KTM 450 SX 2009 Owner's Manual
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KTM 450 SX 2009 Owner's Manual

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OWNER'S MANUAL
2009
450 SX ATV
505 SX ATV
ART. NO. 3211378en

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  • Page 1 OWNER'S MANUAL 2009 450 SX ATV 505 SX ATV ART. NO. 3211378en...
  • Page 3 DEAR KTM CUSTOMER Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous DEAR KTM CUSTOMER pleasure if you service and maintain it accordingly. We wish you great pleasure riding the vehicle! Enter the serial numbers of your vehicle below.
  • Page 4 Reproduction, even in part, is permitted only with the express written permission of the copyright owner. ISO 9001(12 100 6061) According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.

  • Page 5: Table Of Contents

    Indicator lamp overview ............ 35 Important maintenance work to be carried out by an Emergency OFF switch with rip cord........35 authorized KTM workshop. (as additional job)...... 61 Opening filler cap ............. 36 Important checks and maintenance work to be carried out Closing filler cap ..............
  • Page 6 CONTENTS MAINTENANCE ON CHASSIS AND ENGINE ......64 Checking play in gas Bowden cable ........94 Jacking up the vehicle ............64 Adjusting play in gas Bowden cable........95 Removing the vehicle from the work stand ......64 Checking chain dirt ............96 Basic information on changing the chassis settings....
  • Page 7 CONTENTS Checking tire air pressure ..........125 Checking the coolant level..........150 Removing the battery ............126 Draining coolant ............151 Installing the battery............127 Filling coolant/bleeding the cooling system ....153 Recharging the battery ..........127 Carburetor - idle ............. 155 Changing main fuse ............
  • Page 8 CONTENTS Capacity - fuel..............183 TECHNICAL DATA - FRONT SHOCK ABSORBER....184 TECHNICAL DATA - REAR SHOCK ABSORBER..... 186 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ..188 SUBSTANCES..............190 AUXILIARY SUBSTANCES........... 194 STANDARDS..............197 INDEX ................198...

  • Page 9: Means Of Representation

    All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs done in an authorized KTM workshop! There, your vehicle will be serviced optimally by specially trained experts using the specialist tools required.

  • Page 10: Important Notes

    IMPORTANT NOTES Use definition KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently valid regulations and categories of the top international motorsport organizations. Warning Danger of accidents Incorrect assessment of riding situations.
  • Page 11 Spare parts, accessories For your own safety, only use spare parts and accessories that have been approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
  • Page 12 If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for the first time. A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you.
  • Page 13 IMPORTANT NOTES...

  • Page 14: Overview Of Labels

    IMPORTANT NOTES Overview of labels 800043-10...
  • Page 15 IMPORTANT NOTES Hangtag Information on use Emission control 450 SX ATV Emission control 505 SX ATV Warning label Information on not riding as a passenger Information on putting into operation Information on chain tension...
  • Page 16 IMPORTANT NOTES 700367-01 Hangtag...
  • Page 17 IMPORTANT NOTES 700372-01 Information on use 800045-10 Emission control 450 SX ATV...
  • Page 18 IMPORTANT NOTES 800044-10 Emission control 505 SX ATV...
  • Page 19 IMPORTANT NOTES 700368-01 Warning label...
  • Page 20 IMPORTANT NOTES 700370-01 Information on not riding as a passenger 700371-01 Information on putting into operation...
  • Page 21 IMPORTANT NOTES 700369-01 Information on chain tension Notes/warnings Be sure to pay attention to the notes and warnings given here. Info Various notes and warning stickers are attached to the vehicle. Do not remove any notes and warning stickers. If they are missing, you or others may not recognize dangers and may therefore be injured.
  • Page 22 IMPORTANT NOTES 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.

  • Page 24: View Of Vehicle

    VIEW OF VEHICLE View of the vehicle from the left front (example) 800062-10...
  • Page 25 VIEW OF VEHICLE Hand brake lever Fuse box Headlight Front shock absorber Steering damper holder (steering damper is optional) Right-hand brake caliper Front left shock absorber Outside brake disk guard Shift lever Left footrest Heel protector Emergency OFF switch with rip cord Clutch lever Hot start lever...

  • Page 26: View Of The Vehicle From The Right Rear (Example)

    VIEW OF VEHICLE View of the vehicle from the right rear (example) 800046-10...
  • Page 27 VIEW OF VEHICLE Light switch, electric starter button, ENG. STOP switch Filler cap Main silencer Rear shock absorber Rear sprocket with chain Rear wheel eccentric element Rear brake Foot brake pedal Manifold Top A-arm Front right fender Throttle lever Ignition switch...

  • Page 28: Location Of Serial Numbers

    LOCATION OF SERIAL NUMBERS Chassis number The chassis number is stamped on the right side of the frame in the vicinity of the upper  control arm. 800047-10 Type label The type label is located on the frame tube on the right and left in front of the radiator. ...

  • Page 29: Key Number

    LOCATION OF SERIAL NUMBERS Key number The key number is indicated on the KEYCODECARD.  Info You need the key number to order a replacement key. Keep the KEYCODECARD in a safe place. 100089-10 Engine number The engine number is stamped on the left side of the engine under the engine sprocket. ...

  • Page 30: Shock Absorber Part Number, Front

    LOCATION OF SERIAL NUMBERS Shock absorber part number, front The shock absorber part number is stamped on the upper part of the shock absorber.  800067-10 Shock absorber part number, rear The shock absorber part number is stamped on the upper part of the shock absorber. ...

  • Page 31: Control Elements

    CONTROL ELEMENTS Clutch lever The clutch lever is fitted on the left side of the handlebar.  Possible states Clutch lever in neutral position – In this position, the engine is force-locked with the • gear and the starting circuit is interrupted. The electric starter does not turn over when the electric starter button is pressed.

  • Page 32: Handbrake Lever, Parking Brake

    CONTROL ELEMENTS Handbrake lever, parking brake The hand brake lever is located on the right side of the handlebar and operates the front  wheel brakes. The parking brake is combined with the handbrake lever so that the front wheels can be blocked to prevent the vehicle from rolling.

  • Page 33: Throttle Lever

    CONTROL ELEMENTS Throttle lever The throttle lever is fitted on the right side of the handlebar.  The throttle lever is used to control the engine speed. 100007-10 Light switch The light switch is fitted on the left side of the handlebar. ...

  • Page 34: Light Switch

    CONTROL ELEMENTS Light switch The light switch is fitted on the left side of the handlebar.  Possible states High beam on – Light switch is turned upwards. In this position, the high beam and the tail light are switched on. Low beam on –...

