KTM 450 SMR manual

OWNER'S MANUAL 2008 450  SMR ART. NO. 3211243en[...]

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DEAR KTM CUSTOMER 1 '($5 .70 &86720(5 Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below. Ch[...]

CONTENTS 2 &217(176 MEANS OF REPRESENTATION ............................................ 4 IMPORTANT NOTES ............................................ ................ 5 VIEW OF VEHICLE ............................................... ................ 7 View of vehicle, front left side ...... ..................................... 7 View of vehi[...]

CONTENTS 3 Installing the battery  x ......... ......... ............ .......... ......... 50 Recharging the battery  x ...... ............ ......... .......... ......... 51 Removing a fuse ..................................................... ....... 52 Replacing the fuse......................................................... 52 Ignition c[...]

MEANS OF REPRESENTATION 4  0($16 2) 5(35(6(17$7,21 Symbols used The symbols used are explained in the following. Indicates an expected reaction (e.g. of a work step or a function). Indicates an unexpected reaction (e.g. of a work step or a function). All work marked with this symbol requires specialist knowledge and technical understanding. In t[...]

IMPORTANT NOTES 5  ,03257$17 127(6 Use definition KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com- ply with currently valid regulations and categories of the top international motorsport organizations. Info The motorcycle must be used only on secluded property remo[...]

IMPORTANT NOTES 6 Grades of risks Danger Danger that leads immediately and certainly to severe and permanent injury or death. Warning Danger that will probably lead to severe and permanent injury or death. Note Danger of serious damage to machine or material. Warning Risk of environmental damage. OWNER'S MANUAL ಥ Read this owner's manua[...]

VIEW OF VEHICLE 7  9,(: 2) 9(+,&/(  View of vehicle, front left side 500182-10 1 Hand brake lever 2 Start number plate 3 Front fender 4 Front wheel 5 Fork part number 6 Oil filter cover 7 Plug-in stand 8 Shift lever 9 Choke button 10 Air filter 11 Filler cap 12 Clutch lever[...]

VIEW OF VEHICLE 8  View of vehicle, rear right side 500183-10 1 Main silencer 2 Shock absorber 3 Brake caliper of rear wheel brake 4 Rear wheel 5 Foot brake pedal 6 Manifold 7 Chassis number/type label 8 Throttle grip[...]

LOCATION OF SERIAL NUMBERS 9  /2&$7,21 2) 6(5,$/ 180%(56  Chassis number 400193-10 The chassis number   is stamped on the steering head on the right.  Type label 400284-10 The type label   is fixed to the front of the steering head.  Engine number 400194-10 The engine number   is stamped on the le[...]

OPERATING ELEMENTS 10  23(5$7,1* (/(0(176  Clutch lever 400195-10 The clutch lever   is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting.  Hot start lever 400195-12 The hot start lever   is fitted on the left side of the handlebar. If you pull the hot start lever to t[...]

OPERATING ELEMENTS 11  Fuel tap 500178-10 With the tap handle   on the fuel tap, you can open or close the supply of fuel to the carburetor. Possible states • Fuel supply closed OFF ಥ No fuel can flow from the tank to the carburetor. • Fuel supply open ON ಥ Fuel can flow from the tank to the carburetor. The fuel tank em[...]

OPERATING ELEMENTS 12  Shift lever 400204-12 The shift lever   is mounted on the left side of the engine. 400204-11 The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears.  Foot brake pedal 400205-10 The foot brake pedal   is located in front of the ri[...]

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 13  *(1(5$/ 7,36 $1' +,176 21 3877,1* ,172 23(5$7,21  Advice on first use Danger Danger of accidents ಗ Danger from inadequate traffic experience. ಥ Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs. Warning Risk of injury ಗ Risk of injury [...]

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 14  Running in the engine ಥ During the running-in phase, do not exceed the specified engine speed and engine performance. Specification Maximum engine speed During the first 3 service hours 7000  rpm Maximum engine performance during the running-in period During the first 3 service hour[...]

RIDING INSTRUCTIONS 15  5,',1* ,16758&7,216  Checks before putting into operation Info Make sure that the motorcycle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. ಥ Check the engine oil level. ( P. 62) ಥ Check the chain tension[...]

