Professional Documents
Culture Documents
450 XC ATV
525 XC ATV
ART. NO. 3206058en
INTRODUCTION
Read this repair manual carefully and in its entirety before beginning work.
INTRODUCTION
This repair manual was written to correspond to the latest state of this series. We reserve the right to make changes in the interest of
technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop will not be specified
here. It is assumed that the repair work will be performed by a fully trained mechanic.
All specifications are non-binding. In particular, the KTM Sportmotorcycle AG reserves the right to change or cancel technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without giving reasons, and to
adapt the technical specifications to local conditions as well as terminating the production of a specific model without prior notice.
KTM accepts no liability for delivery options, deviations from illustrations and descriptions, as well as printing and other errors. The
models portrayed partly contain special equipment that does not belong to the regular scope of delivery.
CONTENTS
CONTENTS
2
05/EXHAUST ....................................................................
Removing the main silencer............................................
Installing the main silencer ............................................
Removing the manifold ..................................................
Installing the manifold ...................................................
06/AIR FILTER..................................................................
Removing the air filter ...................................................
Installing the air filter ....................................................
Cleaning air filter...........................................................
Removing the air filter box lid with the carburetor
connection boot ............................................................
Installing the air filter box lid and the carburetor
connection boot ............................................................
07/FUEL TANK, SEAT, TRIM..............................................
Removing the seat .........................................................
Mounting the seat .........................................................
Removing the radiator spoiler .........................................
Installing the radiator spoiler ..........................................
Removing the fuel tank ..................................................
Installing the fuel tank ...................................................
Fuel tap........................................................................
08/MASK, FENDER ...........................................................
Removing the front cover................................................
Installing the front cover ................................................
Removing the front trim .................................................
Installing the front trim ..................................................
Removing the rear fender ...............................................
Installing the rear fender ................................................
09/FRONT WHEEL ............................................................
Checking tire air pressure ...............................................
Tire condition checking..................................................
Removing wheel/wheels..................................................
Mounting wheel/wheels ..................................................
Checking brake discs .....................................................
10/REAR WHEEL ..............................................................
Checking chain dirt .......................................................
Cleaning the chain.........................................................
Checking chain wear ......................................................
Checking rear sprocket / engine sprocket for wear .............
Checking the chain tension ............................................
Adjusting chain tension..................................................
Adjusting the toe width of rear axle .................................
Removing the rear axle...................................................
Installing the rear axle ...................................................
Changing the rear axle bearing........................................
11/WIRING HARNESS, BATTERY .......................................
Ignition curve plug connection ........................................
Changing ignition curve..................................................
Removing the battery .....................................................
Installing the battery......................................................
Recharging the battery ...................................................
Changing the main fuse .................................................
Changing the fuses of individual power-consuming
components ..................................................................
Checking the battery voltage...........................................
Checking the charging voltage ........................................
Checking the closed-circuit current .................................
Checking the starter relay ...............................................
13/BRAKE SYSTEM...........................................................
Handbrake lever, parking brake.......................................
Checking free play of hand brake lever.............................
Adjusting basic position of handbrake lever......................
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CONTENTS
Checking the brake fluid level of the front brake ............... 75
Adding brake fluid for the front brake .............................. 75
Checking the front brake linings...................................... 76
Removing the front brake linings..................................... 76
Mounting front brake linings........................................... 76
Changing the front brake linings ..................................... 77
Checking free play of foot brake lever .............................. 77
Adjusting basic position of footbrake lever ....................... 78
Checking the brake fluid level of the rear brake ................ 78
Adding brake fluid for the rear brake ............................... 79
Checking the rear brake linings ....................................... 79
Removing the rear brake linings ...................................... 80
Mounting rear brake linings ............................................ 80
Changing the rear brake linings....................................... 81
30/ENGINE....................................................................... 82
Removing the engine ..................................................... 82
Installing the engine ...................................................... 84
30/DISASSEMBLING THE ENGINE..................................... 87
Preparations.................................................................. 87
Draining the engine oil ................................................... 87
Removing the oil filter.................................................... 87
Removing the starter motor ............................................ 87
Removing the shift lever................................................. 88
Removing the clutch cover ............................................. 88
Removing the clutch discs.............................................. 88
Removing the outer clutch hub ....................................... 89
Removing the starter idler gear/torque limiter ................... 90
Removing the shift shaft ................................................ 90
Removing the shift drum locating.................................... 90
Removing the locking lever ............................................. 90
Removing the oil pump gear ........................................... 90
Removing the primary gear with the free-wheel-gear.......... 91
Removing the spark plug ................................................ 91
Removing the generator cover ......................................... 91
Installing the crankshaft locking bolt ............................... 91
Removing the ignition pulse generator ............................. 92
Removing the rotor ........................................................ 92
Removing the oil pumps................................................. 93
Removing the oil line ..................................................... 93
Removing the timing chain tensioner............................... 94
Removing the water pump cover ..................................... 94
Removing the cylinder head top section........................... 94
Removing the camshaft.................................................. 94
Removing the cylinder head............................................ 95
Removing the cylinder ................................................... 95
Removing the piston ...................................................... 96
Removing the timing chain............................................. 96
Removing the timing chain sprocket................................ 96
Removing the locking shaft lever..................................... 96
Removing the gear sensor............................................... 97
Taking off the left section of the engine case ................... 97
Remove the shift rails and forks. ..................................... 98
Removing the shift drum ................................................ 98
Removing the transmission shaft..................................... 99
Removing the balancer shaft .......................................... 99
Removing the crankshaft ................................................ 99
30/ENGINE - WORK ON INDIVIDUAL PARTS..................... 100
Work on the right section of the engine case .................. 100
Removing the oil pressure regulator valve....................... 101
Checking the spring length of the oil pressure regulator
valve .......................................................................... 101
Installing the oil pressure regulator valve ....................... 101
3
Work on the left section of the engine case ....................
Changing the crankshaft seal ring in the clutch cover......
Disassembling the autodecompressor ............................
Assembling the autodecompressor.................................
Changing the camshaft bearing.....................................
Checking the rocker arms and rocker arm shafts .............
Removing the valves ....................................................
Checking the valves .....................................................
Checking the valve springs ...........................................
Checking the lower valve spring retainer ........................
Checking the cylinder head ..........................................
Installing the valves .....................................................
Checking the timing assembly ......................................
Preparing the timing chain tensioner for installation .......
Changing the conrod bearing ........................................
Checking the crankshaft run-out on the bearing pin ........
Measuring the axial clearance of the crankshaft..............
Correcting the axial clearance of the crankshaft..............
cylinder - Nikasil coating ............................................
Checking/measuring the cylinder...................................
Checking/measuring the piston .....................................
Checking the piston ring end gap ..................................
Checking the piston/cylinder mounting clearance............
Checking the oil pumps for wear ...................................
Checking the shift mechanism ......................................
Disassembling the shift shaft........................................
Preassembling the shift shaft........................................
Checking the clutch.....................................................
Disassembling the main shaft .......................................
Checking the main shaft ..............................................
Assembling the main shaft ...........................................
Disassembling the countershaft ....................................
Checking the countershaft............................................
Assembling the countershaft.........................................
Checking/premounting the reverse gear shaft..................
Checking electric starter operation ................................
Removing the free-wheel ..............................................
Checking the free-wheel ...............................................
Installing the free-wheel...............................................
30/ASSEMBLING THE ENGINE ........................................
Installing the crankshaft...............................................
Installing the balancer shaft .........................................
Installing the transmission shaft ...................................
Installing the shift forks ...............................................
Installing the shift drum...............................................
Installing the shift rails ................................................
Installing the left engine case .......................................
Installing the timing chain sprocket...............................
Installing the timing chain rails.....................................
Installing the piston.....................................................
Installing the cylinder ..................................................
Installing the cylinder head ..........................................
Installing the camshaft ................................................
Installing the cylinder head top section..........................
Installing the timing chain tensioner .............................
Installing the rotor .......................................................
Checking the valve clearance ........................................
Adjusting the valve clearance........................................
Installing the valve cover ..............................................
Installing the water pump cover ....................................
Installing the oil line....................................................
102
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105
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131
132
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133
134
135
135
135
136
136
136
136
CONTENTS
Installing the spark plug...............................................
Installing the primary gear with the free-wheel-gear ........
Installing the oil pumps ...............................................
Installing the ignition pulse generator............................
Installing the generator cover........................................
Installing the gear sensor .............................................
Installing the locking shaft lever ...................................
Installing the locking lever............................................
Installing the shift drum locating ..................................
Installing the shift shaft ...............................................
Installing the starter idler gear/torque limiter..................
Removing the crankshaft locking bolt ............................
Installing the outer clutch hub and clutch discs .............
Installing the clutch cover ............................................
Installing the starter motor ...........................................
Installing the oil drain plug...........................................
Installing the oil screen................................................
Mounting the oil filter ..................................................
Filling up with engine oil..............................................
Installing the shift lever ...............................................
Installing the clutch push rod .......................................
Removing the engine from the universal mounting
rack ...........................................................................
31/CARBURETOR ...........................................................
Choke.........................................................................
Hot start button...........................................................
Removing the carburetor ..............................................
Disassembling the carburetor........................................
Checking/adjusting the carburetor components...............
Checking/adjusting the accelerator pump.......................
Checking the hot start slide ..........................................
Checking the choke slide..............................................
Checking the jet needle................................................
Checking the throttle slide............................................
Checking the needle jet................................................
Checking the float needle valve.....................................
Checking the throttle valve sensorTPS ..........................
Adjusting the position of throttle valve sensorTPS ..........
Checking/adjusting the throttle slide opening .................
Checking/adjusting the float level..................................
Assembling the carburetor ............................................
Installing the carburetor ...............................................
Carburetor - adjusting idle ............................................