  • Page 35: Eng. Stop Switch

    CONTROL ELEMENTS ENG. STOP switch The ENG. STOP switch is fitted on the left side of the handlebar.  Possible states ENG. STOP switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started. ENG.

  • Page 36: Electric Starter Button

    CONTROL ELEMENTS Electric starter button 5.10 Electric starter button is fitted on the left side of the handlebar.  Possible states • Electric starter button in basic position is pressed – In this position, the electric starter is actuated. • Electric starter button 700377-01 Ignition switch...

  • Page 37: Indicator Lamp Overview

    CONTROL ELEMENTS Indicator lamp overview 5.12 Possible states lights up yellow – Ignition is switched on. Ignition indicator lamp  lights up blue – High beam is switched on. High beam indicator lamp  800051-10 Emergency OFF switch with rip cord 5.13 The emergency OFF switch is mounted on the left in front of the fuel tank.

  • Page 38: Opening Filler Cap

    CONTROL ELEMENTS Opening filler cap 5.14 – Press release button , turn filler cap counterclockwise and lift it free.  100012-10 Closing filler cap 5.15 – Replace the filler cap and turn clockwise until the release button locks in place. ...

  • Page 39: Fuel Tap

    CONTROL ELEMENTS Fuel tap 5.16 The fuel tap is located on the right side of the fuel tank. With tap handle on the fuel tap, you can open or close the supply of fuel to the carbure-  tor. Possible states Fuel supply closed OFF –...

  • Page 40: Choke

    CONTROL ELEMENTS Choke 5.17 The choke is fitted on the left side of the carburetor.  Activating the choke function frees an opening through which the engine can draw extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start. Info If the engine is warm, the choke function must be deactivated.

  • Page 41: Foot Brake Pedal

    CONTROL ELEMENTS The gear positions can be seen in the photograph. The neutral or idle position is between the first and second gears. 800054-11 Foot brake pedal 5.19 The foot brake pedal is located in front of the right footrest and operates the rear wheel ...

  • Page 42: Tips On Putting Into Operation

    – A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain. Your KTM dealer will be glad to advise you. Warning Risk of injury Missing or insufficient protective clothing increases the risk of injury.
  • Page 43 TIPS ON PUTTING INTO OPERATION Warning Danger of accidents Accident risk caused by presence of a passenger. – Your vehicle is not designed to carry passengers. Do not ride with a passenger. Warning Danger of accidents Brake system failure. – If the foot brake pedal is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take your foot off the foot brake pedal if you do not want to brake.
  • Page 44 TIPS ON PUTTING INTO OPERATION – Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop. You receive a delivery certificate and the service record at vehicle handover. – Before your first trip, read the entire operating instructions carefully.

  • Page 45: Running In The Engine

    TIPS ON PUTTING INTO OPERATION Running in the engine – During the running-in phase, do not exceed the specified engine speed and engine performance. Guideline Maximum engine speed During the first 3 service hours 7,000 rpm maximum engine performance ≤ 50 % During the first 3 service hours ≤...

  • Page 46: Riding Instructions

    RIDING INSTRUCTIONS Checks before putting into operation Info Make sure that the vehicle is in a perfect technical condition before use. Info In the interests of riding safety, make a habit of making a general check before you ride. – Check the engine oil level.

  • Page 47: Starting

    RIDING INSTRUCTIONS – Check that all operating elements are correctly adjusted and free to move. – Check that the electrical equipment is functioning properly. Starting Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
  • Page 48 RIDING INSTRUCTIONS – Turn the key in the ignition switch to the position The yellow ignition indicator lamp ON lights up. Info Under no circumstances should you open the throttle when switching on the ignition! The vehicle is equipped with a safety system that switches off the engine in case of a malfunction in the throttle lever, Bowden cable or carburetor.

  • Page 49: Starting Up

    RIDING INSTRUCTIONS Starting up Info Switch your lights on before leaving. You will then be seen earlier by other motorists. – Pull and release the handbrake lever. Locking pawl moves into its basic position, parking brake is deactivated. – Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully. Shifting Warning Danger of accidents If you change down at high engine speed, the rear wheels can block.

  • Page 50: Braking

    Danger of accidents Reduced braking caused by spongy pressure point of front or rear brake. – Have the brake system checked in an authorized KTM workshop, and do not ride any further. Warning Danger of accidents Reduced braking due to wet or dirty brakes.

  • Page 51: Riding

    Info If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop. If the vehicle goes out of control and you fall off the vehicle, the clip of the emergency OFF switch is pulled off by the rip cord attached to your clothing.
  • Page 52 RIDING INSTRUCTIONS Warning Danger of accidents Excessive speed and turning at sharp angles can cause the vehicle to roll over. – Decrease your speed before entering into bends. – Handling of the ATV is strongly influenced by shifts in the position of your body weight. Always shift your body weight toward the inside of the bend and forward.

  • Page 53: Riding Downhill

    RIDING INSTRUCTIONS Riding downhill Warning Danger of accidents Danger of accidents when riding on slopes. – Always check the terrain before riding onto a slope. – Never ride on a slope with an inclination of more than 25°. – Never ride on a slope that exceeds your driving skills. –...

  • Page 54: Riding Uphill

    RIDING INSTRUCTIONS Riding uphill Warning Danger of accidents Danger of accidents when riding on slopes. – Always check the terrain before riding onto a slope. – Never ride on a slope with an inclination of more than 25°. – Never ride on a slope that exceeds your driving skills. –...

  • Page 55: Riding Perpendicular To The Slope

    RIDING INSTRUCTIONS Riding perpendicular to the slope 7.10 Warning Danger of accidents When riding perpendicular to a slope, the vehicle can tip easily and roll over. – Avoid riding perpendicular to the slope if possible. – Ride slowly and shift you weight toward the slope. –...
  • Page 56 RIDING INSTRUCTIONS – If you come to a stop on a slope with your vehicle, dismount from the vehicle and turn – Switch off the engine and activate the parking brake. – Dismount from the vehicle on the uphill side. –...

  • Page 57: Riding Through Water

    After riding through water, dry the brakes by lightly activating both brakes until normal braking power is available again. – If the vehicle became submerged, an authorized KTM workshop must perform a thor- ough check and comprehensive service. Do not start the engine. Switching off the engine 7.13...

  • Page 58: Stopping, Parking

    RIDING INSTRUCTIONS Alternative 1 Switch off the engine using the ignition key. – Turn the key in the ignition switch to the position Info All power-consuming components are switched off. Alternative 2 Switch off the engine using the ENG. STOP switch. –...