RIDING INSTRUCTIONS 16  Starting up ಥ Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.  Shifting, riding Warning Danger of accidents ಗ If you change down at high engine speed, the rear wheel can lock up. ಥ Do not change into a low gear at high engine spee[...]

A A RIDING INSTRUCTIONS 17 Note Fire hazard ಗ Some components (engine, radiator and exhaust system) get very hot when the engine is running. ಥ Do not place the vehicle where there are flammable or explosive substances. ಥ Brake the motorcycle. ಥ Shift gear to neutral. ಥ Press the short circuit button  when the engine is idling until the[...]

GREASING AND SERVICE TABLE 18  *5($6,1* $1' 6(59,&( 7$%/(  Important maintenance work to be carried out by an authorized KTM workshop. S3N S10A S30A Engine Change the engine oil and oil filter, and clean the oil screen. ( P. 63) • • Replace spark plug. • Check and adjust valve clearance. • • Check engine mounting scre[...]

GREASING AND SERVICE TABLE 19  Important maintenance work to be carried out by an authorized KTM workshop. (as additional order) S10A S20N S40N J1A J2A Carry out a complete fork service. • Carry out a complete shock absorber service. • Grease the steering head bearing. ( P. 31) • Clean and adjust carburetor. • Treat electric contac[...]

GREASING AND SERVICE TABLE 20 NB1A Check the coolant level. ( P. 55) • Empty the carburetor float chamber. ( P. 62) • Check that all operating elements for smooth operation. • Check braking. • Check all screws, nuts and hose clamps regularly for tightness. • NB1A: Depending on conditions of use according to requirements.[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 21  0$,17(1$1&( :25.21 &+$66,6 $1' (1*,1(  Jacking up the motorcycle 500181-01 Note Danger of damage ಗ Danger of damage by the vehicle running away or falling over. ಥ Always place the vehicle on a firm and even surface. ಥ Jack up the motorcycle underneath the engine. The wheels m[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 22 ಥ Turn back counterclockwise the number of turns corresponding to the shock ab- sorber type. Specification Compression damping, high-speed Standard 1.5  turns Info Turn clockwise to increase damping, turn counterclockwise to reduce sus- pension damping.  Adjusting the low-speed compression dam[...]

0 0 A A 0 0 0 B B 0 0 A A C C 0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 23  Measuring rear wheel sag unloaded ಥ Jack up the motorcycle. ( P. 21) 400389-10 ಥ Measure the distance ಥ as vertical as possible ಥ between the rear axle and a fixed point, for example, a mark on the side cover. ಥ Make a note of the value as measuremen[...]

A A 2 2 1 1 MAINTENANCE WORK ON CHASSIS AND ENGINE 24  Adjusting spring preload of the shock absorber  x Danger Danger of accidents ಗ The shock absorber is under high pressure. ಥ The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any main- tenance on it yourself. Info [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 25  Removing the shock absorber  x ಥ Jack up the motorcycle. ( P. 21) 500186-10 ಥ Remove screw   and lower the rear wheel with the swing arm as far as possible without blocking the rear wheel. Fix the rear wheel in this position. ಥ Remove screw   , push splash protector  [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 26 400206-10 ಥ Turn adjusting screws   clockwise until they stop. Info The adjusting screws   are located at the top end of the fork legs. Make the same adjustment on both fork legs. ಥ Turn back counterclockwise the number of clicks corresponding to the fork type. Specification Compression damp[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 27 500188-10 ಥ Push dust boots   of both fork legs downwards. Info The dust boots should remove dust and coarse dirt particles from the fork tubes. Over time, dirt can penetrate behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak. Warning Danger of accidents ಗ R[...]

0 0 1 1 0 0 B B 0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 28 400387-10 ಥ Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. No play should be noticeable in the steering head bearing. » If there is noticeable play present: ಥ Adjust play of the steering head bearing ( P. 28) ಥ Move[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 29  Setting the fork offset  x ಥ Remove the lower triple clamp. ( P. 30) 500104-10 ಥ Remove screw   . Remove the steering stem. ಥ Clean the parts and check for damage. ಥ Rotate the steering stem 180° and insert into the triple clamp. Mount and tighten screw   . Specification[...]

