KTM 400 manual

OWNERS HANDBOOK MANUALE D’USO MANUEL D’UTILISATION MANUAL DE INSTRUCCIONES 2002 BEDIENUNGSANLEITUNG Art.Nr. 3.210.17 06/2001 400/520 SX, MXC, EXC RACING[...]

ENGLISH 1 IMPOR T ANT WE STRONGL Y SUGGEST THA T YOU READ THIS MANUAL CAREFULL Y AND COMPLETEL Y BEFORE GOING ON YOUR FIRST RIDE. IT CONT AINS A GREA T DEAL OF INFORMA TION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERL Y . IN YOUR OWN INTEREST , PLEASE P A Y P ARTICULAR A TTENTION TO NOTICES THA T ARE MARKED AS FOLLOWS:  WARNIN[...]

Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Y ou are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately . Before you go for your first ride, be sure to read this manual carefully and thoroughly in[...]

ENGLISH 3 Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4 Clutch lever . . . . . . . . . . . . . . . . [...]

ENGLISH 4 Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1. Engine number , engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Please note this number down on page 1. SERIAL NUMBER LOCA TIONS [...]

ENGLISH 5 Digital speedometer , indicator lamps (EXC) The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp 2 lights up when the high beam is on. Speedometer – digital (EXC) Some models are equipped with a digital speedometer 3 . KMH = Speed, max. 200 km/h (is always ind[...]

ENGLISH 6 Combination switch (EXC) The light switch has 2, respetively 3 switch positions. A = Light off (this function is not available in all models) B = Low beam on C = High beam on You may use button 1 to actuate the horn. The red short circuit button 2 serves to switch off the engine. Leave the switch pressed until the engine stops. Headlamp s[...]

ENGLISH 7 Filler cap To open filler cap: Turn the filler cap counter-clockwise. To close filler cap: ut filler cap on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks. Fuel The racing engine needs premium gasoline with an octane number of 95 or higher. ! CAUTION ! U SE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 [...]

ENGLISH 8 Choke If you pull the choke button 1 out as far as possible, a bore in the carbure- tor will be unblocked through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position. Shift lever The shift le[...]

ENGLISH 9 Compression damping of fork Hydraulic compression damping determines the reaction when the fork is compressed. The degree of compression can be adjusted with adjusting screws at the bottom of the fork legs.Remove the protecting cap 1 . Turn the adjusting screws 2 clockwise to increase damping, turn it counter- clockwise to reduce damping [...]

ENGLISH 10 Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a count[...]

ENGLISH 11 DRIVING INSTRUCTIONS  WARNING  –T HE SX MODELS ARE NOT APPROVED FOR USE ON PUBLIC ROADS AND FREEWAYS . –W HEN RIDING YOUR MOTORCYCLE , PLEASE BEAR IN MIND THAT OTHER PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE . Instructions for initial operation – Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Cus[...]

ENGLISH 12 Starting when the engine is cold 1 Open the fuel tap 1 . 2 Swing up the side stand or center stand. 3 Put the gear in neutral. 4 Operate the choke 2 . 5 Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter.  WARNING  –I F YOU WANT TO START THE ENGINE , MAKE SURE THAT YOU ALWAYS PUT ON STURDY[...]

ENGLISH 13 Only give as much gas as the engine can handle. Through quick and high reving of throttle, the fuel usage increases. By shifting down, use the brakes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear. Let clutch lever go slowely and open throttle or shift down again. NOTE: D EDICATED TO N[...]

ENGLISH 14 PERIODIC MAINTENANCE SCHEDULE 2001 1. service after 3 hours or 20 l fuel after/every 15 hours or 100 l fuel IF MOTORCYCLE IS USED FOR COMPETITION 15 HOURS SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! S ERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 2 HOURS OR 15 LITERS OF FUEL . M AINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOP[...]

