceeded, eecLroyLe escapes Lhrough Lhe breaLhng hoes.
The baLLery capacLy s Lhen reduced.
If Lhe baLLery s dscharged from sLarLng, L musL be recharged mmedaLey.
If L sLands for a ong Lme n a dscharged sLaLe, Lhe baLLery becomes over-dscharged and sufaLed, and Lhen L s desLroyed.
The baLLery s manLenance-free, .e., Lhe acd eve does noL have Lo be checked.
SwLch off a power consumers and swLch off Lhe engne.
DsconnecL Lhe mnus (negaLve) cabe of Lhe baLLery Lo avod damage Lo Lhe moLor-
cyce's eecLroncs.
400240-T0
0onnecL Lhe baLLery charger Lo Lhe baLLery. SwLch on Lhe baLLery charger.
BaLLery charger (58429074000)
You can aso use Lhe baLLery charger Lo LesL resL poLenLa and sLarL poLenLa of Lhe
baLLery, and Lo LesL Lhe generaLor. wLh Lhs devce, you cannoL overcharge Lhe baL-
Lery.
Info
Never remove Lhe d O.
0harge Lhe baLLery wLh aL mosL T0% of Lhe capacLy specfed on Lhe baL-
Lery O.
SwLch off Lhe charger afLer chargng. DsconnecL Lhe baLLery.
0udene
The charge currenL, charge voLage and charge Lme musL noL be exceeded.
0harge Lhe baLLery reguary when Lhe
moLorcyce s noL n use.
3 monLhs
9.84 keovin a fuse
SwLch off a power-consumng componenLs and swLch off Lhe engne.
DsmounL Lhe ar fLer box d. ( p. 74)
400270-T0
Remove Lhe proLecLon cover O.
Info
The fuse O s ocaLed n Lhe sLarLer reay O under Lhe fLer box cover.
Remove Lhe fuse O.
9.85 InstaIIin the fuse
Warnin
Fire hazard The eecLrca sysLem can be overoaded by Lhe use of ncorrecL fuses.
Use ony fuses wLh Lhe prescrbed amperage. Never by-pass or repar fuses.
400273-T0
InserL Lhe fuse.
Fuse (580TTT09TT0)
Info
A reserve fuse O s ocaLed n Lhe sLarLer reay.
Repace a burned-ouL fuse O ony by an equvaenL fuse.
If Lhe new fuse burns ouL, conLacL an auLhorzed KTM workshop.
Repace Lhe proLecLon cover.
InsLa Lhe ar fLer box d. ( p. 74)
9.86 keovin the seat
500080-T0
Remove screw O. LfL up Lhe seaL aL Lhe rear, pu L back and Lhen remove from
above.
9.87 Mountin the seat
500068-0T
Hook n Lhe fronL of Lhe seaL aL Lhe coar seeve of Lhe fue Lank, ower L aL Lhe rear
and smuLaneousy push L forward.
Make sure LhaL Lhe seaL s correcLy ocked n.
MounL and LghLen Lhe screw of Lhe seaL fxng.
0udene
9.88 0isountin the fueI tank
0aner
Warnin
Avod conLacL beLween fue and skn, eyes and coLhng. Do noL nhae fue vapors. If fue geLs nLo your eyes, rnse mmed-
aLey wLh waLer and conLacL a docLor. wash affecLed skn areas mmedaLey wLh soap and waLer. If fue s swaowed, con-
LacL a docLor mmedaLey. 0hange coLhng LhaL has come nLo conLacL wLh fue. SLore fue n a suLabe cansLer accordng
Lo reguaLons and keep L ouL of Lhe reach of chdren.
500T57-T0
Pu off Lhe fue hose.
Info
Remanng fue may run ouL of Lhe fue hose.
Remove screws O wLh coar seeve.
(aII X0 odeIs)
Hang Lhe horn and horn brackeL Lo one sde.
8000T9-T0
Remove screw O wLh coar seeve.
Remove Lhe Lube from Lhe fue Lank venL ne.
500067-T0
Pu boLh spoers Lo Lhe sde of Lhe radaLor brackeL O and Lake Lhe fue Lank away
upwards.
9.89 InstaIIin the fueI tank
0aner
Warnin
Avod conLacL beLween fue and skn, eyes and coLhng. Do noL nhae fue vapors. If fue geLs nLo your eyes, rnse mme-
daLey wLh waLer and conLacL a docLor. wash affecLed skn areas mmedaLey wLh soap and waLer. If fue s swaowed,
conLacL a docLor mmedaLey. 0hange coLhng LhaL has come nLo conLacL wLh fue.
500067-0T
PosLon Lhe fue Lank and nsLa Lhe Lwo spoers Lo Lhe sde of Lhe radaLor fxng.
Make sure LhaL no cabes or Bowden cabes are Lrapped or damaged.
8000T9-TT
MounL Lhe fue Lank venL hose.
MounL and LghLen screw O wLh Lhe coar seeve.
0udene
(aII X0 odeIs)
PosLon Lhe horn wLh Lhe horn brackeL.
500T57-TT
MounL and LghLen screws O wLh Lhe coar seeve.
0udene
0onnecL Lhe fue hose.
9.90 0ooIin syste
400335-T0
The waLer pump O n Lhe engne forces Lhe cooanL Lo fow.
The pressure resuLng from Lhe warmng of Lhe coong sysLem s reguaLed by a vave
n Lhe radaLor cap O. The specfed cooanL LemperaLure s Lherefore permssbe wLh-
ouL danger of funcLon probems.
T20 0 (248 F)
0oong s effecLed by Lhe ar sLream.
The ower Lhe speed, Lhe ess Lhe coong effecL. DrLy coong fns aso reduce Lhe coo-
ng effecL.
(X0 8IX 0AY8, X0-W ZA)
The radaLor fan provdes exLra coong. IL s conLroed by a LhermoswLch.
9.91 0heckin antifreeze and cooIant IeveI
Warnin
0aner of scaIdin The cooanL geLs very hoL when Lhe moLorcyce s drven and s under hgh pressure.
Do noL open Lhe radaLor, radaLor hoses or oLher coong sysLem componenLs when Lhe engne s hoL. Aow Lhe engne and
coong sysLem Lo coo down. If you scad yoursef, hod Lhe affecLed area under cod waLer mmedaLey.
Warnin
0aner of poisonin 0ooanLs are posonous and a heaLh hazard.
Avod conLacL beLween cooanLs and skn, eyes and coLhng. If fue geLs nLo your eyes, rnse mmedaLey wLh waLer and
conLacL a docLor. wash affecLed skn areas mmedaLey wLh soap and waLer. If cooanL s swaowed, conLacL a docLor
mmedaLey. 0hange coLhes LhaL have come nLo conLacL wLh cooanLs. Keep cooanLs ouL of Lhe reach of chdren.
400243-T0
SLand Lhe moLorcyce uprghL on a horzonLa surface.
Remove Lhe radaLor cap.
0heck anLfreeze of cooanL.
~25. ~45 0 (~T3. ~49 F)
If Lhe anLfreeze of Lhe coong qud does noL meeL specfcaLons.
0orrecL anLfreeze of cooanL.
0heck Lhe cooanL eve n Lhe radaLor.
0ooanL eve O above radaLor fns. T0 mm (0.39 n)
If Lhe eve of Lhe coong qud does noL meeL specfcaLons.
0orrecL Lhe cooanL eve.
AIternative 1
0ooanL ( p. T06)
AIternative 2
0ooanL (mxed ready Lo use) ( p. T06)
RefL Lhe radaLor cap.
9.92 0heckin the cooIant IeveI
Warnin
Warnin
400243-T0
Remove Lhe radaLor cap.
0heck Lhe cooanL eve n Lhe radaLor.
0ooanL eve O above radaLor fns. T0 mm (0.39 n)
If Lhe eve of Lhe coong qud does noL meeL specfcaLons.
0orrecL Lhe cooanL eve.
AIternative 1
0ooanL ( p. T06)
AIternative 2
9.93 0rainin cooIant
Warnin
Warnin
400335-TT
Pace a suLabe conLaner under Lhe waLer pump cover.
Remove screw O. Remove Lhe radaLor cap O.
0ompeLey dran Lhe cooanL.
MounL and LghL screw O wLh a new sea rng.
0udene
Screw, waLer pump cover M6x25 T0 Nm (7.4 bf fL)
9.94 kefiIIin cooIant
Warnin
400244-T0
Make sure LhaL Lhe screw O s LghLened.
Pour cooanL n up Lo measuremenL O above Lhe radaLor fns.
0udene
T0 mm (0.39 n)
0ooanL 0.95 (T qL.) 0ooanL ( p. T06)
0ooanL (mxed ready Lo use)
( p. T06)
Make a shorL LesL rde.
9.95 0Iass fiber yarn fiIIin of ain siIencer
The man sencer s fed wLh gass fber yarn.
0ver a perod, Lhe fbers of Lhe nsuaLng maLera vansh nLo Lhe ar, and Lhe sencer "burns ouL".
NoL ony s Lhe nose eve hgher, Lhe performance characLersLc changes.
9.96 keovin ain siIencer
Warnin
0aner of burns The exhausL sysLem geLs very hoL when Lhe vehce s drven.
Aow Lhe exhausL sysLem Lo coo down. Do noL Louch hoL componenLs.
800020-T0
DsconnecL sprng O.
Remove screws O and Lake off man sencer.
9.97 InstaIIin the ain siIencer
800020-TT
MounL Lhe man sencer. MounL and LghLen screws O.
0udene
ReconnecL sprng O.
9.98 0isountin the air fiIter box Iid
80002T-T0
Pu off Lhe ar fLer box d n area O Lo Lhe sde and remove Lo Lhe fronL.