  • Page 59: Refueling

    RIDING INSTRUCTIONS Note Danger of damage Danger of damage from accidental rolling of vehicle. – Park the vehicle on a surface that is as horizontal as possible and activate the parking brake. Note Fire hazard Some components (engine, radiator and exhaust system) get very hot when the engine is running. –...
  • Page 60 RIDING INSTRUCTIONS Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 61: Service Schedule

    SERVICE SCHEDULE Important maintenance work to be carried out by an authorized KTM workshop. S10A S30A Engine • • • Change the engine oil and oil filter, clean the oil screen. p. 159) Replace spark plug. • Check the valve clearance and adjust if necessary.
  • Page 62 SERVICE SCHEDULE S10A S30A Brakes Check the rear brake fluid level. ( p. 114) • • • Check that brake lines are undamaged and free of leaks. • • • Check the free play of the hand brake lever. ( p.

  • Page 63: Important Maintenance Work To Be Carried Out By An Authorized Ktm Workshop. (As Additional Job)

    S10A: Every 10 service hours - corresponds to about 70 liters of fuel/after every race S30A: Every 30 service hours - corresponds to about 210 liters of fuel Important maintenance work to be carried out by an authorized KTM workshop. (as additional job) S10A...
  • Page 64 SERVICE SCHEDULE S10A S20A S40A Change the valve springs. • • Check the timing-chain tensioner function. • Check the crankshaft run-out at the bearing pin. • Change the conrod bearing. Check the seating of the piston pin. • Change the crankshaft main bearing. •...

  • Page 65: Important Checks And Maintenance Work To Be Carried Out By The Rider

    SERVICE SCHEDULE Important checks and maintenance work to be carried out by the rider. NB1A Check the engine oil level. ( p. 158) • Check the front brake fluid level. ( p. 105) • Check the rear brake fluid level. ( p.

  • Page 66: Maintenance On Chassis And Engine

    MAINTENANCE ON CHASSIS AND ENGINE Jacking up the vehicle Note Danger of damage Danger of damage from tipping of vehicle. – Jack up the vehicle on a firm and horizontal surface. Use a flex-free work stand. – Jack up the vehicle on the frame underneath the engine. The wheels must no longer touch the ground.

  • Page 67: Compression Damping Of The Shock Absorber

    MAINTENANCE ON CHASSIS AND ENGINE Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced. When changing the chassis settings, always start with the standard setting. Between test rides, always change only one setting.

  • Page 68: Front Shock Absorber - Adjusting The Low-Speed Compression Damping

    MAINTENANCE ON CHASSIS AND ENGINE Info The high-speed setting takes effect during the fast compression of the shock absorber. – Turn adjusting screw clockwise all the way using a ring wrench.  Info Do not loosen screw connection  – Turn back counterclockwise by the number of turns corresponding to the shock absorber type.
  • Page 69 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Do not make any radical changes to the adjustment of the shock absorbers. – Only make adjustments within the recommended range. Info The low-speed setting takes effect during the slow to normal compression of the shock absorber. –...

  • Page 70: Front Shock Absorber - Adjusting The Rebound Damping

    MAINTENANCE ON CHASSIS AND ENGINE Front shock absorber - adjusting the rebound damping Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte- nance on it yourself.

  • Page 71: Front Shock Absorber - Adjusting The Cross Over

    MAINTENANCE ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort 23 clicks Standard 21 clicks Sport 19 clicks Experience has shown that settings outside of this range are detrimental to vehi- cle handling.
  • Page 72 Less cross over makes the spring action at the front harder and the front of the vehicle lies higher. – Jack up the vehicle. ( p. 64) – Clean the shock absorber thoroughly. – Loosen adjusting rings . Suitable tools are available from an authorized KTM   workshop. Hook wrench (83019001000) 800063-10 – Cross over setting...

  • Page 73: Front Shock Absorber - Adjusting The Spring Preload

    MAINTENANCE ON CHASSIS AND ENGINE – Tighten the spring by turning adjusting ring to setting   Info The left and right shock absorbers should have the same settings. – Tighten the adjusting ring. – Remove the vehicle from the work stand. ( p.
  • Page 74 MAINTENANCE ON CHASSIS AND ENGINE – Loosen lock ring  Hook wrench (83019001000) – Turn adjusting ring until the spring pack is fully unloaded.  – Measure the entire spring pack when it is unloaded. 800063-12 – Tighten the spring pack by turning adjusting ring to the specified setting ...

  • Page 75: Rear Shock Absorber - Adjusting The High Speed Compression Damping

    MAINTENANCE ON CHASSIS AND ENGINE Rear shock absorber - adjusting the high speed compression damping 9.10 Danger Danger of accidents The shock absorber is under high pressure. – The shock absorber is filled with highly compressed nitrogen, so never dismantle the shock absorber or carry out any mainte- nance on it yourself.

  • Page 76: Rear Shock Absorber - Adjusting The Low-Speed Compression Damping

    MAINTENANCE ON CHASSIS AND ENGINE – Turn back counterclockwise by the number of turns corresponding to the shock absorber type. Guideline Compression damping, high-speed Comfort 2 turns Standard 2 turns Sport 1.5 turns Info Turn clockwise to increase damping, turn counterclockwise to reduce suspension damping.

  • Page 77: Rear Shock Absorber - Adjusting The Rebound Damping

    MAINTENANCE ON CHASSIS AND ENGINE – Turn adjusting screw clockwise to the last perceptible click using a screwdriver.  Info Do not loosen screw connection  – Turn back counterclockwise by the number of clicks corresponding to the shock absorber type. Guideline Compression damping, low-speed 800060-11...

  • Page 78: Rear Shock Absorber - Adjusting The Spring Preload

    MAINTENANCE ON CHASSIS AND ENGINE Info The rebound damping setting has an impact on the compression of the shock absorber. – Turn adjusting screw clockwise to the last perceptible click.  – Turn back to the left by the number of clicks corresponding to the shock absorber type. Guideline Rebound damping Comfort...
  • Page 79 After removing the shock absorber, clean it thoroughly. – Loosen lock ring . Hold adjusting ring while doing so. Suitable tools are available   from an authorized KTM workshop. Hook wrench (83019002000) – Turn the adjusting ring until the spring pack is fully unloaded. 200601-01...

  • Page 80: Removing The Rear Shock Absorber

    MAINTENANCE ON CHASSIS AND ENGINE – Measure the entire spring pack when it is unloaded. Info Spring preload is the difference in length between the spring pack when it is  unloaded and when it is installed. – Tighten the spring pack by turning the adjusting ring to the specified setting. Guideline Spring preload Comfort...
  • Page 81 MAINTENANCE ON CHASSIS AND ENGINE Note Danger of damage The chain sliding piece and frame can be damaged from incorrect handling. – When removing the rear shock absorber, secure the swingarm with a tension belt to prevent it from swinging down further. –...