Checking the throttle valve sensor position.....................
Emptying the carburetor float chamber ..........................
32/CLUTCH ....................................................................
Checking fluid level of hydraulic clutch .........................
33/TRANSMISSION.........................................................
Removing the engine sprocket ......................................
Installing the engine sprocket .......................................
35/WATER PUMP, COOLING SYSTEM ..............................
Checking antifreeze and coolant level ............................
Checking the coolant level............................................
Draining coolant ..........................................................
Filling coolant / bleeding cooling system ........................
38/LUBRICATION SYSTEM ..............................................
Changing engine oil and oil filter, cleaning oil screens ....
Draining engine oil, cleaning oil screens ........................
Removing the oil filter..................................................
Mounting oil filter........................................................
Filling up with engine oil..............................................
Checking engine oil level..............................................
4
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MEANS OF REPRESENTATION
MEANS OF REPRESENTATION
1
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Formats used
The typographical and other formats used are explained in the following.
Name
Registered trademark
Trademark
IMPORTANT NOTES
IMPORTANT NOTES
2
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the vehicle.
Work rules
When assembling the equipment, non-reusable parts (e.g. self-locking screws and nuts, seals, seal rings, O-rings, pins, lock washers)
must be replaced with new parts.
If a thread locker (e.g.Loctite) is used for screw connections, follow the instructions for use from the manufacturer.
Parts that are to be reused after being disassembled should be cleaned and checked for damage and wear. Replace damaged or worn
parts.
After finishing the repair and maintenance work, ensure that the vehicle is roadworthy.
IMPORTANT NOTES
IMPORTANT NOTES
100106-10
IMPORTANT NOTES
Notes/warning notes
Pay attention to the specified notes and warnings.
Info
Various notes and warning labels are attached to the vehicle. Do not remove any notes or warning labels. If they are missing,
you or others may not recognize dangers and may therefore be injured.
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.
Repair manual
Read this repair manual carefully and in its entirety before beginning work. It contains a lot of information and tips to help you
repair and maintain the vehicle.
It is assumed that the necessary KTM special tools and workshop equipment are available to you.
VIEW OF VEHICLE
10
VIEW OF VEHICLE
3
3.1
600148-10
Fuse box
Headlight
Shift lever
10
Left footrest
11
Heel protector
12
13
Clutch lever
VIEW OF VEHICLE
11
600149-10
Filler cap
Main silencer
Rear brake
10
Manifold
11
Top A-arm
12
13
Throttle lever
14
Ignition switch
12
Chassis number
4.1
The chassis number is stamped on the right side of the frame in the vicinity of the
upper control arm.
100002-10
Type label
4.2
The type label is located on the frame tube on the right in front of the radiator.
100034-10
Key number
4.3
Info
You need the key number to order a replacement key. Keep theKEYCODECARD in
a safe place.
100089-10
Engine number
4.4
The engine number is stamped on the left side of the engine under the engine
sprocket.
100001-10
The setting number is stamped into the top of the shock absorber.
100033-10
The setting number is stamped into the top of the shock absorber.
100032-10
13
VEHICLE
14
VEHICLE
5
5.1
Note
Danger of damageDanger 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.
100054-10
Note
Danger of damageDanger of damage by the vehicle running away or falling over.
02/HANDLEBAR, CONTROLS
15
02/HANDLEBAR, CONTROLS
6
6.1
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
Remove the four screws. Remove the handlebar clamps, swing the handlebar
forward and set it down.
Remove the nuts and remove the handlebar support with the screws.
Check parts for damage and wear. Replace damaged or worn parts.
Place the handlebar bridge onto the steering column in the desired position.
Mount and tighten screw.
Specification
Screw, steering bridge
M8
20Nm
(14.8lbfft)
M20x1,5
25Nm
(18.4lbfft)
M8
20Nm
(14.8lbfft)
100099-10
Mount the handlebar support in the desired position using the screws. Mount
new self-locking nuts and tighten.
Specification
Nut, handlebar support
M10
45Nm
(33.2lbfft)
Position the handlebar and fix it with the handlebar clamps. Mount and tighten
screws.
Specification
Screw, handlebar clamp
M8
20Nm
(14.8lbfft)
Info
Make sure cables and wiring are positioned correctly.
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw.
Info
100039-10
Turn the adjusting screw clockwise to increase the distance between the
clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
02/HANDLEBAR, CONTROLS
16
Move the handlebar to the straight-ahead position. Move the throttle lever back and
forth slightly to ascertain the play in the gas Bowden cable.
Specification
Play in gas Bowden cable
P. 16)
Danger
Danger of poisoningExhaust gases are poisonous and can result in unconsciousness and/or death.
600142-10
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in a closed space.
Start the engine and let it run idle. Move the handlebar to and fro over the entire
steering range.
The idle speed must not change.
P. 16)
Loosen the nut and use the screw to adjust the play in the gas Bowden
cable.
Specification
Play in gas Bowden cable
Tighten nut.
600142-11
Checking the play in the Bowden cable using the reverse gear release lever
6.5
Move the handlebar to the straight-ahead position. Move the reverse gear release
lever back and forth slightly to ascertain the play in the Bowden cable.
Specification
Play in the Bowden cable on the
reverse gear release lever
If the Bowden cable play on the reverse gear release lever does not agree with
the specifications:
600141-10
10mm (0.39in)
Adjust the play in the Bowden cable using the reverse gear release lever.
( P. 16)
Adjusting the play in the Bowden cable using the reverse gear release lever
6.6
Check that the Bowden cable is correctly laid from the reverse gear release lever.
Release the nut and using the screw, adjust the play of the Bowden cable
on the reverse gear release lever.
Specification
Play in the Bowden cable on the
reverse gear release lever
600141-11
Tighten nut.
10mm (0.39in)
02/HANDLEBAR, CONTROLS
17
Loosen nut.
Detach the Bowden cable from abutment plate and locking shaft lever.
600181-10
Attach the Bowden cable to locking shaft lever and abutment plate.
Mount nut in such a way that the specified play is present in the Bowden cable.
Specification
Play in the Bowden cable on the
reverse gear release lever
600181-11
10mm (0.39in)
Tighten nut.
Check the play in the Bowden cable using the reverse gear release lever. (
P. 16)
03/FRAME
18
03/FRAME
7
7.1
Check parts for damage and wear. Replace damaged or worn parts.
Position the engine guard on the frame bearer. Mount and tighten screws
and.
600133-10
Specification
600133-10
M6
10Nm (7.4lbfft)
M8
25Nm
(18.4lbfft)
19
8.1
Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.
Info
The compression damping setting has an impact on the compression of the shock absorber.
14clicks
5 5clicks
100027-10
Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.
Info
Turning clockwise increases damping, while turning counterclockwise
lessens damping.
The left and right shock absorbers should have the same settings.
Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.
Info
The rebound damping setting has an impact on the compression of the shock absorber.
20clicks
5 5clicks
100028-10
Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.
Info
Turning clockwise increases damping, while turning counterclockwise
lessens damping
The left and right shock absorbers should have the same settings.
20
Info
The cross over setting is used to adjust the suspension travel of the short (soft) spring.
Greater cross over makes the suspension at the front softer and the front of the vehicle lies lower. The suspension travel and
the progressive part of the long (hard) spring are not fully utilized.
Less cross over makes the suspension at the front harder and the front of the vehicle lies higher.
P. 14)
P. 210)
100084-10
Cross over setting is measured between sliding bushing and the collar of
spring retainer.
Specification
Cross over
171.5mm (0.670.059in)
Info
The sliding bushing is made of plastic. Therefore, do not lock it too tightly
to avoid damaging the thread.
The left and right shock absorbers should have the same settings.
400348-11
P. 14)
Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.
Info
Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.
Tip
Before you change the spring preload, make a note of the groove in which the securing clip is positioned. When making adjustments, always start from the standard setting.
100083-10
Press the spring pack and spring retainer down to make securing clip accessible.
Using pliers, position the securing clip in one of the upper grooves. Do not overstrain the securing clip.
Release the spring pack and measure the length of the unloaded spring pack.
P. 14)
21
Press together the spring pack, position the securing clip in the corresponding
groove and release the spring pack.
Specification
A
0
5mm (0.2in)
Info
The spring preload is the difference in length between the spring pack
when it is unloaded and when it is installed.
The securing clip must be positioned entirely within the cut-out of the
spring retainer.
The spring pack should never be installed loosely (without preload). The
standard setting is the lowest permissible spring preload. Therefore, you can
only increase the spring preload.
If you increase the spring preload, you should also slightly increase the
rebound damping.
The left and right shock absorbers should have the same settings.
400347-10
P. 14)
Info
The operations are the same on the left and right sides.
Remove screw.
P. 14)
600473-10
600474-10
600475-10
22
Info
The operations are the same on the left and right sides.
Position the front shock absorber with the reservoir toward the rear. Mount and
tighten screw.
Specification
Screw, front shock absorber
M10
45Nm
(33.2lbfft)
600475-11
Position the shock absorber in the lower A-arm. Mount and tighten screw.
Specification
Screw, front shock absorber
M10
45Nm
(33.2lbfft)
P. 14)
600474-11
Measure the spring length in its preloaded state and determine the position of the
locking clip. Note down both values.
P. 21)
200277-10
200278-10
200279-10
23
Alternative1
Measure the overall spring length when not under tension.
Info
A
0
5mm (0.2in)
Alternative2
Position the locking clip in the position determined upon disassembly.
400347-10
Position the spring retainer with the groove facing the locking clip.
Position spring.
200279-11
200278-11
200277-11
P. 22)
P. 20)
24
Note down the current state of the rebound and compression damping.
Fully open the adjusting elements of the rebound and compression damping.
P. 22)
200280-10
P. 215)
200281-10
Info
Do not scratch the inner surface.