9.99 InstaIIin the air fiIter box Iid
80002T-TT
InserL Lhe ar fLer box d nLo Lhe rear area O and cp L nLo Lhe fronL area O.
9.100 keovin the air fiIter
hote
nine faiIure UnfLered nLake ar has a negaLve effecL on Lhe servce fe of Lhe engne.
Never rde Lhe vehce wLhouL an ar fLer snce dusL and drL can geL nLo Lhe engne and resuL n ncreased wear.
Warnin
DsmounL Lhe ar fLer box d. ( p. 74)
500T07-T0
Hang Lhe ar fLer hoder O ouL Lo Lhe boLLom and swng L Lo Lhe sde. Remove Lhe
ar fLer wLh Lhe ar fLer supporL.
Remove Lhe ar fLer from Lhe ar fLer supporL.
9.101 InstaIIin the air fiIter
500T07-T0
MounL Lhe cean ar fLer onLo Lhe ar fLer supporL.
PuL n boLh parLs LogeLher, posLon Lhem and fx Lhem wLh Lhe ar fLer supporL O.
Info
If Lhe ar fLer s noL correcLy mounLed, dusL and drL can peneLraLe nLo Lhe
engne and can cause damage.
InsLa Lhe ar fLer box d. ( p. 74)
9.102 0Ieanin air fiIter
Warnin
Info
Do noL cean Lhe ar fLer wLh fue or peLroeum snce Lhese subsLances aLLack Lhe foam.
Remove Lhe ar fLer. ( p. 75)
wash Lhe ar fLer Lhoroughy n speca ceanng qud and aow L Lo dry propery.
Ar fLer ceaner ( p. T07)
Info
0ny press Lhe ar fLer Lo dry L, never wrng L ouL.
0 Lhe dry ar fLer wLh a hgh quaLy fLer o.
0 for foam ar fLer ( p. T08)
0ean Lhe ar fLer box.
0heck carbureLor connecLon booL for damage and LghLness.
InsLa Lhe ar fLer. ( p. 75)
9.103 Adjustin basic position of cIutch Iever
500T33-TT
Ad|usL Lhe basc seLLng of Lhe cuLch ever Lo your hand sze by Lurnng ad|usLng
screw O.
Info
Turn Lhe ad|usLng screw cockwse Lo ncrease Lhe dsLance beLween Lhe
cuLch ever and Lhe handebar.
Turn Lhe ad|usLng screw counLercockwse Lo decrease Lhe dsLance beLween
Lhe cuLch ever and Lhe handebar.
9.104 0heckin the fIuid IeveI of hydrauIic cIutch
Warnin
Info
The fud eve rses wLh ncreasng wear of Lhe cuLch nng dsc.
400339-T0
Move Lhe cuLch fud reservor mounLed on Lhe handebar Lo a horzonLa posLon.
Remove screws O.
0heck Lhe fud eve.
Fud eve under Lop eve of conLaner. 4 mm (0.T6 n)
If Lhe eve of Lhe fud does noL meeL specfcaLons.
0orrecL Lhe fud eve of Lhe hydrauc cuLch.
Info
0ean up overfowed or spL fud mmedaLey wLh waLer.
9.105 0hanin the hydrauIic cIutch fIuid
Warnin
Warnin
Info
The fud eve rses wLh ncreasng wear of Lhe cuLch nng dsc.
400339-T0
Move Lhe cuLch fud reservor mounLed on Lhe handebar Lo a horzonLa posLon.
Remove screws O.
500T58-T0
F beedng syrnge O wLh Lhe appropraLe hydrauc fud.
Beed syrnge (50329050000)
0n Lhe save cynder, remove beeder screw O and mounL beedng syrnge O.
400340-T0
In|ecL Lhe qud nLo Lhe sysLem unL L escapes from bore hoe O of Lhe masLer
cynder wLhouL bubbes.
To prevenL overfow, dran fud occasonay from Lhe masLer cynder reservor.
Remove Lhe beedng syrnge. MounL and LghLen screws beeder screw.
0orrecL Lhe fud eve of Lhe hydrauc cuLch.
0udene
Fud eve under Lop eve of conLaner. 4 mm (0.T6 n)
Info
0ean up overfowed or spL fud mmedaLey wLh waLer.
9.106 0arburetor - idIe
40034T-T0
The de seLLng of Lhe carbureLor has a bg nfuence on Lhe sLarLng behavor, sLabe
dng and Lhe response Lo LhroLLe openng. ThaL means LhaL an engne wLh a correcLy
seL de speed s easer Lo sLarL Lhan f Lhe de s seL wrongy.
Info
The carbureLor and Ls componenLs are sub|ecL Lo ncreased wear caused by
engne vbraLon. wear can resuL n mafuncLonng.
The de speed s ad|usLed wLh Lhe ad|usLmenL screw O.
The de mxLure s ad|usLed wLh Lhe de mxLure ad|usLmenL screw O.
9.107 0arburetor - adjustin idIe
40034T-T0
Screw n Lhe de ad|usLng screw O unL L sLops and Lhen Lo Lhe prescrbed basc
seLLng.
0udene
Ide mxLure ad|usLng screw (400 EX0)
0pen 0.75 Lurn
Ide mxLure ad|usLng screw (530 EX0, 530 EX0 SIX DAYS, 450 X0-w ZA,
530 X0-w ZA)
0pen T.5 Lurns
Ide mxLure ad|usLng screw (450 EX0, 450 EX0 SIX DAYS, 400 X0-w USA,
450 X0-w USA)
0pen T.75 Lurns
Ide mxLure ad|usLng screw (530 X0-w USA)
0pen 2.0 Lurns
Ad|usLmenL Loo for mxLure conLro screw (77329034000)
Run Lhe engne unL warm.
0udene
warm-up Lme < 5 mn
0aner
Ad|usL Lhe de speed wLh ad|usLng screw O.
0udene
(EX0 AUS, X0-w) ( p. 20)
(EX0 EU, EX0 SIX DAYS) ( p. 2T)
Ide speed T,550. T,650 rpm
Turn Lhe de ad|usLng screw O sowy unL Lhe de speed begns Lo fa.
NoLe Lhe posLon and Lurn Lhe de ad|usLng screw sowy counLercockwse unL
Lhe de speed fas.
Ad|usL Lo Lhe ponL beLween Lhese Lwo posLons wLh Lhe hghesL de speed.
Info
If Lhere s a bg engne speed rse, reduce Lhe de speed Lo a norma eve
and repeaL Lhe above sLeps.
The exLreme sporL moLorcycsL w seL Lhe mxLure abouL of a Lurn back
from Lhs dea vaue (eaner, n a cockwse drecLon) snce Lhe engne
becomes hoLLer n sporLng use.
If Lhe procedure descrbed here does noL ead Lo saLsfacLory resuLs, Lhe
cause may be a wrongy dmensoned dng |eL.
If you can Lurn Lhe de ad|usLng screw Lo Lhe end wLhouL any change of
engne speed, you have Lo mounL a smaer dng |eL.
The de ad|usLng screw musL noL be opened more Lhan Lwo Lurns. If more
Lhan Lwo Lurns are necessary (rch mxLure), use a arger dng |eL.
AfLer changng Lhe dng |eL, sLarL from Lhe begnnng wLh Lhe ad|usLng
sLeps.
Ad|usL Lhe de speed wLh ad|usLng screw O.
0udene
(EX0 AUS, X0-w) ( p. 20)
(EX0 EU, EX0 SIX DAYS) ( p. 2T)
Info
Foowng exLreme ar LemperaLure or aLLude changes, ad|usL Lhe de speed
agan.
9.108 ptyin the carburetor fIoat chaber
0aner
Warnin
Warnin
nvironentaI hazard Improper handng of fue s a danger Lo Lhe envronmenL.
Do noL aow fue Lo geL nLo Lhe ground waLer, Lhe ground, or Lhe sewage sysLem.
Info
0arry ouL Lhs work wLh a cod engne.
No more fue fows from Lhe Lank Lo Lhe carbureLor.
500256-T0
DrecL Lhe hose of Lhe foaL chamber nLo a suLabe conLaner.
Info
waLer n Lhe foaL chamber resuLs n mafuncLonng.
Undo Lhe screw O (Lurn L counLercockwse) a few Lurns and dran Lhe fue from
Lhe foaL chamber.
TghLen screw O.
9.109 0heckin enine oiI IeveI
Info
The engne o eve musL be checked when Lhe engne s cod.
200TT9-T0
0ondition
Engne s cod.
0heck Lhe engne o eve.
The engne o musL be beLween Lhe hafway mark and Lhe Lop of Lhe o eve
vewer O.
If Lhe engne o eve s beow Lhe specfed eve.
Top up Lhe engne o. ( p. 82)
9.110 0hanin enine oiI and oiI fiIter, cIeanin enine oiI screen
Dran Lhe engne o and cean Lhe engne o screen. ( p. 80)
Remove Lhe o fLer. ( p. 80)
MounL Lhe o fLer. ( p. 8T)
F up wLh engne o. ( p. 8T)
9.111 0rainin enine oiI, cIeanin enine oiI screen
Warnin
0aner of scaIdin Engne o and gear o geL very hoL when Lhe moLocyce s drven.
wear suLabe proLecLve coLhng and goves. If you scad yoursef, hod Lhe affecLed area under cod waLer mmedaLey.
Warnin
Info
Dran Lhe engne o ony when Lhe engne s warm.
SLand Lhe moLorcyce on Ls sde sLand on a horzonLa surface.
200TT2-T0
Pace a suLabe conLaner under Lhe engne.
Remove engne o pug screen O.
0ompeLey dran Lhe engne o.
Thoroughy cean Lhe pug and gear o screen.
0ean Lhe seang area on Lhe engne.
MounL and LghLen Lhe pug of engne o screen O.
0udene
Pug, engne o screen MT7xT.5 20 Nm
(T4.8 bf fL)
9.112 keovin the oiI fiIter
Warnin
Warnin
200TT3-T0
Remove screws O. Remove o fLer cover O wLh 0-rng.
200TT4-T0