  • Page 82: Installing The Rear Shock Absorber

    MAINTENANCE ON CHASSIS AND ENGINE Installing the rear shock absorber 9.15 – Position the shock absorber in the vehicle with the reservoir on the right. Mount and tighten the top screw  Guideline Screw, rear top shock absorber 60 Nm (44.3 lbf ft) –...
  • Page 83 MAINTENANCE ON CHASSIS AND ENGINE – Load the vehicle with the specified weight. Guideline Standard rider weight 70… 80 kg (154… 176 lb.) – Move the handlebar into the straight-ahead position and fix it. Handlebar fixation for straight-ahead position (83019015100) 300272-10...
  • Page 84 MAINTENANCE ON CHASSIS AND ENGINE 400333-10 – Measure distances   » If distances are not equal:   – Adjust the toe. p. 83)

  • Page 85: Adjusting The Toe

    MAINTENANCE ON CHASSIS AND ENGINE – Measure distances   Guideline Front 0 mm (0 in) Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv-  ...
  • Page 86 MAINTENANCE ON CHASSIS AND ENGINE 400333-11 – Loosen nuts   – Adjust the distances to the same value by rotating the tie rods   ...

  • Page 87: Checking/Adjusting The Camber

    MAINTENANCE ON CHASSIS AND ENGINE – Adjust the distances to the specified value by evenly rotating the tie rods    Guideline Front 0 mm (0 in) Info The toe is the difference in length between distances by which the wheels are spaced at the front or rear when driv- ...
  • Page 88 MAINTENANCE ON CHASSIS AND ENGINE – Loosen nuts  300273-10 – Remove screws with bushings   300274-10 – Insert tool in the heim joint and clip onto the A-arm.  Camber gauge (83019014000) – Check the camber on both heim joints. »...

  • Page 89: Fork Offset

    MAINTENANCE ON CHASSIS AND ENGINE – Position the A-arm with bushings . Mount and tighten screws   Guideline Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) 300274-10 – Align the heim joint at right angles to screws and tighten nut ...

  • Page 90: Adjusting The Fork Offset

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting the fork offset 9.20 Info The left and right fork offset should have the same settings. The operations are the same on the left and right. – Jack up the vehicle. ( p. 64) –...

  • Page 91: Adjusting The Toe Width Of The Rear Axle

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting the toe width of the rear axle 9.22 Warning Danger of accidents Modifications to the chassis can seriously alter the vehicle's handling characteristics. – Following modifications, ride slowly at first to get the feel of the new handling characteristics. –...
  • Page 92 MAINTENANCE ON CHASSIS AND ENGINE Setting a wide toe width: – Mount spacing sleeve with the cone facing inward.  0 0 2 0 0 3 – Mount conical ring with the cone facing outward.  – Mount wheel hub ...

  • Page 93: Handlebar Position

    MAINTENANCE ON CHASSIS AND ENGINE Handlebar position 9.23 The handlebar position can be adjusted 4-fold by turning the handlebar support and the  handlebar support  The holes on the handlebar support are placed at a distance of from the center. ...

  • Page 94: Adjusting The Handlebar Position

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting the handlebar position 9.24 – Pull the instrument support off the handlebar and swing it to the side. Info Protect the vehicle and its attachments from damage by covering them. Do not bend the cables and lines. 100100-10...
  • Page 95 MAINTENANCE ON CHASSIS AND ENGINE – Remove the four screws . Remove handlebar clamps , swing the handlebar forward   and set it down. – Remove nuts and remove handlebar support with the screws.   – Remove screws ...

  • Page 96: Checking Play In Gas Bowden Cable

    MAINTENANCE ON CHASSIS AND ENGINE – Position the handlebar and fix it with handlebar clamps . Mount and tighten  screws  Guideline Screw, handlebar clamp 20 Nm (14.8 lbf ft) Info Make sure cables and wiring are positioned correctly. –...

  • Page 97: Adjusting Play In Gas Bowden Cable

    MAINTENANCE ON CHASSIS AND ENGINE Danger Danger of poisoning Exhaust gases are poisonous and can result in unconsciousness and/or death. – When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space. –...

  • Page 98: Checking Chain Dirt

    MAINTENANCE ON CHASSIS AND ENGINE Checking chain dirt 9.27 – Check the chain for coarse dirt accumulation. » If the chain is very dirty: – Clean the chain. ( p. 96) Cleaning the chain 9.28 Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 99: Checking The Chain Tension

    MAINTENANCE ON CHASSIS AND ENGINE Checking the chain tension 9.29 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel eccentric element) are under additional load.

  • Page 100: Checking Rear Sprocket / Engine Sprocket For Wear

    MAINTENANCE ON CHASSIS AND ENGINE Checking rear sprocket / engine sprocket for wear 9.30 – Check rear sprocket / engine sprocket for wear. » If the rear sprocket / engine sprocket are worn: – Replace the rear sprocket / engine sprocket. Info When fitting the chain joint, always make sure that the closed side of the joint faces forward (riding direction).
  • Page 101 MAINTENANCE ON CHASSIS AND ENGINE – Pull the lower chain section with the specified weight  Guideline Chain-wear measuring weight 10… 15 kg (22… 33 lb.) – Measure the distance of 18 chain links in the upper chain section.  Info Chain wear is not always even, so you should repeat this measurement at differ- ent chain positions.

  • Page 102: Adjusting Chain Tension

    MAINTENANCE ON CHASSIS AND ENGINE Adjusting chain tension 9.32 Warning Danger of accidents Danger caused by incorrect chain tension. – If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel eccentric element) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break.
  • Page 103 MAINTENANCE ON CHASSIS AND ENGINE – Loosen the screws by four turns.  Alternative 1 – Insert the tool from the tool set into the hole of the rear wheel eccentric ele-   ment. Alternative 2 – Use a special tool on the rear wheel eccentric. Hook wrench (83019011000) –...

  • Page 104: Greasing The Rear Wheel Eccentric Element

     Long-life grease ( p. 192) 100092-10 Checking the brake discs 9.34 Warning Danger of accidents Reduced braking due to worn brake discs. – Worn brake discs should be replaced immediately in an authorized KTM workshop.

  • Page 105: Checking The Free Play Of The Hand Brake Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Check the thickness of the front and rear brake discs at several places on the disc to see if it conforms to measurement  Info Wear reduces the thickness of the brake disc around the area used by the brake linings.