200282-10
Remove the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004) (
P. 213)
200283-10
Remove locking cap of the shock absorber tube using the special tool.
Disassembly fork (83019050006) (
200284-10
P. 213)
25
Info
Do not scratch the inner surface.
200285-10
Remove the floating piston of the reservoir using the special tool.
200286-10
P. 213)
200287-10
200300-10
P. 203)
P. 205)
26
Mount the floating piston using the special tool and slide it all the way into the
reservoir.
Disassembly/assembly tool (83019050005) (
P. 213)
200301-10
Measure and note down the distance from the upper rim of the reservoir to the
upper edge of the floating piston.
Info
Ensure that the floating piston has been pushed all the way in.
200302-10
P. 213)
200303-10
P. 205)
Info
Do not scratch the inner surface.
200285-11
Pull out the piston rod until the seal ring holder is flush with the lock ring.
27
200304-10
Lubricant (T158) (
P. 205)
Mount the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004) (
P. 213)
Info
Do not scratch the inner surface.
200283-10
Pull out the locking cap of the reservoir using the special tool to the point where
the locking cap is flush with the lock ring.
P. 213)
P. 215)
Info
Leave the needle of the special tool inserted in the membrane to ensure that
the floating piston is able to move freely during the filling process.
Attach the rest of the special tool and connect it to the pressure regulator of the
filling cylinder.
P. 28)
200281-11
P. 215)
200305-10
12bar (174psi)
Insert the needle of the special tool through the membrane of the reservoir again.
Open valve of the special tool and leave it open for several seconds until the
required pressure is reached.
Specification
Gas pressure
12bar (174psi)
200280-11
M4
3Nm (2.2lbfft)
P. 23)
28
Info
Before working with the vacuum pump, read the operating manual provided for the vacuum pump carefully.
Fully open the adjusting wheel of the rebound and compression damping.
Leave the needle of the special tool inserted in the membrane to ensure that the floating piston is able to move freely during
the filling process.
P. 213)
P. 215)
P. 213)
Info
200272-11
Info
Clamp the shock absorber only lightly.
The filling port must be located at the highest position.
The piston rod moves in and out during the filling procedures - do not hold
it with your hand!
200274-10
200271-10
As soon as the low pressure gauge has reached the specified value, set control
leverOilreservoir to Equalizepressure.
Specification
4mbar
The pressure gauge rises to the specified value.
0bar
200267-10
As soon as the pressure gauge has reached the specified value, set control lever
Damper to Pressure.
Specification
0bar
Oil is pumped into the shock absorber.
The pressure gauge rises to the specified value.
3bar
200268-10
29
As soon as the pressure gauge has reached the specified value, set control lever
Damper to Vacuum.
Specification
3bar
The pressure gauge drops to the specified value.
0bar
200269-10
As soon as the pressure gauge has reached the specified value, set control lever
Oilreservoir to Vacuum.
Specification
0bar
The low pressure gaugedrops to the specified value.
8mbar
200270-10
As soon as the low pressure gauge has reached the specified value, set control lever
Oilreservoir to EqualizePressure.
Specification
8mbar
The pressure gauge drops to the specified value.
0bar
200267-10
As soon as the pressure gauge has reached the specified value, set control lever
Damper to Pressure.
Specification
0bar
Oil is pumped into the shock absorber.
The pressure gauge rises to the specified value.
3bar
200268-10
As soon as the pressure gauge has reached the specified value, set control lever
Damper to Vacuum.
Specification
3bar
The pressure gauge drops to the specified value.
0bar
200269-10
As soon as the pressure gauge has reached the specified value, press the On/Off
switch.
Specification
0bar
The vacuum pump is switched off.
30
Info
Do not scratch the inner surface.
200237-11
Remove the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)
200238-10
Reduce the dimension determined during assembly by the specified value and slide
the floating piston into the reservoir up to the reduced dimension using the special
tool.
Specification
7mm
Disassembly/assembly tool (83019050005)
Info
200265-10
The floating piston must have the specified distance to the bottom stop.
The floating piston must be at precisely this position, as otherwise damage
may occur when the shock absorber moves.
P. 213)
M5
3Nm (2.2lbfft)
200272-10
Mount the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)
Info
Do not scratch the inner surface.
200238-10
Pull out the piston rod to the point where the seal ring holder is flush with the lock
ring.
31
Remove nut.
P. 24)
200288-10
200289-10
200290-10
200291-10
200292-10
200293-10
32
200294-10
200294-10
P. 213)
Grease the seal ring and slide seal ring holder onto the piston rod.
Lubricant (T625) (
P. 205)
200298-10
200292-10
200291-11
Info
The compression damping shim set must be mounted with the smaller disks
facing downward.
200290-11
33
Info
The side of the piston with partitions must face down and the side with
rectangular surfaces must face up.
200299-10
Info
The rebound shim set must be mounted with the smaller disks facing
upward.
200289-11
M8
22Nm
(16.2lbfft)
Loctite 243
P. 25)
200288-11
Info
The operations are the same on the upper and lower heim joint.
Clamp the shock absorber into the vise with soft jaws.
Turn over the shock absorber and remove flange adapter of the heim joint with a
pin.
200295-10
200296-10
P. 21)
34
Place special tool underneath and press out the heim joint using special tool.
Press drift (83019050015) (
P. 214)
P. 214)
200297-10
Info
The operations are the same on the upper and lower heim joint.
Place special tool underneath and push the heim joint to the middle using special tool.
Mounting sleeve (83019050013) (
Press drift (83019050014) (
P. 214)
P. 214)
200297-11
P. 205)
200296-10
200295-11
Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.
Info
The compression damping setting has an impact on the compression of the shock absorber.
35
15clicks
5 5clicks
100080-10
Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.
Info
Turning clockwise increases damping, while turning counterclockwise
lessens damping.
Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.
Info
The rebound damping setting has an impact on the compression of the shock absorber.
Turn it back to the left by the number of clicks corresponding to the shock absorber
type.
Specification
Rebound damping
Standard
15clicks
5 5clicks
100081-10
Tip
Experience has shown that settings outside of this range are detrimental to
vehicle handling. When changing the chassis settings, always start with the
standard setting.
Info
Turning to the right increases damping, while turning to the left lessens
damping.
Warning
Danger of accidentsDo not make any radical changes to the adjustment of the shock absorbers.
Info
Increasing the spring preload raises the center of gravity of the vehicle. This can have a large impact on vehicle handling.
Tip
Before changing the spring preload, make a note of the present setting, e.g. by measuring the length of the spring.
P. 36)
36
Loosen lock nut. Hold adjusting ring while doing so. Use special tool.
Hook wrench (83019002000) (
P. 210)
Info
Do not loosen lock nut at the top of the shock absorber.
Turn the adjusting ring until the spring is no longer under tension.
100082-10
Info
The spring preload is the difference in length between the spring when it
is unloaded and when it is installed.
Tighten the spring by turning the adjusting ring to the specified measurement.
Specification
Spring preload
Standard
3mm (0.12in)
Info
Adjusting ring is made of plastic. Therefore, do not lock the adjusting
ring too tightly to avoid damaging the thread.
If you increase the spring preload, you should also slightly increase the
rebound damping.
P. 37)
400363-11
P. 14)
P. 57)
Note
Danger of damageThe 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.
Attach the swingarm to the subframe with a tension belt to relieve the shock
absorber.
Tip
Press the screw out of the swingarm with a screw driver while moving the
tension belt.
100078-10
Remove the top screw of the shock absorber and carefully remove the shock
absorber out of the vehicle toward the rear.
37
Check parts for damage and wear. Replace damaged or worn parts.
Position the shock absorber in the vehicle with the reservoir on the right. Mount
and tighten the top screw.
Specification
Screw, rear top shock absorber
M12
60Nm
(44.3lbfft)
Position the shock absorber in the swingarm. Mount and tighten the bottom screw.
Specification
Screw, rear bottom shock absorber
M12
70Nm
(51.6lbfft)
P. 58)
P. 14)
100079-10
Measure and note down the spring length in the preloaded state.
P. 36)
Turn the adjusting ring until the spring is no longer under tension.
200232-10
200233-10
200233-11
38
Alternative1
Measure the overall spring length when not under tension.
Info
The spring preload is the difference in length between the spring
when it is unloaded and when it is installed.
Tighten the spring by turning the adjusting ring to the specified measurement.
Specification
Spring preload
Standard
3mm (0.12in)
400363-11
Info
Adjusting ring is made of plastic. Therefore, do not lock the adjusting
ring too tightly to avoid damaging the thread.
If you increase the spring preload, you should also slightly increase the
rebound damping.
P. 37)
200232-11
Note down the current state of the rebound and compression damping.
Fully open the adjusting elements of the rebound and compression damping.
200234-10
200235-10
P. 37)
200236-10
Info
Do not scratch the inner surface.
200237-10
Remove the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)
200238-10
200239-10
Info
Do not scratch the inner surface.
200240-10
200241-10
39
40
Remove the floating piston of the reservoir using the special tool.
Disassembly/assembly tool (83019050005)
200242-10
P. 205)
200264-10
Mount the floating piston using the special tool and slide it all the way into the
reservoir.
Disassembly/assembly tool (83019050005)
200263-10
Measure and note down the distance from the upper rim of the reservoir to the
upper edge of the floating piston.
Info
Ensure that the floating piston has been pushed all the way in.
200265-10
41
200266-10
P. 205)
Info
Do not scratch the inner surface.
200240-11
Pull out the piston rod to the point where the seal ring holder is flush with the lock
ring.
200239-11
Lubricant (T158) (
P. 205)
Mount the locking cap of the reservoir using the special tool.
Disassembly/assembly tool (83019050004)
Info
Do not scratch the inner surface.
200238-10
Pull out the locking cap of the reservoir using the special tool to the point where
the locking cap is flush with the lock ring.