Pu Lhe o fLer nserL O ouL of Lhe o fLer casng.
0rcp pers reverse (5T0T20TT000)
0ompeLey dran Lhe engne o.
Thoroughy cean parLs and seang area.
9.113 Mountin oiI fiIter
200TT4-TT
Lay Lhe moLorcyce on Ls sde and f Lhe o fLer housng Lo abouL fu wLh
engne o.
F Lhe o fLer O wLh engne o and pace L n Lhe o fLer conLaner.
LubrcaLe Lhe 0-rng O of Lhe o fLer cover.
200TT3-TT
RefL Lhe o fLer cover O.
MounL and LghLen screws O.
0udene
Screw, o fLer cover M6 T0 Nm (7.4 bf fL)
SLand Lhe moLorcyce up.
9.114 FiIIin up with enine oiI
Info
Too LLe engne o or poor-quaLy engne o resuLs n premaLure wear Lo Lhe engne.
200TT5-T0
Remove Lhe screw cap O on Lhe generaLor cover and f up wLh engne o.
Engne o 0.60 (0.63 qL.) Engne o (SAE T0w/50) ( p. T06)
MounL and LghLen screw cap O.
0aner
SLarL Lhe engne and check LhaL L s o-LghL.
9.115 Toppin up enine oiI
Info
Too LLe engne o or poor-quaLy engne o resuLs n premaLure wear Lo Lhe engne.
200TT5-T0
Remove Lhe screw cap O on Lhe generaLor cover and f up wLh engne o.
Engne o (SAE T0w/50) ( p. T06)
0aner
9.116 0heckin ear oiI IeveI
Info
The gear o eve musL be checked when Lhe engne s cod.
200TT6-T0
0ondition
Engne s cod.
Remove gear o eve check screw O. SLand Lhe vehce uprghL.
0heck Lhe gear o eve.
A sma amounL of gear o shoud fow ouL.
If no gear o fows ouL.
Add gear o. ( p. 83)
MounL and LghLen Lhe gear o eve check screw.
0udene
Screw, gear o eve check M6 8 Nm (5.9 bf fL)
9.117 0hanin ear oiI, cIeanin ear oiI screen
Dran Lhe gear o and cean Lhe gear o screen. ( p. 82)
F up wLh gear o. ( p. 83)
9.118 0rainin ear oiI, cIeanin ear oiI screen
Warnin
Warnin
Info
Dran Lhe gear o ony when Lhe engne s warm.
SLand Lhe moLorcyce on Ls sde sLand on a horzonLa surface.
500T59-T0
Remove Lhe gear o dran pug O.
Pug - remove Lhe gear o screen O.
0ompeLey dran Lhe gear o.
Thoroughy cean Lhe gear o dran pug wLh a magneL.
Thoroughy cean Lhe dran pug and gear o screen wLh a magneL.
0ean Lhe seang area on Lhe engne.
MounL and LghLen gear o dran pug O wLh Lhe sea rng.
0udene
0ear o dran pug wLh magneL MT2xT.5 20 Nm
(T4.8 bf fL)
MounL and LghLen Lhe pug of gear o screen O.
0udene
Pug, gear o screen MT6xT.5 20 Nm
(T4.8 bf fL)
9.119 FiIIin up with ear oiI
Info
Too LLe gear o or poor-quaLy o resuLs n premaLure wear Lo Lhe Lransmsson.
200TT8-T0
Remove Lhe screw cap O and f up wLh gear o.
0ear o 0.90 (0.95 qL.) Engne o (SAE T0w/50) ( p. T06)
0aner
0heck Lhe gear o eve. ( p. 82)
9.120 Addin ear oiI
Info
Too LLe gear o or poor-quaLy o resuLs n premaLure wear Lo Lhe Lransmsson.
200TT6-T0
Remove gear o eve check screw O.
200TT8-TT
Remove screw cap O. SLand Lhe vehce uprghL.
Add gear o unL L fows ouL of Lhe bore of Lhe gear o eve screw.
Engne o (SAE T0w/50) ( p. T06)
MounL and LghLen Lhe gear o eve check screw.
0udene
0aner
Tk08L8h00TIh0 85
10 TROUBLESHOOTlNG
FauIts FossibIe cause Action
The engne cannoL be cranked (eecLrc
sLarLer).
0peraLng error 0o Lhrough Lhe sLeps of sLarLng Lhe
engne. ( p. 26)
BaLLery dscharged Recharge Lhe baLLery. ( p. 68)
0heck Lhe chargng voLage.
0heck Lhe cosed currenL.
0heck Lhe generaLor.
Fuse bown Remove Lhe fuse. ( p. 69)
InsLa Lhe fuse. ( p. 69)
SLarLer reay defecLve 0heck Lhe sLarLer reay.
SLarLer moLor defecLve 0heck Lhe sLarLer moLor.
Engne Lurns buL does noL sLarL. 0peraLng error 0o Lhrough Lhe sLeps of sLarLng Lhe
engne. ( p. 26)
MoLorcyce was ouL of use for a ong Lme
and Lhere s od fue n Lhe foaL chamber
EmpLy Lhe carbureLor foaL
chamber. ( p. 79)
Fue feed nLerrupLed 0heck Lhe fue Lank breaLher.
0ean Lhe fue Lap.
0heck/ad|usL Lhe carbureLor compo-
nenLs.
Engne fooded 0ean and dry Lhe spark pug or repace
f necessary.
Spark pug oy or weL 0ean and dry Lhe spark pug or repace
f necessary.
EecLrode dsLance (pug gap) of spark
pug Loo wde
Ad|usL pug gap.
0udene
Spark pug eecLrode gap
0.9 mm (0.035 n)
DefecL n gnLon sysLem 0heck Lhe gnLon sysLem.
ShorL-crcuL cabe n cabe harness
frayed, shorL-crcuL buLLon or emergency
0FF swLch defecLve
0heck Lhe wrng harness (vsua
check).
0heck Lhe eecLrca sysLem.
Pug connecLor of 0DI conLro devce,
puse generaLor or gnLon co oxdzed.
0ean Lhe pug connecLor and LreaL L
wLh conLacL spray.
waLer n carbureLor or |eLs bocked 0heck/ad|usL Lhe carbureLor compo-
nenLs.
Engne has no de. Idng |eL bocked 0heck/ad|usL Lhe carbureLor compo-
nenLs.
Ad|usLng screws on carbureLor dsLorLed 0arbureLor - ad|usL Lhe de speed.
( p. 78)
Spark pug defecLve 0hange spark pug.
IgnLon sysLem defecLve 0heck Lhe gnLon co.
0heck Lhe 0DI unL.
0heck Lhe spark pug connecLor.
0heck Lhe gnLon puse generaLor.
Engne does noL speed up. 0arbureLor runnng over because foaL
neede drLy or worn.
nenLs.
Loose carbureLor |eLs 0heck/ad|usL Lhe carbureLor compo-
nenLs.
0heck Lhe 0DI unL.
Tk08L8h00TIh0 86
FauIts FossibIe cause Action
Engne has Loo LLe power. Fue feed nLerrupLed 0heck Lhe fue Lank breaLher.
0ean Lhe fue Lap.
nenLs.
Ar fLer very drLy 0ean Lhe ar fLer. ( p. 75)
ExhausL sysLem eaky, deformed or Loo L-
Le gass fber yarn fng n man sencer
0heck exhausL sysLem for damage.
0hange gass fber yarn fng of man
sencer.
\ave cearance Loo LLe Ad|usL Lhe vave cearance.
0heck Lhe 0DI unL.
Engne sLas or s poppng nLo Lhe carbu-
reLor
Lack of fue Turn hande O of Lhe fue
Lap Lo Lhe 0h posLon.
(Fgure 500T37-T0 p. 20)
F up wLh fue. ( p. 28)
Engne Lakes n bad ar 0heck rubber seeves and carbureLor
for LghLness.
Engne overheaLs. Too LLe cooanL n coong sysLem 0heck Lhe coong sysLem for eakage.
Too LLe ar sLream SwLch off engne when sLandng.
RadaLor fns very drLy 0ean radaLor fns.
Foam formaLon n coong sysLem Dran Lhe cooanL. ( p. 73)
Ref Lhe cooanL. ( p. 73)
BenL radaLor hose 0hange Lhe radaLor hose.
ThermosLaL defecLve 0heck Lhe LhermosLaL.
0udene
0penng LemperaLure. 70 0 (T58 F)
DefecL n radaLor fan sysLem
(EX0 SIX DAYS, X0-w ZA)
0heck Lhe radaLor fan fuse.
0heck Lhe radaLor fan.
0heck Lhe LhermosLaL.
Hgh o consumpLon Engne venL hose benL RouLe Lhe venL hose wLhouL bends or
repace L f necessary.
Engne o eve Loo hgh 0heck Lhe engne o eve. ( p. 79)
Engne o Loo Lhn (ow vscosLy) 0hange Lhe engne o and o fLer
and cean Lhe engne o screen.
( p. 80)
PsLon or cynder s worn PsLon/cynder - deLermne Lhe mounL-
ng cearance
BaLLery dscharged The baLLery does noL charge 0heck Lhe chargng voLage.
0heck Lhe chargng currenL.
Undesred power consumer 0heck Lhe cosed currenL.
SpeedomeLer vaues deeLed (Lme, sLop
waLch, ap Lmes)
The baLLery n Lhe speedomeLer s empLy. 0hange Lhe baLLery n Lhe speedomeLer.
0LAhIh0 87
11 CLEANlNG
11.1 0Ieanin otorcycIe
hote
MateriaI daae Damage and desLrucLon of componenLs by hgh-pressure ceanng equpmenL.
Never cean Lhe vehce wLh hgh-pressure ceanng equpmenL or a sLrong waLer-|eL. The excessve pressure can peneLraLe eecLr-
ca componenLs, connecLs, Bowden cabes, and bearngs, eLc., and can damage or desLroy Lhese parLs.
Warnin
Info
If you cean Lhe moLorcyce reguary, Ls vaue and appearance are manLaned over a ong perod.
Avod drecL sunshne on Lhe moLorcyce durng ceanng.
