Page 2 - ENGLISH; IMPORTANT; WARNING; Frame number; Tampering with noise control system prohibited; COMSUMER INFORMATION FOR AUSTRALIA ONLY
ENGLISH 1 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ...
Page 3 - Introduction; Before you go for your first ride, be sure to read this manual; Chassis and Engine” of this manual.
Introduction We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that guarantees tobring you lots of fun and enjoyment, provided that you clean and maintain itappropriately. Before you go for your first ride, be sure t...
Page 4 - INDEX
ENGLISH 3 Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - Chassis number; SERIAL NUMBER LOCATIONS; Clutch lever; CAUTION; Hand brake 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 ofthe engine below the engine sprocket. Please note this n...
Page 6 - TRP
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 speedomete...
Page 7 - Flasher switch
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...
Page 8 - Filler cap; Fuel; Fuel tap; OFF; ON; SX
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 orhigher. ! CAUTION ! U ...
Page 9 - Choke; Shift lever; Foot brake pedal; Side stand
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...
Page 10 - Compression damping of fork
ENGLISH 9 Compression damping of fork Hydraulic compression damping determines the reaction when the fork iscompressed. 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 dampi...
Page 11 - Steering lock
ENGLISH 10 Compression damping of shock absorber (MXC, EXC) The compression damping (during compression) can be adjusted for theMXC 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 direct...
Page 12 - DRIVING INSTRUCTIONS; Instructions for initial operation; Check the following before each start
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 th...
Page 13 - Starting when the engine is cold; Starting when the engine is warm; What to do when the engine is „flooded”
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 , ...
Page 14 - Braking; Stopping and parking
ENGLISH 13 Only give as much gas as the engine can handle. Throughquick and high reving of throttle, the fuel usage increases.By shifting down, use the brakes if necessary and close throttleat the same time. Pull clutch lever and shift down to the nextgear. Let clutch lever go slowely and open throt...
Page 15 - PERIODIC MAINTENANCE SCHEDULE 2001; A washed motorcycle can be checked more quickly which saves money!
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 ....
Page 16 - MPORTANT
ENGLISH 15 I MPORTANT 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 dus...
Page 17 - MAINTENANCE WORK ON CHASSIS AND ENGINE; Changing the original position of the clutch lever; Checking and adjusting the steering head bearing *
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 SPECIALIZEDKTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF. ! CA...
Page 18 - Breather plug front fork; Cleaning the dust sleeves of the telescopic fork; Adjusting the spring preload on the fork (SX)
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 wheellifted off the ground. When riding the moto...
Page 19 - How to change the handlebar position
ENGLISH 18 How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put thehandlebar 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 th...
Page 20 - Check chain tension; Correct chain tension; Chain maintenance
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 distancebetween chain and swing arm should be approx. 15 mm (0.6 in). In thecourse of this procedure, the upper chain portion A must be taut (see illustrat...
Page 21 - Chain wear; General information about KTM disc brakes; DOT
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. 10-15Kilogramm (33 lb) upwards (see figure). Now one can measure a space of18 chain reels at the lower chain strand. The chain should be re...
Page 22 - Adjusting of free travel at the hand brake lever; Checking of brake fluid level - front brake; Refilling the front brake fluid reservoir *; Checking the front brake pads
ENGLISH 21 Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustmentscrew 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 pressedagainst the brake ...
Page 23 - Replacing front brake pads *; Changing the basic position of the foot brake pedal *; Checking rear brake fluid level; Refilling the rear brake fluid reservoir *
ENGLISH 22 Replacing front brake pads * Press the brake caliper toward the brake disk, to put the brake piston in itsbasic position. Remove clips 1 and pull out bolt 2 . Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper supportwith compressed air. Check the slee...
Page 24 - Checking the rear brake pads; Replacing the rear brake pads *; Dismounting and mounting the front wheel; bk
ENGLISH 23 Checking the rear brake pads The brake pads can be inspected from the rear. The thickness of the liningsmay 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 SAF...
Page 25 - Dismounting and mounting the rear wheel
ENGLISH 24 The speedometer shaft must be placed as running along the outside of thefork 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 theclamping s...
Page 26 - Checking spoke tension; Replacing the battery of the digital speedometer
ENGLISH 25 Tires, 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 gettingready to go anywhere on your motorcycle.– Tire size can be found in the technical specifications and in their homolo- gat...
Page 27 - TOTAL MILEAGE „DST“
ENGLISH 26 TOTAL MILEAGE „DST“ T I M E „ C L K “ AFTER CHANGING BATTERY 1 sec 5 sec 1 sec 1. use the right button toselect the position to bechanged 1. make sure the time isindicated and push thebutton on the backapprox. 5 seconds (timestarts blinking) 2. push the left button until the rightfigure i...
Page 28 - Check/set distance of the magnetic sensor; WHEEL CIRCUMFERENCE „WS“; Wheel circumference with standard tires = 2205 mm
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 ind...
Page 29 - Charging the battery; VOLT
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. Simplykeep the battery poles clean and slightly grease them with an acid-freegrease if necessary.Removing the battery:First disconnect the...
Page 30 - Replacing headlight lamp/parking light lamp
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 protectioncover A , you will be able to see the fuse. The following loads are connected to it:– E-starter system...
Page 31 - Cooling system; Checking the coolant level; Bleeding the cooling system; when engine is cold
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 (about70°C, 158°F), the thermostat 2 opens and the coolant is also pum...
Page 32 - Cleaning the air filter *; Replacing the glass fiber yarn packing of the silencer *
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 getinto the engine and cause damage. Therefore, change the air filter in regular intervals.For this purpose, rotate th...
Page 33 - Adjusting the throttle cables *; Bleeding of the hydraulic clutch
ENGLISH 32 Checking the adjustment of the hand decompression releasecable * Start the engine and, at idling speed, slowly pull the hand decompressionlever until you can feel the thumping of the rocker arm on the lever. Thebacklash until said thumping should be approx. 10mm, measured at thelever's ou...
Page 34 - Basic information on carburetor wear; Adjusting the mixture control screw *
ENGLISH 33 CARBURETOR – Adjust idling (Keihin-CR39) * Idling adjustment of the carburetor strongly affects the engine’s startingbehavior. That is, an engine whose idling speed is adjusted correctly will beeasier to start than one whose idling speed has not been adjusted correctly.The idle speed is c...
Page 35 - Draining of float chamber of the carburetor; Oil circuit; Checking the engine oil level
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. Clo...
Page 36 - Engine oil; Changing the engine oil *; TEMPERATUR
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 specificationson the container). ! CAUTION ! I NSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE . Changing the e...
Page 38 - TROUBLE SHOOTING
ENGLISH 37 TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an erroroccur 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 op...
Page 40 - RE-INITIATION AFTER TIME OF STORAGE; STORAGE; CLEANING; CONSERVATION FOR WINTER OPERATION
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 ...
Page 41 - BASIC CARBURETOR SETTING
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 20...
Page 43 - ASSEMBLY CLEARANCE, WEAR LIMIT
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 m...
Page 44 - STANDARD ADJUSTMENT - SHOCK ABSORBER; TIGHTENING TORQUES - CHASSIS; USD
ENGLISH 43 TECHNICAL DATA – 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) STANDARD ADJUSTMENT - SHOCK ...
Page 45 - HEAD WORD INDEX
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 .....................
Page 46 - KTM SPORTMOTORCYCLE AG
KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet: www.ktm.at 321017