42
Info
Leave the needle of the special tool inserted in the membrane to ensure that
the floating piston is able to move freely during the filling process.
Attach the rest of the special tool and connect it to the pressure regulator of the
filling cylinder.
P. 28)
200236-10
200275-10
12bar (174psi)
Insert the needle of the special tool through the membrane of the reservoir again.
Open valve of the special tool and leave it open for several seconds until the
required pressure is reached.
Specification
Gas pressure
12bar (174psi)
M4
3Nm (2.2lbfft)
200235-11
P. 37)
200234-11
200244-10
Remove nut.
P. 38)
Remove washer and the upper rebound shim set together with the upper piston.
Remove the upper compression damping shim set with the supporting plate.
Remove the lower piston with the lower rebound shim set and supporting
plate.
Remove the lower compression damping shim set with supporting plate.
200245-10
200246-10
200247-10
200248-10
200249-10
200250-10
43
44
200251-10
200252-10
200252-10
P. 214)
Grease the seal ring and slide seal ring holder onto the piston rod.
Lubricant (T625) (
P. 205)
Mount supporting plate and the lower compression damping shim set.
200257-10
200250-10
Info
The compression damping shim set must be mounted with the smaller disks
facing downward.
200249-11
45
Smooth the lower piston on both sides using 1200-grit sandpaper on a straightening plate.
Info
The side of the piston with rectangular surfaces must face down and the
side with partitions must face up.
200258-10
Info
The rebound shim set must be mounted with the smaller disks facing
upward.
200248-11
200259-10
Specification
Piston rod adapter
M12x1
30Nm
(22.1lbfft)
Loctite2701
200247-11
Mount the supporting plate and the upper compression damping shim set.
Info
Mount the triangular plates of the upper compression damping shim set
facing upward and align them precisely to each other.
The triangular plates should be oil-free to prevent them from slipping
against each other when they are tightened.
200246-11
Smooth the upper piston on both sides using 1200-grit sandpaper on a straightening plate.
Info
The side of the piston with the single drill hole must face down and the
side with the double drill hole must face up.
200260-10
46
Ensure that the triangular plates precisely cover the single drill holes.
200261-10
Info
Mount triangular plates of the upper rebound damping shim set facing
downward and align them precisely to each other.
The triangular plates should be oil-free to prevent them from slipping
against each other when they are tightened.
Ensure that the triangular plates precisely cover the double drill holes.
200262-10
M8
22Nm
(16.2lbfft)
Ensure that the triangular plates do not slip when being tightened.
P. 40)
200244-11
Info
The operations are the same on the upper and lower heim joint.
200253-10
Clamp the shock absorber into the vise with soft jaws.
Turn over the shock absorber and remove flange adapter of the heim joint using
a pin.
P. 36)
47
Place special tool underneath and press out the heim joint using special tool.
200254-10
P. 214)
200255-10
Info
The operations are the same on the upper and lower heim joint.
Place special tool underneath and push the heim joint to the middle using special tool .
Press drift (83019050014)
Mounting sleeve (83019050007) (
P. 214)
200255-11
P. 205)
200254-10
200256-10
P. 37)
05/EXHAUST
48
05/EXHAUST
9
9.1
Remove spring.
Spring hooks (50305017000) (
P. 207)
600153-10
Insert the main silencer and position and tighten screws and.
600154-10
Specification
Remaining screws, chassis
M6
600154-11
Reconnect spring.
Spring hooks (50305017000) (
P. 207)
600153-11
P. 48)
600155-10
P. 207)
10Nm (7.4lbfft)
05/EXHAUST
49
Remove manifold.
600156-10
600157-10
P. 207)
600155-11
M6
10Nm (7.4lbfft)
M8
25Nm
(18.4lbfft)
600157-11
600156-11
P. 48)
06/AIR FILTER
50
06/AIR FILTER
10
Note
Engine failureUnfiltered 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 hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
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 carburetor connection boot from disconnecting from the carburetor.
Unhook the air filter holder and swing it to the side. Remove the air filter with
the air filter support.
Check parts for damage and wear. Replace damaged or worn parts.
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.
P. 52)
100077-10
Info
If the air filter is not correctly mounted, dust and dirt can penetrate into the
engine and can cause damage.
100086-10
P. 52)
Warning
Environmental hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Air filter cleaner (
P. 50)
P. 205)
Info
Only press the air filter to dry it, never wring it out.
06/AIR FILTER
51
P. 205)
P. 50)
Removing the air filter box lid with the carburetor connection boot
10.4
Raise the air filter box lid and remove with carburetor connection boot.
P. 52)
600152-10
Installing the air filter box lid and the carburetor connection boot
10.5
600152-10
Attach the air filter box lid with carburetor connection boot and hose clip to
the carburetor.
P. 52)
52
11.1
Pull the release hook back. Lift up the seat at the rear, pull it back and then
remove from above.
Check parts for damage and wear. Replace damaged or worn parts.
Hook the slot on the seat into the collar sleeve of the fuel tank, lower the rear
of the seat and slide the tab under the fuel tank.
Push down the rear of the seat until the release hook engages.
100041-10
100046-10
100043-10
Info
The operations are the same on the left and right.
Unhinge and remove the radiator spoiler and the fuel tank.
P. 52)
100056-10
100057-10
53
Info
The operations are the same on the left and right.
Check parts for damage and wear. Replace damaged or worn parts.
Hook the catch of the radiator spoiler into the holder of the fuel tank and
position it on the radiator.
100058-10
Specification
Remaining screws, chassis
M6
10Nm (7.4lbfft)
M6
6Nm (4.4lbfft)
P. 52)
100059-10
Danger
Fire hazardFuel can easily catch fire.
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 fuel immediately.
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoningFuel 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 doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
P. 56)
P. 52)
Info
Remaining fuel may run out of the fuel hose.
600150-10
P. 55)
54
600151-10
Danger
Fire hazardFuel can easily catch fire.
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 fuel immediately.
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoningFuel 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 doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Position the fuel tank, insert screw with the bushing and tighten.
Specification
Remaining screws, chassis
M6
600151-11
600150-11
P. 53)
P. 57)
10Nm (7.4lbfft)
55
Fuel tap
11.7
100013-10
08/MASK, FENDER
56
08/MASK, FENDER
12
12.1
Remove screw.
Check parts for damage and wear. Replace damaged or worn parts.
Position the front cover in the slots on both sides of the front trim.
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.
100053-10
100055-10
100075-10
P. 56)
08/MASK, FENDER
57
Check parts for damage and wear. Replace damaged or worn parts.
Connect the plug-in connectors of the head light and the emergency OFF switch
with the rip cord and position the front trim.
M6
6Nm (4.4lbfft)
M6
10Nm (7.4lbfft)
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
carburetor connection boot from disconnecting from the carburetor.
P. 56)
100076-10
P. 52)
200149-10
200148-10
08/MASK, FENDER
58
Check parts for damage and wear. Replace damaged or worn parts.
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
carburetor connection boot from disconnecting from the carburetor.
200148-11
Specification
Remaining screws, chassis
200149-11
P. 52)
M6
10Nm (7.4lbfft)
09/FRONT WHEEL
59
09/FRONT WHEEL
13
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
The tire pressure must be checked and corrected on all wheels.
0.3bar (4psi)
100044-10
Info
Fit only tires approved 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.
The front and rear wheels must be fitted with tires with similar profiles.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
Examine the tires for cuts, foreign bodies and other damage.
Removing wheel/wheels
13.3
Info
Proceed in the same way on the other wheels if necessary.
Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure100006-10 P. 74)
P. 14)
Info
Carefully remove the wheel, making sure it does not become jammed with
the threads of the screws.
700001-01
09/FRONT WHEEL
60
Mounting wheel/wheels
13.4
Note
Material damageDamage and destruction of components from incorrect positioning and mounting.
Do not swap the wheels; the tire valves must always be on the outside when the wheels are positioned and mounted.
Info
Proceed in the same way on the other wheels if necessary.
Info
Carefully position the wheel on the hub, being careful not to damage the
threads of the screws.
Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure100006-10 P. 74)
700002-01
P. 14)
Specification
Wheel nut
M10x1,25
45Nm
(33.2lbfft)
Warning
Danger of accidentsReduced braking due to worn brake discs.
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.
Wear limit of brake discs
400362-10
Front
3.5mm (0.138in)
Rear
3.5mm (0.138in)
10/REAR WHEEL
61
10/REAR WHEEL
14
14.1
P. 61)
Warning
Environmental hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
The service life of the chain depends largely on its maintenance.
Clean the chain regularly and then treat with chain spray.
Chain cleaner (
P. 205)
P. 205)
Info
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Maximum distance at the longest
chain section
272mm (10.71in)
Info
When you replace the chain, you should also replace the rear
sprocket and engine sprocket.
New chains wear out faster on old, worn sprockets.
100096-10
Info
When fitting the chain joint, always make sure that the closed side
of the joint faces forward (riding direction).
The engine sprocket, rear sprocket and chain should always be
replaced together.
400227-01
10/REAR WHEEL
62
Warning
Danger of accidentsDanger 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. On the other hand, if the chain is loose,
it can fall off the engine sprocket or the rear sprocket and block the rear wheels or damage the engine. Check for correct
chain tension and adjust if necessary.
Push the upper chain section at the end of the chain sliding component upwards to
measure the chain tension.
Info
The lower chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
Chain tension
100093-10
P. 62)
Warning
Danger of accidentsDanger 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. On the other hand, if the chain is loose,
it can fall off the engine sprocket or the rear sprocket and block the rear wheels or damage the engine. Check for correct
chain tension and adjust if necessary.
Push the upper chain section at the end of the chain sliding component upwards to
measure the chain tension.
Info
The lower chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at
different chain positions.