Before you cean Lhe moLocyce, sea Lhe exhausL sysLem Lo prevenL peneLraLon by waLer.
FrsL remove coarse drL parLces wLh a genLe waLer spray.
Spray very drLy areas wLh a norma moLorcyce ceaner and Lhen cean wLh a panLbrush.
MoLorcyce ceaner ( p. T07)
Info
Use warm waLer conLanng norma moLorcyce ceaner and a sofL sponge.
AfLer rnsng Lhe moLorcyce wLh a genLe waLer spray, aow L Lo dry Lhoroughy.
Warnin
0aner of accidents Reduced brakng due Lo weL or drLy brakes.
0ean or dry drLy or weL brakes by rdng and brakng genLy.
AfLer ceanng, rde Lhe vehce a shorL dsLance unL Lhe engne warms up, and Lhen appy Lhe brakes.
Info
The heaL produced causes waLer aL naccessbe posLons n Lhe engne and Lhe brakes Lo evaporaLe.
Push back Lhe proLecLon covers on Lhe handebar nsLrumenLs Lo aow waLer Lo evaporaLe.
AfLer Lhe moLorcyce has cooed off, o or grease a movng parLs and bearngs.
TreaL bare meLa parLs (excepL for brake dscs and exhausL sysLem) wLh anL-corroson maLeras.
0eanng and poshng maLeras for meLa, rubber and pasLc ( p. T07)
TreaL a panLed parLs wLh a md panL posh.
Hgh-usLer posh for panL ( p. T07)
To prevenL eecLrca probems, LreaL eecLrc conLacLs and swLches wLh conLacL spray.
0onLacL spray ( p. T07)
(aII X0 odeIs)
LubrcaLe Lhe sLeerng ock.
Unversa o spray ( p. T08)
8T0kA0 88
12 STORAGE
12.1 8torae
Warnin
Info
If you wanL Lo garage Lhe moLorcyce for a onger perod, Lake Lhe foowng acLons.
Before sLorng Lhe moLorcyce, check a parLs for funcLon and wear. If servce, repars or repacemenLs are necessary, you
shoud do Lhs durng Lhe sLorage perod (ess workshop overoad). In Lhs way, you can avod ong workshop waLng Lmes aL Lhe
sLarL of Lhe new season.
0ean Lhe moLorcyce. ( p. 87)
0hange Lhe engne o and o fLer and cean Lhe engne o screen. ( p. 80)
0hange Lhe gear o and cean Lhe gear o screen. ( p. 82)
0heck Lhe anLfreeze and cooanL eve. ( p. 72)
Dran Lhe fue from Lhe Lanks nLo a suLabe conLaner.
Remove Lhe baLLery. ( p. 67)
Recharge Lhe baLLery. ( p. 68)
0udene
SLorage LemperaLure of baLLery wLhouL drecL sunshne. 0. 35 0 (32. 95 F)
The sLorage pace shoud be dry and noL sub|ecL Lo arge LemperaLure dfferences.
Info
KTM recommends proppng up Lhe moLorcyce.
0over Lhe moLorcyce wLh a porous sheeL or bankeL. Do noL use non-porous maLeras snce Lhey prevenL humdLy from escapng,
Lhus causng corroson.
Info
Avod runnng Lhe engne for a shorL Lme ony. Snce Lhe engne cannoL warm up propery, Lhe waLer vapor produced durng
combusLon condenses and causes vaves and exhausL sysLem Lo rusL.
12.2 Futtin into operation after storae
InsLa Lhe baLLery. ( p. 68)
F up wLh fue. ( p. 28)
0hecks before puLLng nLo operaLon ( p. 26)
Make a LesL rde.
T0hhI0AL 0ATA - h0Ih 89
13 TECHNlCAL DATA - ENGlNE
Desgn T-cynder 4-sLroke engne, waLer-cooed
DspacemenL (a 400 modes) 393.4 cm (24.007 cu n)
DspacemenL (a 450 modes) 449.3 cm (27.4T8 cu n)
DspacemenL (a 530 modes) 5T0.4 cm (3T.T47 cu n)
SLroke (a 400 modes) 55.5 mm (2.T85 n)
SLroke (a 450 modes) 63.4 mm (2.496 n)
SLroke (a 530 modes) 72 mm (2.83 n)
Bore 95 mm (3.74 n)
0ompresson raLo (a 400 modes) TT.T.T
0ompresson raLo (a 450/530 modes) TT.9.T
0onLro 0H0, 4 vaves conLroed va rocker arm, drve va LooLh/whee
chan
\ave dameLer, nLake 39.5 mm (T.555 n)
\ave dameLer, exhausL 3T.7 mm (T.248 n)
\ave cearance
0uLfeed aL. 20 0 (68 F) 0.T2. 0.T7 mm (0.0047. 0.0067 n)
Infeed aL. 20 0 (68 F) 0.T0. 0.T5 mm (0.0039. 0.0059 n)
0rankshafL bearng 2 grooved ba bearngs
0onrod bearng Neede bearng
PsLon pn bearng noL a bearng bush - DL0-paLed psLon pns
PsLons Forged ghL aoy
PsLon rngs T compresson rng, T o scraper rng
Engne ubrcaLon Pressure crcuaLon ubrcaLon wLh 2 roLor pumps (engne) / T
roLor pump (Lransmsson)
Prmary Lransmsson 33.76
0uLch MuLdsc cuLch n o baLh / hydraucay acLvaLed
Transmsson raLo
TsL gear T4.36
2nd gear T7.32
3rd gear T9.28
4Lh gear 22.26
5Lh gear 24.23
6Lh gear 26.2T
0eneraLor T2 \, T50 w
IgnLon 0onLacLess conLroed fuy eecLronc gnLon wLh dgLa gn-
Lon ad|usLmenL, Lype Kokusan
Spark pug N0K LKAR 8AI - 9
Spark pug eecLrode gap 0.9 mm (0.035 n)
0oong waLer coong, permanenL crcuaLon of cooanL by waLer pump
SLarLng ad EecLrc sLarLer / kcksLarLer
13.1 0apacity- enine oiI
Engne o 0.60 (0.63 qL.) Engne o (SAE T0w/50) ( p. T06)
T0hhI0AL 0ATA - h0Ih 90
13.2 0apacity - ear oiI
0ear o 0.90 (0.95 qL.) Engne o (SAE T0w/50) ( p. T06)
13.3 0apacity - cooIant
0ooanL 0.95 (T qL.) 0ooanL ( p. T06)
T0hhI0AL 0ATA - h0Ih TI0hThIh0 T0k08 91
14 TECHNlCAL DATA - ENGlNE TlGHTENlNG TORQUES
Screw, cabe hoder n generaLor cover M4 4 Nm (3 bf fL) Loctite
243
0 |eL, rocker arm ubrcaLon M5 2 Nm (T.5 bf fL) Loctite
243
0 |eL, psLon coong M5 2 Nm (T.5 bf fL) Loctite
243
Screw, ockng ever M5 6 Nm (4.4 bf fL) Loctite
243
Screw, gnLon puse generaLor M5 6 Nm (4.4 bf fL) Loctite
243
Lockng screw for bearng M5 6 Nm (4.4 bf fL) Loctite
243
Screw, o pump cover M5 6 Nm (4.4 bf fL) Loctite
222
0 |eL, conrod ubrcaLon M6x0.75 4 Nm (3 bf fL)
Beedng connecLon, Lransmsson M6 4 Nm (3 bf fL) Loctite
243
NuL, waLer-pump whee M6 8 Nm (5.9 bf fL) Loctite
243
Screw, kcksLarLer sLop M6 T0 Nm (7.4 bf fL) Loctite
243
Screw, Lmng chan securng gude M6 8 Nm (5.9 bf fL) Loctite
243
Screw, exhausL fange M6 T0 Nm (7.4 bf fL)
Screw, Lorque governor M6 T0 Nm (7.4 bf fL) Loctite
243
Screw, sLarLer moLor M6 T0 Nm (7.4 bf fL)
Screw, kcksLarLer sprng hanger M6 T0 Nm (7.4 bf fL)
Screw, Lmng chan gude ra M6 8 Nm (5.9 bf fL) Loctite
243
Screw generaLor cover M6x25 T0 Nm (7.4 bf fL)
Screw generaLor cover M6x40 T0 Nm (7.4 bf fL)
Screw, cuLch cover M6x25 T0 Nm (7.4 bf fL)
Screw, cuLch cover M6x30 T0 Nm (7.4 bf fL)
Screw, cuLch sprng M6 T0 Nm (7.4 bf fL)
Screw, engne housng M6x60 T0 Nm (7.4 bf fL)
Screw, engne housng M6x75 T0 Nm (7.4 bf fL)
Screw, camshafL bearng supporL M6 T0 Nm (7.4 bf fL) Loctite
243
Screw, o fLer cover M6 T0 Nm (7.4 bf fL)
Screw, shfL drum ocaLng M6 T0 Nm (7.4 bf fL) Loctite
243
Screw, shfL ever M6 T0 Nm (7.4 bf fL) Loctite
243
Screw, Lmng chan Lensonng ra M6 8 Nm (5.9 bf fL) Loctite
243
Screw, sLaLor brackeL M6 T0 Nm (7.4 bf fL) Loctite
243
Pug, vacuum connecLon M6 5 Nm (3.7 bf fL) Loctite
243
Screw, vave cover M6 T0 Nm (7.4 bf fL)
Screw, der M6 T0 Nm (7.4 bf fL) Loctite
243
Screw, cynder head M6 T0 Nm (7.4 bf fL)
Screw, rocker arm bearng M7xT T5 Nm (TT.T bf fL)
Pug, o channe M7 9 Nm (6.6 bf fL) Loctite
243
Screw, kcksLarLer M8 25 Nm (T8.4 bf fL) Loctite
243
Pug, crankshafL ocaLon M8 T0 Nm (7.4 bf fL)
Baancer shafL nuL MT0xT 40 Nm (29.5 bf fL)
Screw, unockng of Lmng chan Len-
soner
MT0xT T0 Nm (7.4 bf fL)
Screw, engne sprockeL MT0 60 Nm (44.3 bf fL) Loctite
243
Pug, o channe MT0 T5 Nm (TT.T bf fL) Loctite
243
T0hhI0AL 0ATA - h0Ih TI0hThIh0 T0k08 92
Screw, cynder head MT0xT.25 TghLenng sequence.
TghLen dagonay, begn-
nng wLh Lhe rear screw on
Lhe chan shafL.
SLep T
T0 Nm (7.4 bf fL)
SLep 2
30 Nm (22.T bf fL)
SLep 3
50 Nm (36.9 bf fL)
ubrcaLed wLh engne o
NuL, roLor MT2xT 60 Nm (44.3 bf fL)
Spark pug MT2xT.25 T5. 20 Nm (TT.T.
T4.8 bf fL)
0ear o dran pug wLh magneL MT2xT.5 20 Nm (T4.8 bf fL)