ENGLISH 15 I MPORT ANT C HECKS AND M AINTENANCE TO BE C ARRIED OUT BY THE R IDER Check oil level ● Check brake fluid level ● Check brake pads for wear ● Check lights for function ● Check horn for function ● Lubricate and adjust cables and nipples ● Bleed fork legs regulary ● Remove and clean fork dust bellows regulary ● Clean and lu[...]

ENGLISH 16  WARNING  MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF. ! CAUTION ! –W HEN CLEANING THE MOTORCYCLE [...]

ENGLISH 17 Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to hav[...]

ENGLISH 18 How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar to the position that is the most convenient for you. The upper tri- ple clamp 1 includes 2 bores arranged at a distance of 15 mm (0,6 in) from one another. The bores at the handlebar support 2 are offset from the cen- t[...]

ENGLISH 19 Check chain tension To check the chain tension, park the motorcycle. Press chain upward at the end of the chain sliding component. The distance between chain and swing arm should be approx. 15 mm (0.6 in). In the course of this procedure, the upper chain portion A must be taut (see illustration). If necessary, correct chain tension.  [...]

ENGLISH 20 Chain wear In order to check the chain wear, regard the following indications: Shift the gear into idling and pull the upper chain strand with approx. 10-15 Kilogramm (33 lb) upwards (see figure). Now one can measure a space of 18 chain reels at the lower chain strand. The chain should be replaced at the latest when a space of 272 mm (10[...]

ENGLISH 21 Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1 . In this way, the position of the point of pressure (i.e., the resi- stance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. ! CAUTI[...]

ENGLISH 22 Replacing front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips 1 and pull out bolt 2 . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and grease gu[...]

ENGLISH 23 Checking the rear brake pads The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in).  WARNING  A T THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM , OTHERWISE THEY COULD LEAD TO BRAKE FAILURE . F OR YOUR OWN SAFETY DON ’ T PUT OFF HAVING YOUR BRAKE P[...]

ENGLISH 24 The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer. Mount the collar nut 4 , turn the speedometer drive such that the speedo- meter shaft leads upward parallel to the fork leg (see photo), tighten the clamping sceews on the right side 6 to prevent the wheel [...]

ENGLISH 25 Ti res, air pressure Tire type, tire condition, and air pressure level affect the way your motor- cycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in their homolo- gation certificate – Tire condition has to be[...]

ENGLISH 26 TOT AL MILEAGE „DST“ TIME „CLK“ AFTER CHANGING BATTERY 1 sec 5 sec 1 sec 1. use the right button to select the position to be changed 1. make sure the time is indicated and push the button on the back approx. 5 seconds (time starts blinking) 2. push the left button until the right figure is showed in the display 3. by pushing the[...]

ENGLISH 27 Check/set distance of the magnetic sensor The distance between magnet 2 and sensor 1 must be 2-4 mm (0,08-0,16 in), otherwise malfunctions on the speedometer might occur. This distance can be corrected by screwing in or off the sensor 1 . WHEEL CIRCUMFERENCE „WS“ 1. make sure that the indication "TRP" is active and push the[...]

ENGLISH 28 Battery (MXC/EXC) The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. Removing the battery: First disconnect the negative and then the positive pole of the b[...]

ENGLISH 29 Fuse (MXC/EXC) The fuse 1 is disposed in the starter relay of the E-starter 2 underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover A , you will be able to see the fuse. The following loads are connected to it: – E-starter system – horn – flasher lights The starter rela[...]

Cooling system Coolant is circulated by a water pump 1 located in the engine. When the engine is cold the coolant circulates only through the cylinder and the cylin- der head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat 2 opens and the coolant is also pumped through both aluminum radiators. Air blowi[...]

ENGLISH 31 Cleaning the air filter * A dirty air filter impairs the air-flow rate, reduces the engine performance, and increases the fuel consumption. In extreme cases, dirt may even get into the engine and cause damage. Therefore, change the air filter in regular intervals. For this purpose, rotate the two quick-release fasteners 1 counter-clock- [...]

ENGLISH 32 Checking the adjustment of the hand decompression release cable * Start the engine and, at idling speed, slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever. The backlash until said thumping should be approx. 10mm, measured at the lever's outer end. If necessary, correct this backl[...]