100093-10
10/REAR WHEEL
63
Alternative1
Insert the tool from the tool set into the hole of the rear wheel eccentric
element.
Alternative2
Use a special tool on the rear wheel eccentric.
Hook wrench (83019011000) (
P. 210)
To adjust the chain tension, use the special tool to slowly turn at the rear wheel
to rotate the rear wheel eccentric element forward or backward.
Specification
Chain tension
Info
Rotating the rear wheel eccentric element forward increases chain tension.
Rotating the rear wheel eccentric element backward reduces chain tension.
The rear wheel eccentric element should always be positioned such that the
grease nipple is visible. This ensures that the vehicle has the greatest
ground clearance.
100094-10
M8
20Nm
(14.8lbfft)
Remove tool.
Warning
Danger of accidentsChanges to the chassis can strongly influence how the vehicle handles.
After making changes, always ride slowly to allow yourself to respond to vehicle handling.
Remove the nuts on both sides and take all parts off of the rear axle.
Check parts for damage and wear. Replace damaged or worn parts.
P. 14)
Info
The left and right toe width should have the same settings.
100102-10
2
3
00
0
1
100103-10
10/REAR WHEEL
64
Setting a wide toe width:
Mount the spacing sleeve with the cone facing inward.
2 3
0
0
0
1
100104-10
P. 14)
Specification
Nut, rear wheel hub
M18x1,5
130Nm
(95.9lbfft)
Remove nuts on both sides and take all parts off of the rear axle.
Remove chain joint. Remove the chain from the rear sprocket.
Loosen screw.
Turn clamping nut counterclockwise using the special tool until lock rings are
freely accessible. Remove the lock rings.
100102-10
P. 14)
100102-12
600409-10
P. 210)
Turn clamping nut clockwise using the special tool and remove.
Remove screws.
Push back the brake linings by tilting brake caliper slightly to one side on the
brake disc. Carefully pull the brake caliper off of the brake disc and let it hang to
one side.
600410-10
Info
Do not operate the foot brake when the brake caliper has been removed.
600411-10
10/REAR WHEEL
65
Take brake disc off the rear axle with the holder.
Push the rear axle slightly to the left. Using a plastic hammer, lightly strike against
the chain sprocket carrier to release the chain sprocket carrier from the lock
rings. Remove lock rings.
Pull the rear axle out of the swingarm in the direction of the arrow.
600412-10
Info
Hold the rear sprocket carrier.
600414-10
Warning
Danger of accidentsReduced braking due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Slide on the rear axle from the left to the right all the way.
Info
The machined surfaces must be to the right of bearing seat.
600422-10
Position O-ring. Attach chain sprocket carrier with the nuts facing outward.
Carefully insert sealing area on the chain sprocket carrier into the shaft seal ring
of the rear wheel eccentric by lightly turning and tilting the rear axle.
Info
Do not damage the sealing lip of the shaft seal ring.
600423-10
600424-10
Position lock ring with the high collar facing to the left. Slide the main shaft all
the way in in the direction of the arrow.
10/REAR WHEEL
66
Position O-ring. Attach brake disc holder with the thread facing outward.
Carefully insert sealing area on the brake disc carrier into the shaft seal ring of
the rear wheel eccentric by lightly turning and tilting the rear axle.
Info
Do not damage the sealing lip of the shaft seal ring.
600425-10
P. 203)
Ensure that the rear axle and the brake disc holder have been correctly installed.
Turn clamping nut all the way onto the brake disc holder.
Info
LH thread!
600426-10
Tighten the clamping nut in the direction of the arrow using the special tool.
600427-10
Specification
Clamping nut, rear axle
2"-10UNS2B-LH
25Nm
(18.4lbfft)
600428-10
P. 210)
Tighten screw.
Specification
Screw, clamping nut, rear axle
M6
10Nm (7.4lbfft)
600429-10
M6
10Nm
(7.4lbfft)
Loctite 243
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a pressure point.
Fill the rear wheel eccentric with grease via grease nipple.
Long-life grease (
P. 203)
10/REAR WHEEL
67
Info
When installing the chain joint, always make sure that the closed side of the
joint is facing forward (direction of travel).
600409-11
bp
b0q
0 bq
0
bo
100103-11
b0p bbq
bp
0q
0
bo
100104-11
P. 14)
Specification
Nut, rear wheel hub
M18x1,5
130Nm
(95.9lbfft)
Loosen screw. Remove the rear wheel eccentric in the direction of the arrow.
P. 62)
100102-11
P. 64)
600415-10
600416-10
10/REAR WHEEL
68
Take out shaft seal rings on both sides and remove inner bearing races.
600417-10
Specification
100C (212F)
Mount the new outer bearing races using the special tool.
Press mandrel (83019012000) (
600418-10
P. 211)
After the rear wheel eccentric has cooled, check that the bearing races are firmly
seated.
Insert the inner bearing race in rear wheel eccentric on the left side.
Mount shaft seal ring with the blue marking on the left side. Use the special
tool.
Press mandrel (83019012000) (
P. 211)
Insert the inner bearing race in rear wheel eccentric on the right side.
Mount shaft seal ring with the green marking on the right side. Use the special tool.
Press mandrel (83019012000) (
P. 211)
Info
Do not swap the shaft seal rings, as otherwise grease may get onto the brake
disc from the rear wheel eccentric.
P. 203)
600420-10
Insert the rear wheel eccentric into the swingarm and align it with the marking
made when it was dismantled.
Tighten screws.
Specification
Screw, rear wheel eccentric element
M8
20Nm
(14.8lbfft)
Info
The rear wheel eccentric element should always be positioned such that the
grease nipple is visible. This ensures that the vehicle has the greatest
ground clearance.
600416-11
600415-11
P. 65)
69
15.1
The plug-in connector is located under the trim at the front on the frame tube.
Possible states
Soft The plug-in connector is connected for better driveability.
Performance The plug-in connector is disconnected for better performance.
100105-10
P. 56)
P. 69)
P. 69)
P. 69)
P. 69)
P. 57)
Warning
Risk of injuryBattery acid and battery gases cause serious cauterization.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Switch off all power-consuming components and switch off the engine.
Pull back the plus pole cover and disconnect the positive (plus) cable of the battery.
Check parts for damage and wear. Replace damaged or worn parts.
P. 57)
200150-10
4Ah battery(YTX5L-BS) (
200150-11
P. 190)
Attach the plus cable and replace the plus pole cover.
P. 58)
70
Warning
Risk of injuryBattery acid and battery gases cause serious cauterization.
Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Warning
Environmental hazardComponents and battery acid are a danger to the environment.
Do not dispose of batteries in normal household waste. Take defective or used batteries to a battery recycling operator.
Warning
Environmental hazardProblem 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.
Fast recharging with a high charge current shortens the battery's service life.
If the charge current, the charge voltage and the charge time are exceeded, electrolyte escapes through the breathing holes.
The battery capacity is then reduced.
If the battery is discharged from starting, it must be recharged immediately.
If it stands for a long time in a discharged state, the battery becomes over-discharged and sulfated, and then it is destroyed.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Switch off all power-consuming components and switch off the engine.
Disconnect the minus (negative) cable of the battery to avoid damage to the vehicle's electronics.
Connect the battery charger to the battery. Switch on the battery charger.
P. 57)
Battery charger(58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the generator. With this device, you cannot overcharge the battery.
Info
Never remove the lid.
Charge the battery according to the instructions on the battery casing.
100087-10
P. 58)
3months
71
Switch off all power-consuming components and switch off the engine.
Info
You can recognize a blown fuse by its broken filament.
Warning
Fire hazardThe electrical system can be overloaded by the use of incorrect
fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.
Tip
Replacement fuse should always be present in the starter relay to make
sure it is available when needed.
100091-10
Switch off all power-consuming components and switch off the engine.
P. 56)
Info
The designation of the fuses is located on the inside cover of the fuse
box.
Info
100090-10
72
Warning
Fire hazardThe electrical system can be overloaded by the use of incorrect
fuses.
Use only fuses with the prescribed amperage. Never by-pass or repair
fuses.
Tip
The replacement fuses should always be present in the fuse box to make
sure they are available when needed.
Make the measurement when there is no load on the battery (no electrical components are switched on).
P. 56)
P. 57)
Battery voltage
unloaded:
12.4 12.8V
600405-01
Condition
All plug connectors must be in corrosion-free condition and the plug-in connectors
must be tight-fitting.
The battery must be charged enough to start the engine but not fully charged. If the
battery is already fully charged, start the engine a few times.
Connect the multimeter. The black measuring lead is connected to the negative
pole (ground) of the battery. Place the red measuring lead on the positive terminal.
P. 57)
Charging voltage
under load at: 5,000rpm
600405-01
13.5 15V
P. 170)
Switch off all power-consuming components and switch off the engine.
P. 57)
73
Connect the multimeter between the negative cable and the negative terminal of
the battery. Check the closed-circuit current.
Maximum closed-circuit current
<1mA
600404-01
Info
Typical power-consuming components are a defective voltage regulator or rectifier or leakage currents in the plug connectors.
Detach the starter relay from bracket on the side of the battery.
P. 57)
600406-10
Info
When the relay switches, you hear a click.
Resistance of activated starter relay
700089-01
13/BRAKE SYSTEM
74
13/BRAKE SYSTEM
16
16.1
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.
To actuate the parking brake, pull the handbrake lever, push the locking pawl downwards, and release the handbrake lever.
Possible states
Handbrake lever in basic position Front wheels not blocked.
Handbrake lever pulled and latched Front wheels blocked.
100006-10
Warning
Danger of accidentsBrake system failure.
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 according to specifications.
Push the hand brake lever forwards and check free play.
Free play of hand brake lever
3mm (0.12in)
P. 74)
100088-10
Adjust the basic setting of the handbrake lever to your hand size by turning adjusting screw.