Pug, SLS MT2xT.5 20 Nm (T4.8 bf fL)
0 pressure conLro vave pug MT2xT.5 20 Nm (T4.8 bf fL)
Pug, rocker arm MT4xT.25 20 Nm (T4.8 bf fL)
Pug, gear o screen MT6xT.5 20 Nm (T4.8 bf fL)
Pug, engne o screen MT7xT.5 20 Nm (T4.8 bf fL)
NuL, nner cuLch hub MT8xT.5 80 Nm (59 bf fL)
NuL, prmary gear M20LHxT.5 T00 Nm (73.8 bf fL) Loctite
243
Pug, Lmng chan Lensoner M24xT.5 30 Nm (22.T bf fL)
T0hhI0AL 0ATA - 0Ak8kT0k 93
15 TECHNlCAL DATA - CARBURETOR
15.1 400 X0
0arbureLor Lype KEIHIN F0R-MX 39
0arbureLor denLfcaLon number 3900N
Neede posLon 5Lh posLon from Lop
Ide mxLure ad|usLng screw
0pen 0.75 Lurn
Pump membrane sLop 2.T5 mm (0.0846 n)
Man |eL T80
JeL neede 0BDYU (0BDT0)
Idng |eL 42
Ide ar |eL T00
0od sLarL |eL 65 (85)
Leakage nozze 40
Sde sLop presenL
15.2 400 X0-W 8A
0arbureLor denLfcaLon number 3900w
Neede posLon TsL posLon from Lop
0pen T.75 Lurns
Man |eL T80
JeL neede 0BDT0
Idng |eL 42
Ide ar |eL T00
0od sLarL |eL 85
Leakage nozze 40
15.3 450 X0, 450 X0 8IX 0AY8
0arbureLor denLfcaLon number 3900I
0pen T.75 Lurns
Man |eL T80
JeL neede 0BDYU (0BDT0)
Idng |eL 40
Ide ar |eL T00
Leakage nozze 40
Sde sLop presenL
T0hhI0AL 0ATA - 0Ak8kT0k 94
15.4 450 X0-W
0arbureLor denLfcaLon number 3900L
Neede posLon (450 X0-w USA) TsL posLon from Lop
Neede posLon (450 X0-w ZA) 4Lh posLon from Lop
Ide mxLure ad|usLng screw (450 X0-w ZA)
0pen T.5 Lurns
0pen T.75 Lurns
Man |eL (450 X0-w USA) T80
Man |eL (450 X0-w ZA) T85
JeL neede 0BDT0
Idng |eL 40
Ide ar |eL T00
0od sLarL |eL 85
Leakage nozze 40
15.5 530 X0, 530 X0 8IX 0AY8
0arbureLor denLfcaLon number 3900J
0pen T.5 Lurns
Man |eL T80
JeL neede 0BDZT (0BDTR)
Idng |eL 40
Ide ar |eL T00
Leakage nozze 40
Sde sLop presenL
15.6 530 X0-W
0arbureLor denLfcaLon number 3900M
Neede posLon (530 X0-w USA) TsL posLon from Lop
Neede posLon (530 X0-w ZA) 4Lh posLon from Lop
Ide mxLure ad|usLng screw (530 X0-w ZA)
0pen T.5 Lurns
0pen 2.0 Lurns
Man |eL (530 X0-w USA) T80
Man |eL (530 X0-w ZA) T85
JeL neede 0BDTR
Idng |eL 40
Ide ar |eL T00
0od sLarL |eL 85
Leakage nozze 40
T0hhI0AL 0ATA - 0hA88I8 95
16 TECHNlCAL DATA - CHASSlS
Frame 0enLra Lube frame made of chrome moybdenum sLee Lubng
Fork WF 8uspension 4860 MXMA PA
Suspenson Lrave
FronL 300 mm (TT.8T n)
Rear 335 mm (T3.T9 n)
Fork offseL (EX0 SIX DAYS, X0-w USA) T9 mm (0.75 n)
Fork offseL (EX0 EU, EX0 AUS, X0-w ZA) 20 mm (0.79 n)
Shock absorber WF 8uspension PDS 50T8 D00
Brake sysLem Dsc brakes, brake capers on foaLng bearngs
DameLer of brake dscs
FronL 260 mm (T0.24 n)
Rear 220 mm (8.66 n)
wear mL of brake dscs
FronL 2.5 mm (0.098 n)
Rear 3.5 mm (0.T38 n)
Tre ar pressure off road
FronL T.0 bar (T5 ps)
Rear T.0 bar (T5 ps)
Road Lre pressure (a EX0 modes)
fronL T.5 bar (22 ps)
Rear 2.0 bar (29 ps)
Fna drve (400 EX0, 450 EX0, 450 EX0 SIX DAYS) T5.45 (T3.52)
Fna drve (400 X0-w, 450 X0-w) T3.52
Fna drve (530 X0-w) T4.52
Fna drve (530 EX0, 530 EX0 SIX DAYS) T5.45 (T4.52)
0han 5/8 x T/4"
Rear sprockeLs avaabe 38, 40, 42, 45, 48, 49, 50, 5T, 52
SLeerng head ange 63.5
wheebase T,475T0 mm (58.070.39 n)
SeaL heghL unoaded 985 mm (38.78 n)
0round cearance unoaded 380 mm (T4.96 n)
weghL wLhouL fue, approx. (a EX0 modes) TT3.9 kg (25T.T b.)
weghL wLhouL fue, approx. (X0-w USA) TT2.2 kg (247.4 b.)
weghL wLhouL fue, approx. (X0-w ZA) TT3 kg (249 b.)
Maxmum permssbe fronL axe oad T45 kg (320 b.)
Maxmum permssbe rear axe oad T90 kg (4T9 b.)
Maxmum permssbe overa weghL 335 kg (739 b.)
4Ah baLLery YTX5L-BS BaLLery voLage. T2 \
Nomna capacLy. 4 Ah
manLenance-free
16.1 Lihtin equipent
HeadghL (EX0, EX0 SIX DAYS, X0-w ZA) BA20d T2 \
35/35 w
Parkng ghL (EX0, EX0 SIX DAYS,
X0-w ZA)
w2,Tx9,5d T2 \
5 w
IndcaLor ghLs (a EX0 modes) w2x4,6d T2 \
T.2 w
Fasher ghL (a EX0 modes) BAT5s T2 \
T0 w
Brake / La ghL (EX0, EX0 SIX DAYS,
X0-w ZA)
LED
T0hhI0AL 0ATA - 0hA88I8 96
Lcence paLe amp (a EX0 modes) w2,Tx9,5d T2 \
5 w
16.2 Tires
VaIidity Front tire kear tire
(a EX0 modes) 90/90 - 21 M/0 54M M+8 TT
MeLzeer M0E 6 DAYS EXTREME
140/80 - 18 M/0 70M M+8 TT
MeLzeer M0E 6 DAYS EXTREME
(a X0-w modes) 80/100 - 21 51M TT
BrdgesLone M59
110/100 - 18 64M TT
BrdgesLone M402
For furLher nformaLon, see Lhe Servce secLon under.
hLLp.//www.kLm.com
16.3 0apacity - fueI
ToLa fue Lank capacLy,
approx. (EX0, EX0 SIX DAYS,
X0-w ZA)
9.0 (2.38 US ga) Super uneaded (R0Z 95 / R0N 95 / P0N 9T) ( p. T06)
ToLa fue Lank capacLy,
approx. (X0-w USA)
9.2 (2.43 US ga) Super uneaded (R0Z 95 / R0N 95 / P0N 9T) ( p. T06)
Fue reserve, approx. 2 (2 qL.)
T0hhI0AL 0ATA - F0kk 97
17 TECHNlCAL DATA - FORK
Fork parL number T4.T8.7E.06
Fork WF 8uspension 4860 MXMA PA
0ompresson dampng
0omforL 26 ccks
SLandard 22 ccks
SporL 20 ccks
Rebound dampng
0omforL 24 ccks
SLandard 22 ccks
SporL 22 ccks
Sprng engLh wLh preoad spacer(s) 5T0 mm (20.08 n)
Sprng raLe
weghL of rder. 65. 75 kg (T43. T65 b.) 4.4 N/mm (25.T b/n)
weghL of rder. 75. 85 kg (T65. T87 b.) 4.6 N/mm (26.3 b/n)
weghL of rder. 85. 95 kg (T87. 209 b.) 4.8 N/mm (27.4 b/n)
Ar chamber engLh TT0
+20
~30
mm (4.33
+0.79
~T.T8
n)
Sprng preoad - FreIoad Adjuster
0omforL 2 Lurns
SLandard 2 Lurns
SporL 4 Lurns
Fork engLh 940 mm (37.0T n)
F0RK 0IL Fork o (SAE 5) ( p. T06)
T0hhI0AL 0ATA - 8h00k A880k8k 98
18 TECHNlCAL DATA - SHOCK ABSORBER
Shock absorber parL number T2.T8.7E.06
Shock absorber WF 8uspension PDS 50T8 D00
0ompresson dampng, ow-speed
0omforL T8 ccks
SLandard T5 ccks
SporL T2 ccks
0ompresson dampng, hgh-speed
0omforL 2 Lurns
SLandard T.5 Lurns
SporL T Lurn
Rebound dampng
0omforL 26 ccks
SLandard 24 ccks
SporL 22 ccks
Sprng preoad 9 mm (0.35 n)
Sprng raLe
weghL of rder. 65. 75 kg (T43. T65 b.) 69 N/mm (394 b/n)
weghL of rder. 75. 85 kg (T65. T87 b.) 72 N/mm (4TT b/n)
weghL of rder. 85. 95 kg (T87. 209 b.) 76 N/mm (434 b/n)
Sprng engLh 250 mm (9.84 n)
0as pressure T0 bar (T45 ps)
SLaLc sag 35 mm (T.38 n)
Rdng sag T05 mm (4.T3 n)
FLLed engLh 4TT mm (T6.T8 n)
T0hhI0AL 0ATA - 0hA88I8 TI0hThIh0 T0k08 99
19 TECHNlCAL DATA - CHASSlS TlGHTENlNG TORQUES
Spoke nppe, fronL whee M4,5 5 Nm (3.7 bf fL)
Spoke nppe, rear whee M5 5 Nm (3.7 bf fL)
Screw, spoer on fue Lank (X0-w USA) M5xT2 T.5 Nm (T.TT bf fL)
Remanng nuLs, chasss M6 T5 Nm (TT.T bf fL)
Screw, rear brake dsc M6 T4 Nm (T0.3 bf fL)
Screw, fronL brake dsc M6 T4 Nm (T0.3 bf fL)
Screw, shock absorber ad|usLng rng M6 5 Nm (3.7 bf fL)
Screw, ba |onL of push rod on fooL-
brake cynder
M6 T0 Nm (7.4 bf fL)
NuL, rear sprockeL screw M8 35 Nm (25.8 bf fL) Loctite
243
NuL, rm ock M8 T0 Nm (7.4 bf fL)
Remanng nuLs, chasss M8 30 Nm (22.T bf fL)
Remanng screws, chasss M8 25 Nm (T8.4 bf fL)
Screw, fronL brake caper M8 25 Nm (T8.4 bf fL) Loctite
243
Screw, Lop Lrpe camp
(EX0 SIX DAYS, X0-w USA)
M8 T7 Nm (T2.5 bf fL)
Screw, Lop Lrpe camp (EX0 EU,
EX0 AUS, X0-w ZA)
M8 20 Nm (T4.8 bf fL)
Screw, boLLom Lrpe camp
M8 T2 Nm (8.9 bf fL)
Screw, boLLom Lrpe camp (EX0 EU,
EX0 AUS, X0-w ZA)
M8 T5 Nm (TT.T bf fL)
Screw, fork sLub M8 T5 Nm (TT.T bf fL)
Screw, Lop sLeerng sLem
M8 T7 Nm (T2.5 bf fL) Loctite
243
Screw, Lop sLeerng sLem (EX0 EU,
EX0 AUS, X0-w ZA)
M8 20 Nm (T4.8 bf fL)
Screw, handebar camp (EX0 EU,
EX0 AUS, X0-w)
M8 20 Nm (T4.8 bf fL)
Screw, handebar camp
(EX0 SIX DAYS)
M8 T6 Nm (TT.8 bf fL)
Screw, engne brace M8 33 Nm (24.3 bf fL)
Screw, subframe M8 35 Nm (25.8 bf fL) Loctite
243
Screw, sde sLand fxng M8 40 Nm (29.5 bf fL) Loctite
243
Engne carryng screw MT0 60 Nm (44.3 bf fL)
Remanng nuLs, chasss MT0 50 Nm (36.9 bf fL)
Remanng screws, chasss MT0 45 Nm (33.2 bf fL)
Screw, handebar supporL MT0 40 Nm (29.5 bf fL) Loctite
243
NuL, seaL fxng MT2xT 20 Nm (T4.8 bf fL)
Screw, Lop shock absorber MT2 80 Nm (59 bf fL) Loctite
243
Screw, boLLom shock absorber MT2 80 Nm (59 bf fL) Loctite
243
NuL, swngarm pvoL MT6xT.5 T00 Nm (73.8 bf fL)
Screw-n nozzes, coong sysLem M20xT.5 T2 Nm (8.9 bf fL) Loctite
243
Screw, fronL whee spnde M24xT.5 45 Nm (33.2 bf fL)
B
T
/3
B
G
/3
A
H
/2
A
K
/2
1
2
B
V
/2
B
O
/2
AH1/2
AK1/2
B
F
/1
B
A
/1
A
C
/6
B
C
/6
B
A
1
/1
B
F
1
/1
G
A
H
2
/2
AJ1/3
BG1/3
v
BA2/1
U
CE/4
CA/4
B
U
/1
8
CW/2
CX/2
CW1/2
CX1/2
CW2/2
CX2/2
CW3/2
CX3/2
E
I/1
E
H
/1
1
2
.1
B
K
/4
B
R
/4
1
2
3
4
5
A
t
M
AJ/3
BG/3
B
V
/2
B
S
/2
1 2 3
2
.1
2
.2
1 2
DI/2
CY/3
CZ/3
DA/4
DB/4
CW/2
CX/2
BP/4
DG/4
M
A
1
0
A
F
/4
4
3
2
A
M
/3
A
R
/3
G
3
3
2
2
2
1
A
T
/2
1
1
A
T
1
/2
A
L
/2
A
L
1
/2
2
3
4
2
6
2
5
1
1
3
1
1
1
1
2
2
1
2
2
2
2
CR1/1
CR/1
1 1
1
2 3
3
4
4
3
3
3 2
P1
B3
H13
H15
H18
S2
H4
H11
H7
H2
H9
H3
H5
H1
N2
G
2
B
1
L
1
L
2
A
6
S
5
S
6
S
7
K
2
S
8
E
6
S
1
0
M
1
K
1
G
1
H
1
4
S
1
1
4
1
2
5
6
7
1
1
1
0
1
2
1
3
1
4
2 1 2 1
2 1
2 1
4
re-wh
re-bl
gn
re
re
gn
re-bl
re-wh
ye-bl
br
ye-bl
ye
br
or
pu
bl
or
ye-re
br
re
ye
gn
bu
wh
b
u
g
n
ye-re
br
ye-re
br
ye
wh
bu
ye
bl
bl
ye
bu
br
ye-re
br
bl
wh-re
ye-re
bl
wh-re
ye-re
ye-bl
wh-gn
br
wh
bu-wh
bu-wh
br
gr
gr bl-wh
bl
br
br
br bl
br
bl
y
e
-
r
e
y
e
b
r
b
l
w
h
b
r
p
u
b
r
b
l
b
r
w
h
b
r
p
u
r
e y
e
-
r
e
y
e
-
b
l
y
e
-
b
l
y
e
b
u
b
r
b
l
p
u
b
l
b
l
r
e
b
u
w
h
b
r
y
e
-
r
e
b
r
-
b
l
b
r
b
l
p
u
b
r
b
r
b
r
w
h
-
g
n
w
h
-
g
n
w
h
4/
K
B
4/
R
B
1
2
3
4
S
1
0
S
1
1
C
V
/2
B
L
/2
B
V
/2
B
S
/2
X
1
WIkIh0 0IA0kAM 100
20 WlRlNG DlAGRAM
20.1 Wirin diara (aII X0 odeIs)
500247-T0
WIkIh0 0IA0kAM 101
0oponents
A6 0DI conLroer
BT ThroLLe posLon sensor
B3 whee speed sensor
E6 ThermoswLch (EX0 SIX DAYS)
0T BaLLery
02 0eneraLor
HT RghL rear fasher
H2 LefL fronL fasher
H3 LefL rear fasher
H4 RghL fronL fasher
H5 Brake/La ghL
H7 Parkng ghL
H9 Lcense paLe amp
HTT Low/hgh beam
HT3 Horn
HT4 RadaLor fan (EX0 SIX DAYS)
HT5 Fasher ndcaLor ghL
HT8 Hgh beam ndcaLor ghL
KT SLarLer reay wLh man fuse
K2 Fasher reay
LT Puse generaLor
L2 IgnLon co
MT SLarLer moLor
N2 \oLage reguaLor/recLfer
PT SpeedomeLer
ST Rear brake ghL swLch
S2 FronL brake ghL swLch
S5 TrpmasLer swLch (opLona)
S6 LghL swLch
S7 Horn buLLon, shorL crcuL buLLon
S8 Fasher swLch
ST0 EecLrc sLarLer buLLon
STT Emergency 0FF swLch (EX0-R AUS)
XT IgnLon curve pug connecLon
0abIe coIors
b Back
b-wh Back-whLe
br Brown
br-b Brown-back
bu Bue
bu-wh Bue-whLe
gn 0reen
gr 0ray
or 0range
pu \oeL
re Red
re-b Red-back
re-wh Red-whLe
wh whLe
wh-gn whLe-green
wh-re whLe-red
WIkIh0 0IA0kAM 102
ye Yeow
ye-b Yeow-back
ye-re Yeow-red
WIkIh0 0IA0kAM 103
G
3
v
M
A
0
1
bl
U
2/
V
B
_
C
A
5
t
M
e
r
-
e
y
e
y
h
w
r
b
h
w
r
b
wh
ye
re-wh
re-bl
gn
re
re
gn
re-bl
re-wh
bu-wh
br
ye-bl
bu-wh
br
br
ye
r
b
e
r
-
e
y
r
b
l
b
-
e
y
l
b
l
b
e
r
u
b
h
w
r
b
bu
ye
bl
bl
ye
bu
ye-re
wh-re
wh-re
ye-re
br
ye-re
br
wh
ye-bl
h
w
h
w
gr
gr bl-wh
bl
br
br
br bl
br
bl
H7 H11
B3
P1
S
5
S
9
S
6
S
1
0
E
6
H
1
4
M
1
K
1
G
1
N2
H5
G
2
L
1
B
1
A
6
L
2