ENGLISH 33 CARBURETOR – Adjust idling (Keihin-CR39) * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel 1[...]

ENGLISH 34 Draining of float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carbure- tor should be drained in order to remove any water that may have penetra- ted into it. Water in the float chamber causes malfunction. Perform this task on a cold engine. Close the fuel tap and place a cloth underneath the[...]

ENGLISH 35 Engine oil Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or sur- passing the quality requirements of API classes SG or SH (see specifications on the container). ! CAUTION ! I NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE . Changing the engine oil * NOTE: W HEN CHANGING THE ENGINE OIL [...]

ENGLISH 36 CHANGING THE OIL FILTERS Remove the screw 1 and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws 2 and dismount the two oil filter covers. Using circlip pliers, you may now pull the oil-filter inserts 3 out of the housing. Clean the oil filter cover, the se[...]

ENGLISH 37 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case[...]

ENGLISH 38 TROUBLE Engine does not rev high Engine will not reach full power Engine stops or splutters in carburettor Engine gets to hot High oil consumption All switched on lamps blown out Horn, flasher lights, and E-starter do not work The battery is discharged CAUSE Carburettor fuel level too high because float needle valve is dirty or worn out [...]

ENGLISH 39 Should you desire to make a pause over a longer space of time, please observe the following instructions: – Clean motorcycle thoroughly (see chapter: CLEANING) – Change engine oil, short and long oil filters (old engine oil contains aggressive contaminations). – Check antifreezer and amount of cooling liquid. – Warm up the engine[...]

ENGLISH 40 BASIC CARBURETOR SETTING Type Keihin CR39 Keihin CR39 Keihin CR39 Keihin CR39 Keihin CR39 Keihin CR39 Carb.-setting number 031299 130799 100699 250899 250401 240401 Main jet 175 175 175 175 175 175 Jet needle OBDTM OBDVR OBDTM OBDTM OBDVR OBDVR Idling jet 48 48 48 48 48 48 Main air jet 200 200 200 200 200 200 Idling air jet 100 100 100 1[...]

ENGLISH 41   – + 0°C 32°F 15W 40 15W 50 10W 40 10W 50 API: SG, SH TEMPERA TUR TIGHTENING TORQUES Hexagon collar screw engine case, clutch cover, ignition cover M6 10 Nm (6 ft.lb) Oil drain plug M12x1,5 20 Nm (15 ft.lb) Allan head plug oil screen short M16x1,5 10 Nm (7 ft.lb) Hexagon plug oil screen long M20x1,5 15 Nm (11 ft.lb) Plug press[...]

ENGLISH 42 400 520 Crankshaft axial clearance 0,03 - 0,15 mm/0,0012 - 0,006 in run out of crank stud max. 0,08 mm/0,003 in Conrod bearing radial clearance max. 0,05 mm/0,002 in axial clearance max. 1,10 mm/0,043 in Cylinder bore diameter size I 89,000 - 89,012 mm/3,5039 - 3,5044 in 95,000 - 95,012 mm/3,7401 - 3,7406 in bore diameter size II 89,013 [...]

ENGLISH 43 TECHNICAL DA T A – CHASSIS 400/520 SX, MXC, EXC RACING 2002 WP 5018 PDS WP 5018 PDS DCC MCC 1218W738 1218W739 Compression adjuster 15 LS (Low speed) 15 2 HS (high speed) Rebound adjuster 25 25 Spring PDS7–260 PDS6-260 Spring preload 4 mm (0.24 in) 5 mm (0.24 in) ST ANDARD ADJUSTMENT - SHOCK ABSORBER WP4860MXMA WP4357MXMA 1418W710 051[...]

ENGLISH 44 Page Adjust the throttle cables ....................................................32 Adjusting digital speedometer .............................................26 Adjusting of free travel at the hand brake lever...................21 Adjusting the mixture control screw ....................................33 Adjusting the spring preload [...]

KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet: www.ktm.at 321017[...]