  • Page 106: Adjusting Basic Position Of Handbrake Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Push the hand brake lever forward and check free play.  ≥ 3 mm (≥ 0.12 in) Free play of hand brake lever » If the free travel does not meet specifications: – adjust the basic position of handbrake lever. ( p.

  • Page 107: Checking Front Brake Fluid Level

    Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
  • Page 108 If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 109: Checking The Front Brake Linings

    Clean up overflowed or spilt brake fluid immediately with water. 100036-10 Checking the front brake linings 9.39 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. – Remove the wheel/wheels. ( p. 122)

  • Page 110: Removing Front Brake Linings

    Removing front brake linings 9.40 Warning Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. Info The operations are the same on the left and right. – Remove the wheel/wheels. ( p.

  • Page 111: Installing The Front Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.

  • Page 112: Changing The Front Brake Linings

    MAINTENANCE ON CHASSIS AND ENGINE – Insert the inside brake lining into the brake caliper and fix with bolt  – Insert the external brake lining into the brake caliper and slide the bolts in all the way. 100072-10 – Mount locking split pins ...
  • Page 113 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 114: Checking Free Play Of Foot Brake Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the front brake linings. p. 108) – Move the brake fluid reservoir mounted on the handlebar to a horizontal position. – Remove screws  – Remove cover with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir.

  • Page 115: Adjusting Basic Position Of Footbrake Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Disconnect spring  – Move the foot brake lever backwards and forwards between the end stop and the foot brake cylinder piston bracket and check free play  Guideline Free play at foot brake lever 3…...

  • Page 116: Checking Rear Brake Fluid Level

    If the brake fluid level falls below the bottom of the viewer, this indicates a leakage in the brake system or worn-out brake lin- ings. Have the brake system checked in an authorized KTM workshop, and do not ride any further.

  • Page 117: Adding Rear Brake Fluid

    MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. – Park the vehicle on a horizontal surface. –...
  • Page 118 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 119: Checking Rear Brake Linings

    Checking rear brake linings 9.47 Warning Danger of accidents Reduced braking due to worn brake linings. – Worn brake linings should be replaced immediately in an authorized KTM workshop. – Check the brake linings for minimum thickness  ≥ 1 mm (≥ 0.04 in) Minimum thickness ...

  • Page 120: Removing Rear Brake Linings

    Danger of accidents Improper brake maintenance and repair. – Always have your brake system maintained and repaired in an authorized KTM workshop. – Press the brake caliper by hand on to the brake disc in order to press back the brake piston.

  • Page 121: Installing The Rear Brake Linings

    Brake linings available from accessory suppliers are often not tested and approved for use on KTM vehicles. The construction and friction factor of the brake linings and therefore the brake power can differ considerably from the original KTM brake lin- ings.
  • Page 122 MAINTENANCE ON CHASSIS AND ENGINE – Check that sliding plate is seated correctly in the brake caliper support and insert  the brake linings. Info Make sure that decoupling plate is mounted on the piston side of the brake  pad.

  • Page 123: Changing The Rear Brake Linings

    If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately. Warning Danger of accidents Reduced braking due to old brake fluid. – Have the front and rear brake fluid replaced according to the service plan in an authorized KTM workshop. Warning Environmental hazard Problem materials cause environmental damage. –...

  • Page 124: Removing Wheel/Wheels

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the rear brake linings. p. 118) – Remove screw with membrane   – Press the brake piston back to its basic position and make sure that no brake fluid over- flows from the brake fluid reservoir. –...

  • Page 125: Installing The Wheel/Wheels

    MAINTENANCE ON CHASSIS AND ENGINE – Loosen the wheel nuts  – Jack up the vehicle. ( p. 64) – Remove the wheel nuts. Remove the wheel. Info Carefully remove the wheel, making sure it does not become jammed with the threads of the screws.
  • Page 126 MAINTENANCE ON CHASSIS AND ENGINE Info Proceed in the same way on the other wheels if necessary. – Position the wheel on the hub. Info Note the direction of travel of the front wheels. Carefully position the wheel on the hub, being careful not to damage the threads of the screws.

  • Page 127: Checking The Tire Condition

    9.53 Info Only mount tires approved and/or recommended by KTM. Other tires could have a negative effect on riding behavior. The type, condition and air pressure of the tires all have an important impact on the riding behavior of the vehicle.

  • Page 128: Removing The Battery

    MAINTENANCE ON CHASSIS AND ENGINE Removing the battery 9.55 Warning Risk of injury Battery acid and battery gases cause serious chemical burns. – Keep batteries out of the reach of children. – Wear suitable protective clothing and goggles. – Avoid contact with battery acid and battery gases. –...

  • Page 129: Installing The Battery

    MAINTENANCE ON CHASSIS AND ENGINE Installing the battery 9.56 – Place the battery in the battery holder. 4Ah battery (YTX5L-BS) ( p. 183) – Reconnect rubber band  – Attach the positive (plus) cable and replace the plus pole cover ...
  • Page 130 MAINTENANCE ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. Info Even if there is no load on the battery, it loses power every day. The charge state and the type of charge are very important for the service life of the battery.

  • Page 131: Changing Main Fuse

    MAINTENANCE ON CHASSIS AND ENGINE – Connect the battery charger to the battery. Switch on the battery charger. Battery charger (58429074000) You can also use the battery charger to test rest potential and start potential of the bat- tery, and to test the generator. With this device, you cannot overcharge the battery. Info Never remove the lid ...

  • Page 132: Changing The Fuses Of Individual Power-Consuming Components

    Use only fuses with the prescribed amperage. Never by-pass or repair fuses. – Insert a new fuse. Fuse (58011109120) Info If the new fuse burns out, contact an authorized KTM workshop. 300257-10 The spare fuse should always be present in the starter relay so that it is avail- ...
  • Page 133 MAINTENANCE ON CHASSIS AND ENGINE – Open the cover of the fuse box   Info The designation of the fuses is located on the inside cover of the fuse box  – Remove the faulty fuse. Guideline Fuse 1 - 10A - ignition, CDI contoller, indicator lamps ON Fuse 2 - 15A - high beam, low beam, parking light, tail light, brake light, high beam indicator lamp Fuse 3 - 10A - radiator fan...
  • Page 134 Insert a new fuse of the appropriate strength. Fuse (58011109110) Fuse (58011109115) Info If the new fuse burns out, contact an authorized KTM workshop. The spare fuse should always be present in the starter relay so that it is available if needed. –...