0 0 2 2 0 0 1 1 0 0 3 3 MAINTENANCE WORK ON CHASSIS AND ENGINE 30 500200-13 ಥ Position the brake line. Put the clamp on, mount and tighten screws   . ಥ Fit front wheel. ( P. 47)  Removing the lower triple clamp  x ಥ Remove the fork legs. ( P. 29) ಥ Dismount the start number plate ( P. 32) ಥ Dismount the front fender. [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 31 500099-11 ಥ Position the upper triple clamp with the steering. ಥ Mount and tighten screw   . Specification Screw, top steering head M20x1,5 10  Nm (7.38  lbf  ft) ಥ Position the clutch line, wiring harness and CDI control unit. Mount and tighten screws   . Specification Remaining [...]

0 0 B B 0 0 A A 0 0 2 2 0 0 1 1 MAINTENANCE WORK ON CHASSIS AND ENGINE 32  Dismount the start number plate 500191-10 ಥ Remove screw   and take off clamp. ಥ Remove screw   . Remove the start number plate.  Fitting the start number plate 500191-11 ಥ Check parts for damage and wear. Replace damaged or worn par[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 33  Checking gas Bowden cable route 500201-10 ಥ The two gas Bowden cables must run parallel behind the handlebar down to the frame. They must be routed directly on the frame above the tank bearing to the car- buretor.  Checking play in the gas Bowden cable 400192-10 ಥ Move the handl[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 34  Checking chain dirt ಥ Check the chain for coarse dirt accumulation. » If the chain is very dirty: ಥ Clean the chain. ( P. 34)  Cleaning the chain Warning Danger of accidents ಗ Oil or grease on the tires reduces their grip. ಥ Remove oil and grease with a suitable cleaning ma[...]

1 2 3 1 6 1 7 1 8 0 0 0 B B 0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 35  Checking the chain tension when fitting rear wheel Warning Danger of accidents ಗ Danger caused by incorrect chain tension. ಥ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings i[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 36  Adjusting the chain tension Warning Danger of accidents ಗ Danger caused by incorrect chain tension. ಥ If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bear- ings in transmission and rear wheel) are under additional load. A[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 37  Adjusting chain tension - after checking 500193-13 ಥ Loosen nut   . ಥ Loosen nuts   . ಥ Adjust the chain tension by turning the adjusting screws   left and right. Specification Chain tension 8… 10  mm (0.31… 0.39  in) Turn the adjusting screws   left and [...]