Info
Pull the brake lever forward and turn the adjusting screw.
Turn the adjusting screw clockwise to increase the distance between the
handbrake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between
the handbrake lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
100052-10
P. 74)
13/BRAKE SYSTEM
75
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
When the brake fluid level has dropped to the bottom of the viewer:
P. 75)
100035-10
Warning
Skin irritationsBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws.
5mm (0.2in)
P. 203)
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
100036-10
13/BRAKE SYSTEM
76
Check the brake linings of both front brake calipers for minimum thickness.
P. 59)
1mm (0.04in)
Minimum thickness
P. 77)
P. 60)
100074-10
Info
The operations are the same on the left and right sides.
P. 59)
Locking pawl moves into its basic position, parking brake is deactivated.
Push the brake piston back to release pressure on the brake linings.
Remove locking split pins, withdraw the bolt and take out the brake pads.
100071-10
Warning
Danger of accidentsReduced braking due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsReduced braking due to use of non-approved 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 linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Info
The operations are the same on the left and right.
100072-10
Check parts for damage and wear. Replace damaged or worn parts.
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.
P. 60)
13/BRAKE SYSTEM
77
Operate the hand brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
P. 60)
100073-10
Warning
Skin irritationsBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
Remove screws.
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
P. 76)
P. 76)
Specification
Measurement of
Brake fluid DOT4/DOT5.1 (
5mm (0.2in)
P. 203)
Position the cover with the membrane. Mount and tighten screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
100036-10
Warning
Danger of accidentsBrake system failure.
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 according to specifications.
13/BRAKE SYSTEM
78
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.
Specification
Free play at foot brake lever
100085-10
P. 78)
Reconnect spring.
Warning
Danger of accidentsBrake system failure.
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 according to specifications.
Disconnect spring.
Loosen nut and with push rod, turn it back until you have maximum free play.
To adjust the basic position of the footbrake lever individually, loosen nut and
turn screw accordingly.
Info
The range of adjustment is limited.
Turn push rod accordingly until you have free play. If necessary, adjust the
basic position of the footbrake lever.
Specification
Free play at foot brake lever
M8
30Nm
(22.1lbfft)
M6
15Nm
(11.1lbfft)
100061-10
Reconnect spring.
When the brake fluid level has dropped to the bottom of the viewer:
100040-10
P. 79)
13/BRAKE SYSTEM
79
Warning
Skin irritationsBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
100049-10
P. 203)
Info
Clean up overflowed or spilt brake fluid immediately with water.
100050-10
100038-10
1mm (0.04in)
P. 81)
13/BRAKE SYSTEM
80
Press the brake caliper by hand on to the brake disc in order to press back the
brake piston.
Loosen screw while holding hexagonal head of the bearing bolt. Unscrew the
screw by approx. 10 turns and use the screw to press the bearing bolt out of the
brake caliper. Remove screw.
100063-10
100064-10
Note
Danger of damageKinking of brake line.
100066-10
Position and handle the brake line without straining it. The brake line must be
replaced if it is kinked.
Swing the brake caliper up, unhook it from brake caliper support and set it
down.
Warning
Danger of accidentsReduced braking due to oil or grease on the brake discs.
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidentsReduced braking due to use of non-approved 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 linings. If brake linings are used that differ from the originals, there is no guarantee that they comply with the original license. The vehicle no longer corresponds to the condition at delivery, and the warranty is no longer valid.
Check parts for damage and wear. Replace damaged or worn parts.
Check that the sliding plate is seated correctly in the brake caliper support and
insert the brake linings.
P. 60)
Info
Make sure that the decoupling plate is mounted on the piston side of the
brake pad.
100067-10
13/BRAKE SYSTEM
81
Grease the bearing bolt and insert the brake caliper with the bearing bolt into
the brake caliper support.
100068-10
Specification
Screw, rear brake caliper
M6
10Nm
(7.4lbfft)
Loctite 243
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc
and there is a tight spot.
100069-10
Warning
Skin irritationsBrake fluid can cause skin irritation on contact.
Avoid contact with skin and eyes, and keep out of the reach of children.
If brake fluid gets into your eyes, rinse thoroughly with water and contact a doctor immediately.
Warning
Environmental hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Never user DOT5 brake fluid! It is based on silicone oil and is colored purple. Oil seals and brake lines are not designed for
DOT5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container!
Press the brake piston back to its basic position and make sure that no brake fluid
overflows from the brake fluid reservoir.
100070-10
P. 80)
P. 80)
P. 203)
Info
Clean up overflowed or spilt brake fluid immediately with water.
30/ENGINE
82
30/ENGINE
17
17.1
P. 18)
P. 163)
P. 36)
P. 48)
P. 145)
P. 161)
P. 17)
Info
Do not activate the clutch lever if the slave cylinder of the clutch has been
removed.
600166-10
Slide back the cover. Remove nut from the electrical connection on the starter
motor and take off the cable.
600167-10
600168-10
600169-10
30/ENGINE
83
Release hose clamps and take off the radiator hoses and hose clamps.
600170-10
P. 207)
600171-10
Lower the mounting platform until all wheels touch the ground.
Take the rear brake line out of the guides of the swingarm.
600172-10
600173-10
Info
Do not kink the brake line.
600174-01
600175-10
30/ENGINE
84
Remove screw and take the engine out of the frame toward the front right.
600179-10
Info
Having an assistant is helpful in this step.
600177-10
Position the engine in the frame. Mount screw but do not tighten it yet.
Info
Having an assistant is helpful in this step.
600177-11
Position the engine bearer on the frame. Mount screws but do not tighten them
yet.
Specification
Engine bracket screw
M10
60Nm
(44.3lbfft)
Insert screw.
Position the engine bearer on the frame. Mount screws but do not tighten them
yet.
600178-10
Specification
Engine bracket screw
M10
60Nm
(44.3lbfft)
M10
60Nm
(44.3lbfft)
600176-11
600180-10
Raise the swingarm and position it between the frame and the engine. Insert
swingarm pivot.
30/ENGINE
85
M16x1,5
100Nm
(73.8lbfft)
M10
60Nm
(44.3lbfft)
M10
60Nm
(44.3lbfft)
600173-11
If the vehicle is to be raised, secure the swingarm to the subframe with a tension
belt.
600172-11
Specification
Screw, foot brake cylinder
M6
7Nm
(5.2lbfft)
Loctite 243
Reconnect spring.
Spring hooks (50305017000) (
P. 207)
600171-11
Position the electrical connection on the starter motor. Mount and tighten nut.
Slide on the cover.
600170-11
Specification
Screw, starter engine
M6
10Nm (7.4lbfft)
600169-11
600168-11
30/ENGINE
86
600167-11
Specification
Slave cylinder of the clutch on engine
case
600166-11
M6
P. 161)
P. 156)
P. 17)
P. 49)
P. 37)
P. 18)
P. 169)
P. 162)
P. 164)
10Nm (7.4lbfft)
87
Preparations
18.1
Thoroughly clean the outside of the engine and attach it to the universal mounting
rack using the special tool.
Engine holder (83112001050) (
P. 215)
P. 207)
Remove plug and the small oil screen with both O-rings.
Remove plug and the large oil screen with both O-rings.
Remove screws. Take off oil filter cover with the O-ring.
600441-01
600183-10
600184-10
P. 207)
600185-10
600186-10
Remove screws. Remove the spring holder. Take off the clutch cover.
Remove centering pin and dowels. Take off the clutch cover seal.
Undo screws and remove them with the washers and springs.
600182-10
600187-10
600188-10
600189-10
600190-11
88
89
Apply counterpressure against the inner clutch hub using special tool. Loosen
nut.
600193-10
P. 208)
Block the primary drive with special tool and remove nut.
600194-10
P. 208)
Info
LH thread!
600195-10
Remove inner clutch hub sleeves and inner clutch hub. Remove the stepped
washer and half washers.
Info
Behind the inner clutch hub are two half washers that can fall off.
600196-10
600197-10
Take off outer clutch hub and remove both needle bearings from the main shaft.
90
P. 207)
Remove torque limiter with bearing bolt and both needle bearings.
Press sliding plate away from the shift drum locating. Remove shift shaft with
the washer.
Remove screw.
Press locking lever away from shift drum locating and take off the shift drum
locating.
Undo screw and take off it together with locking lever, washer, sleeve and
spring.
600198-01
600199-10
600200-11
600271-10
Info
Make sure that the pin remains in place.
600202-10
91
P. 209)
Info
Make sure that the washer spring remains in place.
600204-10
P. 210)
600207-10
600205-10
600206-10
Info
In the top dead center position, conductive element is located above the
ignition pulse generator.
600208-10
92
Remove screw.
600209-11
P. 207)
Info
With perceptible resistance, move the flywheel back and forth so that the
special tool can engage in the recess of the crankshaft.
600210-10
Remove screws.
Pull the cable support sleeve out of the engine case. Take off ignition pulse generator.
Attach special tool to the rotor. Apply counterpressure with the special tool and
pull off rotor by turning in the screw.
600211-10
600212-10
Extractor (58012009000) (
P. 207)
Info
Make sure that the washer spring remains in place.
600213-10
Remove screws.
Remove oil pump shaft together with pin, internal rotor and external
rotor.
Remove screws.
600214-10
600215-10
600216-10
600217-10
600218-10
93
94
Info
Screw is spring loaded!
600221-10
600222-10
600219-10
600220-10
P. 209)
Info
Ensure that the bolt that is pushed out does not drop into the engine.
Hold the timing chain so that it does not fall into the timing chain shaft.
600223-01
Prevent the timing chain from falling down using cable ties.
Remove screws.
Remove cylinder toward the top. Hold the piston in place while doing so.
600224-10
600225-10
600226-10
Info
Make sure that the pins on the cylinder base remain in place.