X
1
WIkIh0 0IA0kAM 104
20.2 Wirin diara (aII X0-W odeIs)
500248-T0
WIkIh0 0IA0kAM 105
0oponents
A6 0DI conLroer
BT ThroLLe posLon sensor
B3 whee speed sensor
E6 ThermoswLch (X0-w ZA)
0T BaLLery
02 0eneraLor
H5 Brake/La ghL (X0-w ZA)
H7 Parkng ghL (X0-w ZA)
HTT Low/hgh beam (X0-w ZA)
HT4 RadaLor fan (X0-w ZA)
KT SLarLer reay wLh man fuse
LT Puse generaLor
L2 IgnLon co
MT SLarLer moLor
N2 \oLage reguaLor/recLfer
PT SpeedomeLer
S5 TrpmasLer swLch (opLona)
S6 LghL swLch
S9 ShorL crcuL buLLon
ST0 EecLrc sLarLer buLLon
XT IgnLon curve pug connecLon
0abIe coIors
b Back
b-wh Back-whLe
br Brown
bu Bue
bu-wh Bue-whLe
gn 0reen
gr 0ray
re Red
re-b Red-back
re-wh Red-whLe
wh whLe
wh-re whLe-red
ye Yeow
ye-b Yeow-back
ye-re Yeow-red
888TAh08 106
21 SUBSTANCES
8rake fIuid 00T 4 / 00T 5.1
Accordin to
D0T
0uideIine
Use ony brake fud LhaL compes wLh Lhe specfed sLandards (see specfcaLons on Lhe conLaner) and LhaL possesses Lhe corre-
spondng properLes. KTM recommends 0astroI and Motorex
producLs.
8uppIier
0astroI
k8F0h8 8kAk FLI0 8Fk 00T 4
Motorex
8rake FIuid 00T 5.1