0 0 A A MAINTENANCE WORK ON CHASSIS AND ENGINE 38  Adjusting chain guide  x 500194-10 ಥ Remove screws   and   . Take off the chain guide. Conditions Number of teeth: 싨 44  teeth ಥ Insert nut   in hole   . Position the chain guide. ಥ Mount and tighten screws   and   . Specification Rem[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 39  Checking free play of hand brake lever Warning Danger of accidents ಗ Brake system failure. ಥ If there is no free travel on the hand brake lever, pressure builds up on the front brake in the brake system. The front brake can fail due to overheating. Adjust free travel on hand brake lever acc[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 40  Topping up the front brake fluid  x Warning Danger of accidents ಗ Brake system failure. ಥ If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Have the brake system checked in an authorized KTM workshop, and do not rid[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 41  Removing front brake linings  x Warning Danger of accidents ಗ Improper brake maintenance and repair. ಥ Always have your brake system maintained and repaired in an authorized KTM workshop. 500203-11 ಥ Remove locking split pins   . 500204-10 ಥ Press the spring hanger of the sprin[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 42 500204-11 ಥ Fit the brake linings. Position the springs   and mount the bolts   . Info The spring hanger of the springs   must be positioned upwards. 500203-12 ಥ Fit the locking splint pins   . ಥ Operate the hand brake lever repeatedly until the brake linings lie on the brake d[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 43  Checking free play of foot brake lever Warning Danger of accidents ಗ Brake system failure. ಥ If there is no free travel on the foot brake pedal, pressure builds up on the rear brake in the brake system. The rear brake can fail due to overheating. Adjust free travel on foot brake pedal accor[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 44 400234-10 ಥ Stand the vehicle upright. ಥ Check the brake fluid level in the viewer   . » When in the viewer   an air bubble is visible: ಥ Add rear brake fluid. ( P. 44)  Adding rear brake fluid  x Warning Danger of accidents ಗ Brake system failure. ಥ If the brake fluid [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 45 500206-11 ಥ Check the brake linings for minimum thickness   . » Minimum thickness   : 싩 1  mm ( 싩 0.04  in) If the minimum thickness is less than specified: ಥ Change the rear brake linings. ( P. 46)  Removing rear brake linings  x Warning Danger of accidents ?[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 46  Changing the rear brake linings  x Warning Skin irritations ಗ Brake fluid can cause skin irritation on contact. ಥ Avoid contact with skin and eyes, and keep out of the reach of children. ಥ If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 47 500210-10 ಥ Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork. Info Always lay the wheel down in such a way that the brake disc is not dam- aged. 500211-10 ಥ Remove the spacing sleeves   .  Fitting front wheel  x Warning Danger of accidents ?[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 48 500209-11 ಥ Operate the hand brake lever repeatedly until the brake linings lie on the brake disc and there is a tight spot. ಥ Remove the motorcycle from the work stand. ( P. 21) ಥ Pull the front wheel brake and push down hard on the fork several times to align the fork legs. ಥ Fully tighten screw ?[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 49 500215-10 ಥ Lift the rear wheel into the swing arm, position it, and insert the wheel spindle   . ಥ Put the chain on. 500193-12 ಥ Position the chain adjuster   . Fit nut   , but do not tighten it yet. ಥ Check the chain tension when fitting rear wheel. ( P. 35) ಥ Make sure that th[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 50  Checking spoke tension Warning Danger of accidents ಗ Unstable riding behavior due to loose spokes. ಥ If you ride with loose spokes, the spokes can break. Have the spoke tension corrected in an authorized KTM workshop. Info A loose spoke can cause wheel imbalance, which leads to more loose s[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 51 ಥ Mount the seat. ( P. 53)  Recharging the battery  x Warning Risk of injury ಗ Battery acid and battery gases cause serious cauterization. ಥ Keep batteries out of the reach of children. ಥ Wear suitable protective clothing and goggles. ಥ Avoid contact with battery acid and battery ga[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 52  Removing a fuse ಥ Switch off all power-consuming components and switch off the engine. ಥ Dismount the air filter box lid. ( P. 58) 400270-10 ಥ Remove the protection cover   . Info The fuse   is located in the starter relay   under the filter box cover. ಥ Remove the fus[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 53  Removing the seat 500080-10 ಥ Remove screw   . Lift up the seat at the rear, pull it back and then remove from above.  Mounting the seat 500068-01 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Hook the front of the seat into the flange adapter of th[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 54 500220-10 ಥ Pull both spoilers to the side of the radiator bracket   and take the fuel tank away upwards.  Installing the fuel tank  x Danger Fire hazard ಗ Fuel can easily catch fire. ಥ Never fill up the vehicle near open flames or burning cigarettes, and always switch off the eng[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 55  Cooling system 400242-10 The water pump   in the engine forces the coolant to flow. The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap   . The specified coolant temperature is therefore permissible with- out danger of function p[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 56 400243-10 ಥ Stand the motorcycle upright on a horizontal surface. ಥ Remove the radiator cap. ಥ Check the coolant level in the radiator. Coolant level   above radiator fins. 10  mm (0.39  in) » If the level of the cooling liquid does not meet specifications: ಥ Correct the coolant level. [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 57  Removing main silencer Warning Danger of burns ಗ The exhaust system gets very hot when the vehicle is driven. ಥ Allow the exhaust system to cool down. Do not touch hot components. 500221-10 ಥ Disconnect spring   . ಥ Remove screws   and take off main silencer.  Fi[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 58  Fitting glass fiber yarn filling of main silencer  x 500226-11 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Attach the glass fiber yarn filling to inner tube   . Fit the inner tube into the outer tube   . ಥ Insert cap   . Mount and tighten screw[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 59  Installing the air filter  x 500223-10 ಥ Check parts for damage and wear. Replace damaged or worn parts. ಥ Fit a clean air filter. Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage. ಥ Position and tighten the hose clip [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 60  Checking fluid level of hydraulic clutch Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. 400245-10 ಥ Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. ಥ Remove screws   . ಥ Remove the cover  ?[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 61  Carburetor - idle 400266-10 The idle setting of the carburetor has a big influence on the starting behavior, stable idling and the response to throttle opening. That means that an engine with a correctly set idle speed is easier to start than if the idle is set wrongly. Info The carburetor a[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 62  Emptying the carburetor float chamber  x Danger Fire hazard ಗ Fuel can easily catch fire. ಥ Never fill up the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt [...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 63  Changing engine oil and oil filter, cleaning oil screen  x ಥ Drain the engine oil. ( P. 63) ಥ Remove the oil filter. ( P. 64) ಥ Mount the oil filter. ( P. 64) ಥ Fill up with engine oil. ( P. 64)  Draining engine oil  x Warning Danger of scalding ಗ Engine oil an[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 64  Removing the oil filter  x Warning Danger of scalding ಗ Engine oil and gear oil get very hot when the motocycle is driven. ಥ Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard ಗ Probl[...]