600227-10
95
96
Remove piston.
Remove screws. Remove timing chain guide rail and timing chain tensioning
rail.
600228-10
Info
Mark the direction of travel of the timing chain.
600229-10
600230-10
Pull timing chain sprocket off of the crankshaft using special tool.
Extractor (59029033000)
Info
Make sure that the washer spring remains in place.
600231-10
600232-10
97
600233-10
600234-10
600235-10
Remove screws.
600210-10
98
600236-10
Info
The bosses on the engine case can be used for lightly striking with the plastic hammer.
Remove dowels.
Remove shift rail with the springs and disassemble shift fork with the shift
roller.
600237-10
Info
Make sure not to misplace the shift roller.
600238-10
Remove the shift railwith locking lever and dismantle shift forks with the
shift rollers.
Info
Make sure not to misplace the shift rollers.
600239-10
600240-10
Pull main shaft and countershaft out of the bearing seats together with the
axle for the reverse gear.
600241-10
Info
Some of the gear wheels are not firmly attached to the shaft and can fall
off.
Make sure that the stop disks remains in place.
600242-10
Turn balancer shaft to the marking and pull out of the bearing.
Remove crankshaft.
600243-10
600244-10
99
100
19.1
Remove any sealing compound remnants and clean the engine case section thoroughly.
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
Check parts for damage and wear. Replace damaged or worn parts.
600247-10
150C (302F)
Insert the new cold bearing into the bearing seat of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing from the inside to
the outside all the way or so it is flush.
Info
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring, otherwise the bearings will be
damaged when they are pressed in.
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine house when warm. In this case, the engine case must
be renewed.
Press the shaft seal ring of the crankshaft from the outside to the inside with the
open side facing inward.
Info
The shaft seal ring must be flush with the outside.
M5
6Nm
(4.4lbfft)
Loctite 243
M6x0,75
4Nm
(3lbfft)
Loctite 243
M5
2Nm (1.5lbfft)
101
Blow though all oil holes with compressed air and check that they are clear.
600249-01
600250-10
P. 101)
P. 101)
200155-10
Check parts for damage and wear. Replace damaged or worn parts.
600250-11
M12x1.5
20Nm
(14.8lbfft)
102
Remove the shaft seal ring of countershaft, shift rail with locking lever and
shift shaft.
Remove any sealing compound remnants and clean the engine case section thoroughly.
Knock the engine case section against a level wooden plate. This will cause the
bearings to drop out of the bearing seats.
Info
Any bearings that remain in the engine case section must be removed using
a suitable tool.
Check parts for damage and wear. Replace damaged or worn parts.
600246-10
Insert the new cold bearing into the bearing seat of the hot engine case section
and, if necessary, use a suitable press drift to push the bearing in all the way or
so it is flush.
Info
When pressing the bearing in, ensure that the engine case section is level to
prevent damage.
Only press the bearings in via the outer ring, otherwise the bearings will be
damaged when they are pressed in.
After the engine case section has cooled, check that the bearings are firmly seated.
Info
If the bearings are not firmly seated after cooling, it is likely that they will
rotate in the engine house when warm. In this case, the engine case must
be renewed.
Press in the shaft seal ring of countershaft, shift rail with lock and shift
shaft with the open side facing inward until they are flush.
Blow though all oil holes with compressed air and check that they are clear.
600248-01
600251-10
Press the new crankshaft seal ring into the clutch cover with the open side facing inward until it is flush.
Blow though oil hole with compressed air and check that it is clear.
103
P. 207)
600261-10
Info
After removing, always replace the shaft seal rings in the seal holder.
600262-10
600263-10
Extractor (59029033000) (
P. 209)
600264-10
Disconnect spring.
600260-10
600266-10
104
Check parts for damage and wear. Replace damaged or worn parts.
600266-11
600260-11
Attach special tool to the camshaft. Mount the seal holder with the new shaft
seal rings and O-rings.
600263-11
P. 208)
Info
When mounting the seal holder, the threads in the seal holder must be at
the top.
Mount pin.
600267-10
600262-11
600261-11
P. 207)
105
P. 207)
600261-10
Info
After removing, always change the shaft seal rings in the seal holder.
600262-10
600263-10
Extractor (59029033000) (
P. 209)
600264-10
Check parts for damage and wear. Change damaged or worn parts.
Attach special tool to the camshaft. Mount seal holder with the new shaft seal
rings and O-rings.
600263-12
P. 208)
Info
When mounting the seal holder, the threads in the seal holder must be at
the top.
600267-11
106
Mount pin.
600262-12
600261-12
Extractor (59029033000) (
P. 209)
600321-10
600322-10
Pull rocker arm shafts out of the cylinder head top section.
600273-10
600274-10
Check rocker arm rollers for smooth operation and radial clearance.
600275-10
Check the contact surface of adjusting screws for damage and wear.
107
Install the short rocker arm shaft and the long rocker arm shaft.
Align the holes in the shafts with the holes in the cylinder head top section.
Clean the end caps thoroughly and check for damage and wear. Replace damaged
or worn parts.
600276-10
Info
The hole in the end cap must be aligned with the hole in the cylinder
head top section and the rocker arm shaft.
600277-10
P. 208)
Remove the valve keys and release the tension on the valve springs.
Pull valve downward out of the valve guide, remove the valve stem seal and
remove the lower valve spring retainer.
600278-01
600279-10
Info
Place the valve into a box according to the installation position and label the
box.
200189-10
108
Info
The valve stem is chrome-hardened, and wear normally takes place in the valve guide.
0.05mm (0.002in)
200193-10
1.50mm (0.0591in)
Valves
0
A
If the sealing area is not in the center of the valve seat or if it differs from the
specified value:
400373-10
2.00mm (0.0787in)
Check the valve springs for breakage and wear (visual check).
600280-01
39.20mm (1.5433in)
36.45mm (1.435in)
Check the lower valve spring retainer for breakage and wear (visual check).
600281-01
109
Check the sealing area of the spark plug thread and the valve seats for damage and
cracking.
600282-10
P. 209)
Check the sealing area of the cylinder for distortion using a straight edge and the
special tool.
Feeler gauge (59029041100) (
P. 209)
0.10mm (0.0039in)
400375-10
1.50mm (0.0591in)
Valves
0
A
400373-10
2.00mm (0.0787in)
Blow though all oil holes with compressed air and check that they are clear.
Check parts for damage and wear. Replace damaged or worn parts.
Position the lower valve spring retainers. Mount the new valve stem seals.
Mount outer valve spring, inner valve spring and upper valve spring
retainer.
600283-10
600284-10
110
P. 208)
Info
When mounting the valve keys, check that they are seated correctly; preferably, fix the valve keys to the valve with a little grease.
600285-01
Check timing chain crankshaft sprocket and timing chain camshaft sprocket
for damage and wear.
Check that the timing chain links move easily. Let the timing chain hang down
freely.
600269-10
Press on the ratcheting pawl and check that the pressure bolt moves easily.
Change the timing chain tensioner.
To mount the timing chain tensioner, press ratcheting pawl and push pressure
bolt all the way into the housing.
600270-10
111
A
600455-01
Position the new crank pin and press it into the first crank web.
The oil hole in the crank web is aligned with the oil hole in the crank pin.
Info
If the oil holes are not correctly aligned, the conrod bearing will not be provided with oil.
Info
Oil the bearing thoroughly.
650.05mm (2.560.002in)
P. 111)
If the crankshaft run-out on the bearing pin is greater than the specified value:
600254-01
0.12mm (0.0047in)
112
Clamp the right section of the engine case into the engine work stand.
Universal mounting rack (56012001000) (
P. 207)
Install crankshaft.
Mount the left section of the engine case. Mount and tighten the screws.
600244-10
Specification
600437-10
M6x30
10Nm (7.4lbfft)
M6x45
10Nm (7.4lbfft)
M6x60
10Nm (7.4lbfft)
M6x65
10Nm (7.4lbfft)
M6x75
10Nm (7.4lbfft)
Using a dial gauge, measure and note down the axial clearance of crankshaft.
Crankshaft - axial clearance
P. 112)
P. 112)
Specification
Use soft jaws.
Info
Do not strike the inner bearing race!
600440-01
P. 208)
Slide the heated special tool onto the inner bearing race, press together firmly and
pull both off of the crankshaft.
Info
If the axial clearance is too large, correction shims need to be added. If the
axial clearance is too small, correction shims need to be removed.
Only add the correction shims on the ignition side.
P. 208)
P. 112)
113
Nikasil is a surface protection layer for a coating procedure developed by the Mahle
company. The name is derived from the two materials used in this procedure - a layer
of nickel into which is embedded the particularly hard silicone carbide.
The most important advantages of the Nikasil coating are very good heat conductivity,
resulting in much improved performance, low wear, and a lightweight cylinder.
600272-01
Measure the cylinder diameter at several places on the and axes using a
micrometer to check for oval wear.
Specification
Cylinder - bore diameter (450 XC ATV)
Diameter size I
Diameter size II
600252-01
Diameter size II
Check the sealing area of the cylinder head for distortion using a straight edge and
the special tool.
600255-10
P. 209)
400376-10
0.10mm (0.0039in)
114
Check that the piston rings can move easily in the piston ring grooves.
Tip
Use an old piston ring to clean the piston ring groove.
600253-01
Info
Mount the piston ring with the marking facing upward.
Insert the piston pin into the connecting rod and check the bearing for play.
Change the connecting rod and the piston pin.
Measure the piston at the piston skirt, at right-angles to the piston pin.
Specification
Piston diameter (450 XC ATV)
Size I
Size II
Size I
Size II
Info
Piston size is marked on the piston head.
Place the piston ring in the cylinder and align it with the piston.