0ooIant
0uideIine
Use ony suLabe cooanL (even n counLres wLh hgh LemperaLures). Usng nferor anLfreeze can resuL n corroson and foamng.
KTM recommends Motorex
producLs.
Mixture ratio
AnLfreeze. ~25. ~45 0 (~T3. ~49 F) 50 % AnL-corroson/anLfreeze
50 % dsLed waLer
0ooIant (ixed ready to use)
AnLfreeze ~40 0 (~40 F)
8uppIier
Motorex
Anti Freeze
nine oiI (8A 10W/50)
Accordin to
JAS0 T903 MA ( p. T09)
SAE ( p. T09) (SAE T0w/50)
0uideIine
Use ony engne os LhaL compy wLh Lhe specfed sLandards (see specfcaLons on Lhe conLaner) and LhaL possess Lhe corre-
spondng properLes. KTM recommends Motorex
producLs.
SynLheLc engne o
8uppIier
Motorex
0ross Fower 4T
Fork oiI (8A 5)
Accordin to
SAE ( p. T09) (SAE 5)
0uideIine
Use ony os LhaL compy wLh Lhe specfed sLandards (see specfcaLons on Lhe conLaner) and LhaL possesses Lhe correspondng
properLes. KTM recommends Motorex
producLs.
8uppIier
Motorex
kacin Fork 0iI