MAINTENANCE WORK ON CHASSIS AND ENGINE 65 ಥ Check the engine oil level. ( P. 62)  Topping up engine oil Info Too little engine oil or poor-quality engine oil results in premature wear to the engine. 400265-10 ಥ Remove the screw cap   on the clutch cover and fill up with engine oil. Engine oil (SAE 10W/50) ( P. 82) ಥ Mount[...]

TROUBLESHOOTING 66  7528%/(6+227,1* Faults Possible cause Measure The engine cannot be cranked (electric starter). Battery discharged ಥ Recharge the battery. ( P. 51) ಥ Check the cause of discharging. Fuse blown ಥ Remove the fuse. ( P. 52) ಥ Replace the fuse. ( P. 52) Low external temperature ಥ Use the battery supplied in the acces-[...]

TROUBLESHOOTING 67 Faults Possible cause Measure Engine has no idle. Ignition system defective ಥ Have ignition system checked. Engine does not speed up. Carburetor running over because float needle dirty or worn ಥ Have carburetor checked. Loose carburetor jets ಥ Have carburetor checked. Electronic ignition adjustment defective ಥ Have igniti[...]

CLEANING 68  &/($1,1*  Cleaning motorcycle Note Material damage ಗ Damage and destruction of components by high-pressure cleaning equipment. ಥ Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electri- cal components, connects, Bowden cables, and bearin[...]

STORAGE 69  6725$*(  Storage Warning Danger of poisoning ಗ Fuel is poisonous and a health hazard. ಥ Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme- diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fu[...]

TECHNICAL DATA - ENGINE 70  7(&+1,&$/ '$7$  (1*,1( Design 1-cyliner 4-stroke engine, water-cooled Displacement 449.3  cm³ (27.42  cu  in) Stroke 60.8  mm (2.39  in) Bore 97  mm (3.82  in) Compression ratio 12,5:1 Idle speed 1600… 1650  rpm Control 4 valves controlled by cam levers ad 2 camshafts, dri[...]

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 71  7(&+1,&$/ '$7$ (1*,1( 7,*+7(1,1* 72548(6 Engine housing vent jet M4 Loctite ® 243™ Oil jet, piston cooling M 4 4  Nm (2.95  lbf  ft) Loctite ® 243™ Oil jet, cam lever lubrication M4 6  Nm (4.43  lbf  ft) Loctite ® 243™ Oil jet, clutch oil supply M5x1 6 ?[...]

TECHNICAL DATA - ENGINE TIGHTENING TORQUES 72 Stud, cylinder head M10x1,25 20  Nm (14.75  lbf  ft) ಥ Screw, engine sprocket M10 60  Nm (44.26  lbf  ft) Loctite ® 243™ Spark plug M10 10… 12  Nm (7.38… 8.85  lbf  ft) ಥ Screw-in studs for clutch cover M12x1,5 20  Nm (14.75  lbf  ft) ಥ Oil drain plug wit[...]

TECHNICAL DATA - CARBURETOR 73  7(&+1,&$/ '$7$  &$5%85(725 Carburetor type KEIHIN FCR-MX 41 Carburetor identfication number 4125I Needle position 4th position from top Idle mixture adjusting screw Open 1.5  turns Pump membrane stop 2.15  mm (0.08  in) Hot start button Diameter of bore in carburetor body 2.5  mm[...]

TECHNICAL DATA - CHASSIS 74  7(&+1,&$/ '$7$  &+$66,6 Frame Central tube frame made of chrome molybdenum steel tubing Fork WP 4860 MXMA CC Suspension travel front 280  mm (11.02  in) Rear 310  mm (12.2  in) Fork offset Front marking 14  mm (0.55  in) Rear marking 16  mm (0.63  in) Shock absorber WP P[...]