  • Page 135: Ignition Curve Plug Connection

    MAINTENANCE ON CHASSIS AND ENGINE Ignition curve plug connection 9.60 Plug-in connector is located under the trim at the front on the frame tube.  Possible states Performance – The plug-in connector is connected to achieve better performance. • Soft – The plug-in connector is disconnected for better driveability. •...

  • Page 136: Removing The Seat

    MAINTENANCE ON CHASSIS AND ENGINE Removing the seat 9.62 – Pull the release hook back. Lift up the seat at the rear, pull it back and then remove  from above. 100041-10 Mounting the seat 9.63 – Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the seat ...

  • Page 137: Removing The Radiator Spoiler

    MAINTENANCE ON CHASSIS AND ENGINE – Push down the rear of the seat until release hook engages.  – Make sure that the seat is correctly locked in. 100043-10 Removing the radiator spoiler 9.64 Info The operations are the same on the left and right. –...

  • Page 138: Installing The Radiator Spoiler

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the screws on the radiator.  – Unhinge and remove the radiator spoiler and the fuel tank. 300250-10 Installing the radiator spoiler 9.65 Info The operations are the same on the left and right. –...

  • Page 139: Removing The Front Cover

    MAINTENANCE ON CHASSIS AND ENGINE – Mount and tighten screws on the radiator.  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount and tighten screws on the fuel tank.  Guideline Screw on fuel tank 6 Nm (4.4 lbf ft) –...

  • Page 140: Installing The Front Cover

    MAINTENANCE ON CHASSIS AND ENGINE Installing the front cover 9.67 – Position the front cover in slots on both sides of the front trim.  – Mount and tighten the screw. 300253-10 Removing the front trim 9.68 – Remove the front cover. ( p.
  • Page 141 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws  – Raise the front trim and disconnect the plug-in connectors from the head light and the emergency OFF switch with the rip cord. – Remove the front trim. 300256-10...

  • Page 142: Installing The Front Trim

    MAINTENANCE ON CHASSIS AND ENGINE Installing the front trim 9.69 – Connect the plug-in connectors of the head light and the emergency OFF switch with the rip cord and position the front trim. – Mount all screws. – Fully tighten screws ...
  • Page 143 MAINTENANCE ON CHASSIS AND ENGINE – Remove screws  300254-10 – Raise the rear of the air filter box lid . At the same time, use your other hand to press  on the carburetor connection boot to kink it at that location. This prevents the carbure- tor connection boot from disconnecting from the carburetor.

  • Page 144: Installing The Rear Fender

    MAINTENANCE ON CHASSIS AND ENGINE Installing the rear fender 9.71 – Raise the rear of air filter box lid . At the same time, use your other hand to press on  the carburetor connection boot to kink it at that location. This prevents the carburetor connection boot from disconnecting from the carburetor.
  • Page 145 MAINTENANCE ON CHASSIS AND ENGINE – Mount and tighten screws  Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) – Mount the seat. ( p. 134) 300254-11...

  • Page 146: Removing The Engine Guard

    MAINTENANCE ON CHASSIS AND ENGINE Removing the engine guard 9.72 – Remove screws . Remove the engine guard.   600133-10 Installing the engine guard 9.73 – Position the engine guard on the frame bearer. Mount and tighten screws  ...

  • Page 147: Removing The Air Filter

    MAINTENANCE ON CHASSIS AND ENGINE Removing the air filter 9.74 Note Engine failure Unfiltered intake air has a negative effect on the service life of the engine. – Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 148: Installing The Air Filter

    MAINTENANCE ON CHASSIS AND ENGINE Installing the air filter 9.75 – Mount the clean air filter onto the air filter support. – Put in both parts together, position them and fix them with the air filter support  Info If the air filter is not correctly mounted, dust and dirt can penetrate into the engine and can cause damage.

  • Page 149: Adjusting Basic Position Of Clutch Lever

    MAINTENANCE ON CHASSIS AND ENGINE – Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Air filter cleaner ( p. 194) Info Only press the air filter to dry it, never wring it out. –...

  • Page 150: Checking The Fluid Level Of The Hydraulic Clutch

    MAINTENANCE ON CHASSIS AND ENGINE Checking the fluid level of the hydraulic clutch 9.78 Info The fluid level rises with increasing wear of the clutch lining disc. Do not use brake fluid. – Move the clutch fluid reservoir mounted on the handlebar to a horizontal position. –...

  • Page 151: Radiator Fan

    MAINTENANCE ON CHASSIS AND ENGINE Radiator fan 9.80 The radiator fan is located on the radiator under the fuel tank.  Working range within which radiator fan is switched on and off. Thermoswitch Switch-off temperature 80 °C (176 °F) Switch-on temperature 85 °C (185 °F) 300260-10 Checking the antifreeze and coolant level...

  • Page 152: Checking The Coolant Level

    MAINTENANCE ON CHASSIS AND ENGINE – Remove the radiator cap . – Check the antifreeze of the coolant. −25… −45 °C (−13… −49 °F) » If the antifreeze of the coolant does not meet specifications: – Correct the antifreeze of the coolant. –...

  • Page 153: Draining Coolant

    MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.
  • Page 154 MAINTENANCE ON CHASSIS AND ENGINE Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately. Change clothes that have come into contact with coolants.

  • Page 155: Filling Coolant/Bleeding The Cooling System

    MAINTENANCE ON CHASSIS AND ENGINE Filling coolant/bleeding the cooling system 9.84 Warning Danger of poisoning Coolants are poisonous and a health hazard. – Avoid contact between coolants and skin, eyes and clothing. If fuel gets into your eyes, rinse immediately with water and con- tact a doctor.
  • Page 156 MAINTENANCE ON CHASSIS AND ENGINE – Open screw to bleed the radiator. Tighten the screw when coolant emerges from the  opening. Guideline Remaining screws, chassis 10 Nm (7.4 lbf ft) 300268-10 – Add coolant to level above the radiator fins. ...

  • Page 157: Carburetor - Idle

    MAINTENANCE ON CHASSIS AND ENGINE Carburetor - idle 9.85 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.
  • Page 158 MAINTENANCE ON CHASSIS AND ENGINE – Adjust the idle speed with adjusting screw  Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 38) Idle speed 1,500… 1,600 rpm Info If the idle speed is set significantly higher, the engine does not start. When the electric starter button is activated, the electric starter turns over the engine, but the engine does not start because there is no ignition spark.

  • Page 159: Emptying The Carburetor Float Chamber

    MAINTENANCE ON CHASSIS AND ENGINE – Adjust the idle speed with adjusting screw  Guideline Choke function deactivated – The choke lever is pushed in to the stop. ( p. 38) Idle speed 1,500… 1,600 rpm Info Following extreme air temperature or altitude changes, adjust the idle speed again.