8uper unIeaded (k0Z 95 / k0h 95 / F0h 91)
Accordin to
DIN EN 228 (R0Z 95 / R0N 95 / P0N 9T)
AXILIAkY 888TAh08 107
22 AUXlLlARY SUBSTANCES
Air fiIter cIeaner
8pecification
producLs.
8uppIier
Motorex
Twin Air 0irt 8io keover

0hain cIeaner
8pecification
producLs.
8uppIier
Motorex
0hain 0Iean 611

0Ieanin and poIishin ateriaIs for etaI, rubber and pIastic
8pecification
producLs.
8uppIier
Motorex
Frotect & 8hine 645

0ontact spray
8pecification
producLs.
8uppIier
Motorex
Accu 0ontact
hih-Iuster poIish for paint
8pecification
producLs.
8uppIier
Motorex
Moto FoIish
Lon-Iife rease
8pecification
producLs.
8uppIier
Motorex
Fett 2000
MotorcycIe cIeaner
8pecification
producLs.
8uppIier
Motorex
Moto 0Iean 900

0ffroad chain spray
8pecification
producLs.
8uppIier
Motorex
0hain Lube 622

AXILIAkY 888TAh08 108
0iI for foa air fiIter
8pecification
producLs.
8uppIier
Motorex
Twin Air Liquid 8io Fower

niversaI oiI spray
8pecification
producLs.
8uppIier
Motorex
!oker 440 niversaI

8TAh0Ak08 109
23 STANDARDS
!A80 T903 MA
DfferenL Lechnca deveopmenL drecLons requred a new specfcaLon for 4-sLroke moLorcyces Lhe JAS0 T903 MA
SLandard.Earer, engne os from Lhe auLomobe ndusLry were used for 4-sLroke moLorcyces because Lhere was no separaLe
moLorcyce specfcaLon.whereas ong servce nLervas are demanded for auLomobe engnes, hgh performance aL hgh engne speeds
are n Lhe foreground for moLorcyce and AT\ engnes.wLh mosL moLorcyces and AT\s, Lhe gearbox and Lhe cuLch are ubrcaLed wLh
Lhe same o as Lhe engne. The JAS0 MA SLandard meeLs Lhese speca requremenLs.
8A
The SAE vscosLy casses were defned by Lhe SoceLy of AuLomoLve Engneers and are used for cassfyng os accordng Lo Lher vs-
cosLy. The vscosLy descrbes ony one properLy of o and says noLhng abouL quaLy.
Ih0X 110
lNDEX
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air fiIter
ceanng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Air fiIter box Iid
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Antifreeze
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8
8asic chassis settin
checkng wLh rder's weghL . . . . . . . . . . . . . . . . . . . . 33
8attery
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
rechargng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8rake discs
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8rake fIuid
fronL brake, addng . . . . . . . . . . . . . . . . . . . . . . . . . . 57
rear brake, addng . . . . . . . . . . . . . . . . . . . . . . . . . . 6T
8rake fIuid IeveI
of fronL brake, checkng . . . . . . . . . . . . . . . . . . . . . . . 57
of rear brake, checkng . . . . . . . . . . . . . . . . . . . . . . . 6T
8rake Iinins
fronL brake, changng . . . . . . . . . . . . . . . . . . . . . . . . 59
fronL brake, checkng . . . . . . . . . . . . . . . . . . . . . . . . 58
fronL brake, nsLang . . . . . . . . . . . . . . . . . . . . . . . . 59
of fronL brake, removng . . . . . . . . . . . . . . . . . . . . . . 58
of rear brake, removng . . . . . . . . . . . . . . . . . . . . . . . 62
rear brake, changng . . . . . . . . . . . . . . . . . . . . . . . . . 63
rear brake, checkng . . . . . . . . . . . . . . . . . . . . . . . . . 62
rear brake, nsLang . . . . . . . . . . . . . . . . . . . . . . . . . 62
0
0arburetor
ad|usLng de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
foaL chamber, empLyng . . . . . . . . . . . . . . . . . . . . . . 79
de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
0hain
ceanng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5T
0hain uide
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
0hain tension
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
0hain wear
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
0hassis nuber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
0hoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2T
0LAhIh0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
0Iutch
changng fud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
checkng fud eve . . . . . . . . . . . . . . . . . . . . . . . . . . 76
0Iutch Iever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TT
ad|usLng basc posLon . . . . . . . . . . . . . . . . . . . . . . . 76
0opression dapin
fork, ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
0opression dapin, hih-speed
of shock absorber, ad|usLng . . . . . . . . . . . . . . . . . . . . 33
0opression dapin, Iow-speed
shock absorber, ad|usLng . . . . . . . . . . . . . . . . . . . . . 34
0ooIant
dranng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
refng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
0ooIant IeveI
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
0ooIin syste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7T
0
0ust boots
ceanng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Iectric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . T2

erency 0FF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . TT
nine
runnng n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
nine nuber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
nine oiI
changng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
dranng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
refng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T
Loppng up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
nine oiI IeveI
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
nine oiI screen
ceanng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
nvironent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F
FiIIer cap
cosng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
openng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FiIIin up
Fue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FIasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T3
Foot brake pedaI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2T
ad|usLng basc posLon . . . . . . . . . . . . . . . . . . . . . . . 60
checkng free Lrave . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fork
checkng basc seLLng . . . . . . . . . . . . . . . . . . . . . . . . 38
Fork Ies
beedng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fork protector
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Front fender
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ih0X 111
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Front wheeI
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
FueI tank
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7T
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
FueI tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FueI, oiIs, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuse
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
0
0as 8owden cabIe route
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
0ear oiI
addng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
changng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
dranng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
refng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
0ear oiI IeveI
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
0ear oiI screen
ceanng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
h
hand brake Iever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TT
basc posLon, ad|usLng . . . . . . . . . . . . . . . . . . . . . . 56
free Lrave, ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . 57
free Lrave, checkng . . . . . . . . . . . . . . . . . . . . . . . . . 56
handIebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2
k
key nuber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2T
L
Liht switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2
Lower tripIe cIap
fLLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-46
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-44
M
Main siIencer
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MotorcycIe
ceanng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
0
0iI fiIter
changng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
fLLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
0verview of indicator Iaps . . . . . . . . . . . . . . . . . . . . . . . T3
0Whk'8 MAhAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F
FIay in as 8owden cabIe
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Futtin into operation
advce on frsL use . . . . . . . . . . . . . . . . . . . . . . . . . . 24
afLer sLorage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
0hecks before puLLng nLo operaLon . . . . . . . . . . . . . . 26
k
kear sprocket / enine sprocket
checkng for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
kear wheeI
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
kebound dapin
fork, ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
kidin sa
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8
8eat
mounLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8ervice scheduIe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
8hift Iever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2T
8hock absorber
checkng sLaLc sag . . . . . . . . . . . . . . . . . . . . . . . . . . 35
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
rdng sag, checkng . . . . . . . . . . . . . . . . . . . . . . . . . 36
8hort circuit button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TT
8ide stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8pare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8peedoeter
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T5
funcLon descrpLon . . . . . . . . . . . . . . . . . . . . . . . . . T3
SeLLng komeLers or mes . . . . . . . . . . . . . . . . . . . . . T4
SeLLng Lhe cock . . . . . . . . . . . . . . . . . . . . . . . . . . . T4
8poke tension
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8prin preIoad
fork, ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8tart nuber pIate
nsLang . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8tartin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
steerin
ockng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
unockng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8teerin head bearin
greasng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8teerin head bearin pIay
ad|usLng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4T
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ih0X 112
8torae . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
T
TechnicaI data
0arbureLor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-94
chasss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95-96
chasss LghLenng Lorques . . . . . . . . . . . . . . . . . . . . . 99
Engne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-90
engne LghLenng Lorques . . . . . . . . . . . . . . . . . . . 9T-92
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Tire air pressure
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Tire condition
checkng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tk08L8h00TIh0 . . . . . . . . . . . . . . . . . . . . . . . . . . . 85-86
Type IabeI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V
View of vehicIe
efL fronL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
rghL rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wirin diara . . . . . . . . . . . . . . . . . . . . . . . . . . . T00-T05
Work ruIes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
32TT355en
kTM-3crtmctcrcycle A0
o2U Mattghc!en/Austra
ktt://www.ktm.ccm
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KTM 450XC-W Users Manual

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0Whk'8 MAhAL 2009

IdenLfes a proLecLed name.

), foow Lhe nsLrucLons for use from Lhe manufacLurer.

Press Lhe buLLon

Press Lhe buLLon

0ear o dran pug wLh magneL MT2xT.5 20 Nm (T4.8 bf fL)

8rake FIuid 00T 5.1

kacin Fork 0iI

Twin Air 0irt 8io keover

0hain 0Iean 611

Frotect & 8hine 645

Moto 0Iean 900

0hain Lube 622

Twin Air Liquid 8io Fower

!oker 440 niversaI

Iectric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . T2

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