TECHNICAL DATA - CHASSIS 75  Capacity - fuel Tank capacity 8.2  l (2.17  US  gal) Super unleaded (ROZ 95 / RON 95 / PON 91) ( P. 82)[...]

TECHNICAL DATA - FORK 76  7(&+1,&$/ '$7$  )25. Fork part number 14.18.7D.18 Fork WP 4860 MXMA CC Compression damping Standard 15  clicks Rebound damping Standard 15  clicks Spring length with preload spacer(s) 482  mm (18.98  in) Spring rate Weight of rider: 65… 75  kg (143.3… 165.34  lb.) 4.6  N/mm (2[...]

TECHNICAL DATA - SHOCK ABSORBER 77  7(&+1,&$/ '$7$  6+2&. $%625%(5 Shock absorber part number 12.18.7D.15 Shock absorber WP PDS 5018 DCC Compression damping, low-speed Standard 10  clicks Compression damping, high-speed Standard 1.5  turns Rebound damping Standard 20  clicks Spring preload 11  mm (0.43  in) [...]

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 78  7(&+1,&$/ '$7$  &+$66,6 7,*+7(1,1* 72548(6 Spoke nipple, front wheel M4,5 5  Nm (3.69  lbf  ft) ಥ Spoke nipple, rear wheel M5 5  Nm (3.69  lbf  ft) ಥ Remaining nuts, chassis M6 15  Nm (11.06  lbf  ft) ಥ Remaining screws, chassis M6 10  Nm ([...]

79[...]

M A 0 1 U G 0 0 0 . 2 3 0 . 9 3 . 3 7 7 s s e n r a h I D C 0 0 0 . 5 7 0 . 1 1 . 3 7 7 s s e n r a h n i a m s s e n r a h t r a t s - s s e n r a h I D C e t i h w - e u l b n w o r b k c a l b e t i h w - n w o r b e t i h w - k c a l b e t i h w d e r n e e r g white red-white black yellow blue green red brown blue-white black yellow blue yello[...]

WIRING DIAGRAM 81 Components 1 Battery 2 Generator 3 Ignition coil 4 Pulse generator 5 Voltage regulator/rectifier 6 Starter button 7 Starter relay 8 Starter motor 9 Short circuit button 10 Throttle valve sensor TPS 11 Ignition curve plug connection 12 CDI controller Cable colors black black black-white black-white brown brown brown-white brown-whi[...]

SUBSTANCES 82  68%67$1&(6 Super unleaded (ROZ 95 / RON 95 / PON 91) according to ಥ DIN  EN  228 (ROZ 95 / RON 95 / PON 91) Brake fluid DOT 5.1 according to ಥ DOT Specification ಥ Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- sponding propertie[...]

SUBSTANCES 83 Supplier Motorex ಥ Motorex ®  Racing  Fork  Oil[...]

AUXILIARY SUBSTANCES 84  $8;,/,$5< 68%67$1&(6 Universal oil spray Specification ಥ KTM recommends Motorex ® products. Supplier Motorex ಥ Motorex ®  Joker  440  Universal Long-life grease Specification ಥ KTM recommends Motorex ® products. Supplier Motorex ಥ Motorex ®  Long  Therm  2000 Chain cleaner Specific[...]

AUXILIARY SUBSTANCES 85 High-luster polish for paint Specification ಥ KTM recommends Motorex ® products. Supplier Motorex ಥ Motorex ®  Moto  Polish Contact spray Specification ಥ KTM recommends Motorex ® products. Supplier Motorex ಥ Motorex ®  Accu  Contact[...]

STANDARDS 86  67$1'$5'6 JASO  T903  MA Different technical development directions required a new specification for 4-stroke motorcycles ಥ the JASO T903 MA Standard. Ear- lier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specifi- cation. Whereas long ser[...]

INDEX 87 ,1'(; A Accessories .......... ........ ........ ......... 5 Air filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Air filter box lid fitting [...]

INDEX 88 Fuel tank fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Fuel tap ............ .......... ......... ..... 1 1 Fuel, oils, etc. ...... ........ .......... ......... 5 Fuse fitting . . . . . . . . . . . . . . . . . . . . . . . . . [...]

*3211243 en* 3211243en KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com 9/2007 Photo Mitterbauer[...]