  • Page 160: Checking Engine Oil Level

    MAINTENANCE ON CHASSIS AND ENGINE Info Carry out this work with a cold engine. – Turn handle of the fuel tap to the OFF position. (Figure 800052-10 p. 37)  Fuel no longer flows from the tank to the carburetor. –...

  • Page 161: Changing The Engine Oil And Oil Filter, Cleaning The Oil Screen

    MAINTENANCE ON CHASSIS AND ENGINE Condition The engine is at operating temperature. – Check the engine oil level. Info After switching off the engine, wait one minute before checking the level. The engine oil reaches the middle of the viewer ...

  • Page 162: Draining The Engine Oil

    MAINTENANCE ON CHASSIS AND ENGINE Draining the engine oil 9.90 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.

  • Page 163: Cleaning The Oil Screen

    MAINTENANCE ON CHASSIS AND ENGINE Cleaning the oil screen 9.91 Warning Danger of scalding Engine oil and gear oil get very hot when the vehicle is driven. – Wear suitable protective clothing and gloves. If you scald yourself, hold the affected area under cold water immediately. Warning Environmental hazard Problem materials cause environmental damage.
  • Page 164 MAINTENANCE ON CHASSIS AND ENGINE Warning Environmental hazard Problem materials cause environmental damage. – Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations. – Place a suitable container under the engine. – Remove screws . Take off the oil filter cover with the O-ring. ...

  • Page 165: Installing The Oil Filter

    MAINTENANCE ON CHASSIS AND ENGINE Installing the oil filter 9.93 – Fill oil filter with engine oil and place it in the oil filter housing.  300263-11 – Oil the O-ring of the oil filter cover and install it with the oil filter cover. –...

  • Page 166: Topping Up Engine Oil

    MAINTENANCE ON CHASSIS AND ENGINE – Remove screw cap on the clutch cover and fill up with engine oil.  Engine oil 2.00 l (2.11 qt.) External Engine oil temperature: (SAE 10W/50) ≥ 0 °C (≥ 32 °F) p. 191) External Engine oil (SAE temperature:...
  • Page 167 MAINTENANCE ON CHASSIS AND ENGINE – Check the engine for leakage. – Remove the screw cap on the clutch cover and fill up with engine oil.  Condition External temperature: ≥ 0 °C (≥ 32 °F) Engine oil (SAE 10W/50) ( p.

  • Page 168: Troubleshooting

    TROUBLESHOOTING Faults Possible cause Action – Engine turns but does not start. Operating error Follow the instructions on starting the engine. p. 45) – Vehicle was out of use for a long time Empty the carburetor float chamber. and there is old fuel in the float cham- p.
  • Page 169 – Do not touch parts of the ignition sys- tem. Have work on the ignition sys- tem carried out in an authorized KTM workshop. – Remove spark plug, connect ignition cable, hold spark plug to ground (bare metal area on engine), and try to start the engine.
  • Page 170 129) – Check electrical system. – Low external temperature Recharge the battery. Establish the reason for discharging or have it checked in a KTM work- shop. – Engine does not speed up. Carburetor running over because float Have carburetor checked.
  • Page 171 TROUBLESHOOTING Faults Possible cause Action – Engine has no idle. Idling jet blocked Clean carburetor. – Adjusting screws on carburetor dis- Have the carburetor adjusted. torted – Spark plug defective Change spark plug. – Ignition system defective Have ignition system checked. –...
  • Page 172 TROUBLESHOOTING Faults Possible cause Action – Engine has too little power. Air filter very dirty Clean the air filter. p. 146) – Exhaust system leaky, deformed or too Check exhaust system for damage. little glass fiber yarn filling in main silencer.

  • Page 173: Cleaning

    CLEANING Cleaning the vehicle 11.1 Note Material damage Damage and destruction of components by high-pressure cleaning equipment. – Never clean the vehicle with high-pressure cleaning equipment or a strong water-jet. The excessive pressure can penetrate electrical components, connects, Bowden cables, and bearings, etc., and can damage or destroy these parts. Warning Environmental hazard Problem materials cause environmental damage.
  • Page 174 CLEANING – After rinsing the vehicle with a gentle water spray, allow it to dry thoroughly. – Clean and dry the air filter box. – Empty the carburetor float chamber. p. 157) Warning Danger of accidents Reduced braking due to wet or dirty brakes. –...

  • Page 175: Storage

    STORAGE Storage 12.1 Warning Danger of poisoning Fuel is poisonous and a health hazard. – Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doc- tor immediately.

  • Page 176: Putting The Vehicle Into Operation After Storage

    STORAGE – Recharge the battery. p. 127) Guideline Storage temperature of battery without direct sunshine. 0… 35 °C (32… 95 °F) – The storage place should be dry and not subject to large temperature differences. – Cover the vehicle with a porous sheet or blanket. Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.

  • Page 177: Technical Data - Engine

    TECHNICAL DATA - ENGINE Design 1-cylinder 4-stroke engine, water-cooled Displacement (450 SX ATV) 449.3 cm³ (27.418 cu in) Displacement (505 SX ATV) 477.5 cm³ (29.139 cu in) Stroke 60.8 mm (2.394 in) Bore (450 SX ATV) 97 mm (3.82 in) Bore (505 SX ATV) 100 mm (3.94 in) Compression ratio...

  • Page 178: Capacity - Engine Oil

    TECHNICAL DATA - ENGINE 3rd gear 20:26 4th gear 23:25 5th gear 26:24 Generator 12 V, 200 W Ignition Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan Spark plug NGK CR 9 EKB Spark plug electrode gap 0.7 mm (0.028 in) Cooling Water cooling, permanent circulation of coolant by water pump...

  • Page 179: Technical Data - Engine Tightening Torques

    TECHNICAL DATA - ENGINE TIGHTENING TORQUES ® Engine housing vent jet Loctite 243™ ® Oil jet, cam lever lubrication 6 Nm (4.4 lbf ft) Loctite 243™ ® Oil jet, piston cooling 4 Nm (3 lbf ft) Loctite 243™ ® Locking screw for bearing 6 Nm (4.4 lbf ft) Loctite 243™...
  • Page 180 TECHNICAL DATA - ENGINE TIGHTENING TORQUES – Screw, generator cover 10 Nm (7.4 lbf ft) ® Screw, ignition pulse generator cable 10 Nm (7.4 lbf ft) Loctite 243™ holder ® Screw, oil pump casing 10 Nm (7.4 lbf ft) Loctite 243™...
  • Page 181 TECHNICAL DATA - ENGINE TIGHTENING TORQUES Nut, cylinder head M10x1.25 Tightening sequence: lubricated with engine oil Tighten in diagonal sequence. Tightening stage 1 10 Nm (7.4 lbf ft) Tightening stage 2 30 Nm (22.1 lbf ft) Tightening stage 3 50° –...

  • Page 182: Technical Data - Carburetor

    TECHNICAL DATA - CARBURETOR Carburetor type KEIHIN FCR-MX 41 Carburetor identification number 4125L Needle position 3 th position from top Idle mixture adjusting screw Open 1.5 turns Pump membrane stop 2.15 mm (0.0846 in) Hot start button Bore diameter in carburetor body 2.5 mm (0.098 in) Main jet Jet needle...

  • Page 183: Technical Data - Chassis

    TECHNICAL DATA - CHASSIS Frame Double cradle of chromium molybdenum steel tubes, powder- coated Wheel suspension Front Single wheel suspension with double transverse control arm Rear Rigid axle Suspension travel Front 244 mm (9.61 in) Rear 258 mm (10.16 in) Fork offset Front 50 mm (1.97 in)
  • Page 184 TECHNICAL DATA - CHASSIS Maximum allowable axle load Front 144 kg (317 lb.) Rear 149 kg (328 lb.) Maximum permissible overall weight 293 kg (646 lb.) Vehicle length 1,810 mm (71.26 in) Vehicle width 1,265 mm (49.8 in) Vehicle height 1,100 mm (43.31 in) Brake system Front...

  • Page 185: Lighting Equipment

    20 x 6.00 - 10 18 x 10.00 - 8 MAXXIS Razr MX‑931 MAXXIS Razr MX‑932 For further information, see the Service section under: http://www.ktm.com Capacity - fuel 16.3 Total fuel tank capacity approx. 10.3 l (2.72 US gal) Super unleaded (ROZ 95 / RON 95 / PON 91) (...

  • Page 186: Technical Data - Front Shock Absorber

    TECHNICAL DATA - FRONT SHOCK ABSORBER Shock absorber part number 03.18.7E.16 Shock absorber WP Suspension 3612 BAVP DCC Compression damping, high-speed Comfort 2 turns Standard 2 turns Sport 1.5 turns Compression damping, low-speed Comfort 24 clicks Standard 22 clicks Sport 24 clicks Rebound damping Comfort...
  • Page 187 TECHNICAL DATA - FRONT SHOCK ABSORBER Gas pressure 10 bar (145 psi) Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p. 192)

  • Page 188: Technical Data - Rear Shock Absorber

    TECHNICAL DATA - REAR SHOCK ABSORBER Shock absorber part number 15.18.7E.16 Shock absorber WP Suspension PDS 4618 BAVP DCC Compression damping, high-speed Comfort 2 turns Standard 2 turns Sport 1.5 turns Compression damping, low-speed Comfort 22 clicks Standard 20 clicks Sport 18 clicks Rebound damping...
  • Page 189 TECHNICAL DATA - REAR SHOCK ABSORBER Spring length, main spring 200 mm (7.87 in) Spring length, auxiliary spring 55 mm (2.17 in) Fitted length 440.5 mm (17.342 in) Gas pressure 10 bar (145 psi) Shock absorber oil Shock absorber oil (SAE 2.5) (50180342S1) ( p.

  • Page 190: Technical Data - Chassis Tightening Torques

    TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Remaining nuts, chassis 15 Nm (11.1 lbf ft) – Remaining screws, chassis 10 Nm (7.4 lbf ft) – Screw on fuel tank 6 Nm (4.4 lbf ft) – Screw, clamping nut, rear axle 10 Nm (7.4 lbf ft) ®...
  • Page 191 TECHNICAL DATA - CHASSIS TIGHTENING TORQUES – Screw, front shock absorber 45 Nm (33.2 lbf ft) – Screw, steering column at bottom of 25 Nm (18.4 lbf ft) steering lever – Nut, ball head, A-arm top M10x1.25 35 Nm (25.8 lbf ft) ®...

  • Page 192: Substances

    – Guideline – Use only brake fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Castrol and Motorex products. Supplier Castrol – RESPONSE BRAKE FLUID SUPER DOT 4 ®...
  • Page 193 SAE ( p. 197) (SAE 10W/50) Guideline – Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding ® properties. KTM recommends Motorex products. Synthetic engine oil Supplier ® Motorex –...
  • Page 194 – ISO VG (15) Guideline – Use only hydraulic fluid that complies with the specified standards (see specifications on the container) and that possesses the corre- ® sponding properties. KTM recommends Motorex products. Supplier ® Motorex – Hydraulic Fluid 75...
  • Page 195 SUBSTANCES Super unleaded (ROZ 95 / RON 95 / PON 91) According to – DIN EN 228 (ROZ 95 / RON 95 / PON 91)

  • Page 196: Auxiliary Substances

    AUXILIARY SUBSTANCES Air filter cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Dirt Bio Remover Chain cleaner Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Chain Clean 611 Cleaning and polishing materials for metal, rubber and plastic Specification –...
  • Page 197 AUXILIARY SUBSTANCES High-luster polish for paint Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Moto Polish Lubricant (T625) Specification – ® KTM recommends Molykote products. Supplier ® Molykote – 33 Medium Motorcycle cleaner Specification – ® KTM recommends Motorex products.
  • Page 198 AUXILIARY SUBSTANCES Oil for foam air filter Specification – ® KTM recommends Motorex products. Supplier ® Motorex – Twin Air Liquid Bio Power...

  • Page 199: Standards

    STANDARDS JASO T903 MA Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard.Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle and ATV engines.With most motorcycles and ATVs, the gearbox and the clutch are lubricated with the same oil as the engine.

  • Page 200: Index

    INDEX installing ........109 INDEX removing ........108 Accessories .
  • Page 201 INDEX topping up ....... . . 164 Clutch checking fluid level ......148 Engine oil level Clutch lever .
  • Page 202 INDEX spring preload, adjusting ......71 Front trim Light switch ....... . . 31-32 installing .
  • Page 203 INDEX Radiator fan ........149 Seat Radiator spoiler mounting .
  • Page 204 INDEX Tire condition checking ........125 adjusting ........83 checking .
  • Page 205 *3211378en* 3211378en 06/2008 Photo: Mitterbauer KTM-Sportmotorcycle AG 5230 Mattighofen/Austria http://www.ktm.com...

This manual is also suitable for:

505 sx 2009

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