Specification
under the upper edge of the cylinder
10mm (0.39in)
200163-10
<1.00mm (<0.0394in)
P. 113)
<0.80mm (<0.0315in)
Compression ring
Mount the piston ring with the marking facing toward the piston head.
115
The smallest piston/cylinder mounting clearance is the result of the smallest cylinder bore diameter minus the largest piston diameter. The largest piston/cylinder mounting clearance is the result of the largest cylinder bore diameter minus the smallest piston
diameter.
P. 113)
P. 114)
Specification
Piston/cylinder - mounting clearance (450 XC ATV)
Size I
Size II
Wear limit
0.120mm (0.00472in)
Size II
Wear limit
0.120mm (0.00472in)
Info
An example of how to check the oil pumps for wear is shown in the figures here, but the method applies to all pumps.
Use feeler gauge to measure the clearance between the external rotor and the
engine case.
Oil pump - clearance between external
rotor and engine housing
0.20mm (0.0079in)
600324-10
Use feeler gauge to measure the clearance between the external rotor and the
internal rotor.
Oil pump - clearance between external
rotor and internal rotor
600325-10
0.20mm (0.0079in)
116
1
A
3
6
4
7
6
3
4
2
3
Check that guide pin is firmly seated and check it for wear.
600287-01
If there is run-out:
Check the shift rail with locking lever for wear on the locking lever.
If there is run-out:
Check shift rail for grooving, signs of corrosion and smooth operation in shift fork.
The shift rail has grooving or signs of corrosion or is not smooth in operation in the shift fork:
117
P. 118)
B
0
400372-10
600288-10
600289-10
600290-10
118
5
0
2
0
1
0
6
0
30
0
4
200175-01
Mount sliding plate with the guide pin facing downward and attach the guide pin
to the shift quadrant.
Push on spring guide, push return spring over the spring guide with the offset
end facing upward and lift the offset end over abutment bolt.
1
LOCTITE 243
bk
87
LOCTITE 243
3
6
2
5
bl
600286-01
>1.90mm (>0.0748in)
Check the contact surfaces of the clutch facing discs in outer clutch hub for wear.
Change the clutch facing discs and the outer clutch hub.
Check the contact surface of pressure cap for damage and wear.
119
If there is run-out:
0
1
bbl
0l
b0m
bm
0
70
6
0
5
4
0
bbk
0k 0
9
8
0
3
0
0
2
600316-01
Clamp main shaft in the vise with the toothed end of the coupling side facing downward.
Specification
Use soft jaws.
120
1
0
0
2
0
3
50
0
4
0
3
0
2
0
4
5
0
6
0
0
6
0
7
600295-01
Check the pivot points of main shaft for damage and wear.
Check the tooth faces of idler gears and fixed gears for damage and wear.
Check the dog teeth of idler gears and fixed gears for damage and wear.
Check the pivot points of idler gears for damage and wear.
Check the tooth profiles of main shaft for damage and wear.
Check the tooth profiles of fixed gears for damage and wear.
Check fixed gears for smooth operation in the profile of the main shaft.
121
Info
Use new lock rings in every repair job.
P. 123)
0
1
0
3
2
0
0
70
8
9
0
b0k
bk
40
0
5
6
0
b0l
bl
0m
bbm
600316-11
Clamp main shaft in the vise with the toothed end of the coupling side facing downward.
Specification
Use soft jaws.
Mount needle bearing and fifth-gear idler gear with the recesses facing upward.
Mount the third-gear sliding gear with the shift groove facing upward.
Mount the fourth-gear idler gear with the shift dogs facing downward.
Mount the second-gear fixed gear with the chamfered teeth facing downward.
122
0
2
0
3
6
0
00
4
5
bbn
0n
bbo
0o
9
0
0
70
8
b0s
bbp
0p bq
b0qbr
b0r bs
0k bbl
bbk
0l bbm
0m
0l
bbt
0tck
c0k ccl
0m
ccm
1
0
600311-01
Fix countershaft in the vise with the geared end facing downward.
Specification
Use soft jaws.
123
0
8
0
2
0
6
7
30
0
8 0
0
2
2
0
0
50
4
00
3
40
5
0
6
00
3
4
50
0
40
3
0
2
1
0
600296-01
Check the tooth faces of idler gears and fixed gears for damage and wear.
Check the dog teeth of idler gears and fixed gears for damage and wear.
Check the pivot points of idler gears for damage and wear.
Check the tooth profiles of fixed gears for damage and wear.
Check sliding sleeve for smooth operation in the profile of the countershaft.
Check the dog teeth of sliding sleeve for damage and wear.
124
Info
Use new lock rings in every repair job.
ccm
0m
0l
ccl
0l
bbl
P. 123)
0s
bbs
cck
0k bt
b0t
bbk
0k
b0p
bp
0r bq
bbr
b0q
6
0
0
90
80
7
0o bbn
bbo
0n bbm
0m
3
0
0
50
4
0
2
1
0
600311-11
Fix countershaft in the vise with the geared end facing downward.
Specification
Use soft jaws.
Mount needle bearing and second-gear idler gear with the recesses facing upward.
Mount the fourth-gear sliding gear with the shift groove facing upward.
Mount the third-gear idler gear with the shifting dogs facing downward.
Mount the fifth-gear idler gear with the sleeve facing downward.
Mount needle bearing and reverse-gear idler gear with the recesses facing upward.
Mount needle bearing and first-gear idler gear with the collar facing upward.
125
0
1
0
5
3 4
0
0
6 0
0
7
600319-01
Check the pivot points of reverse gear shaft for damage and wear.
Check the tooth faces and pivot point of reverse gear wheel for damage and wear.
Mount reverse gear wheel with the smaller recess first. Mount stop disk.
Info
After installation, stop disk is flush with surface .
Stop disk is somewhat lower in the reverse gear wheel and is not flush.
600320-10
126
0
2
0
3
1
0
0
4
0
5
0
6
0
7
0
A
600323-01
Clamp the negative cable of a 12 volt supply to the starter motor housing. Connect the positive cable of the voltage supply briefly
to the connectionof the starter motor.
If the starter motor does not turn when you close the circuit:
Check the toothing and seating of starter idler gear for damage and wear.
Check the toothing of primary gear and contact surface for damage and wear.
Check the toothing or seating of torque limiter and the bearing bolt for damage and wear.
Check free-wheel-gear and the bearing when removed for damage and wear.
127
Press together spreader ring with suitable pliers and take it off.
600435-10
600436-11
The primary pinion cannot be rotated clockwise or does not block counterclockwise:
P. 127)
P. 127)
600313-10
Info
Note the direction of rotation.
600436-10
600435-11
Ensure that all protrusions of the spreader ring engage through slots of the freewheel in the groove of the primary pinion.
128
20.1
Clamp the right section of the engine case into the engine work stand.
Universal mounting rack (56012001000) (
Engine holder (83112001050) (
P. 207)
P. 215)
Slide crankshaft all the way into the bearing seat of the right section of the
engine case.
Align the marking on balancer shaft and the crankshaft to each other and insert
the balancer shaft.
Slide both transmission shafts, and reverse gear shaft into the bearing
seats together.
600244-10
600243-10
600328-10
Info
Make sure not to misplace the washers.
600331-10
600332-10
129
For all shift forks, secure shift rollers with a small amount of grease.
Mount the short shift fork with the long side of the guide facing downward.
Mount shift forks with the long side of the guide facing toward each other.
Attach the shift forks with the shift rollers to the shift grooves.
Install shift rail with the spring at the bottom and top.
Attach special tool to the shift rail with the locking lever.
600329-10
600330-10
600443-10
600333-10
600334-10
P. 208)
130
Insert dowels.
Grease the sealing areas. Apply sealing compound to the left section of the engine
case.
Loctite5910
Mount the left section of the engine case. If necessary, tap it lightly with a rubber
hammer and turn the transmission shaft.
Info
600335-10
600235-11
Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing
M6x30
10Nm (7.4lbfft)
Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing
M6x45
10Nm (7.4lbfft)
Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing
M6x60
10Nm (7.4lbfft)
Mount screws and tighten them when all screws have been mounted on the left section of the engine case.
Specification
Screw, engine housing
M6x65
10Nm (7.4lbfft)
M6x75
10Nm (7.4lbfft)
131
P. 208)
Position O-ring and mount spacing sleeve with the phase facing downward.
600336-10
Specification
Crankshaft - axial clearance
600327-01
Heat timing chain sprocket and install with the collar facing inward.
Specification
80C (176F)
Thread timing chain rail from above. Mount and tighten screw.
600230-11
Specification
Screw, timing chain tensioning rail
M6
6Nm
(4.4lbfft)
Loctite 243
Thread timing chain guide rail from above. Mount and tighten screw.
Specification
Screw, timing chain guide
rail
M6
6Nm
(4.4lbfft)
Loctite 243
600337-10
Fix the crankshaft using the special tool in the top dead center position.
Crankshaft locking bolt (113080802) (
600338-10
P. 207)
132
Info
Note the orientation of the piston when installing it. The arrow on the piston
must point in the direction of travel.
600228-11
Shift the joint of the compression ring and oil scraper ring by 180.
Oil special tool on the inside and the piston on its sliding surface.
600445-01
P. 208)
Mount cylinder onto the piston using the special tool and slide both over the piston.
600339-10
600340-10
600341-10
133
Mount the cylinder head. Mount screws and tighten in a crisscross pattern.
Specification
Screw, cylinder head
M10
Step 1
40Nm
(29.5lbfft)
Step 2
50Nm
(36.9lbfft)
M6
10Nm (7.4lbfft)
600342-10
600343-10
Insert the camshaft. Drill hole in the seal holder must face upward and autdecompression stop must be at the top.
Place the timing chain over the camshaft gear and connect with a new rivet link.
Clamp tab with the special tool.
600346-10
600347-10
600348-10
P. 209)
134
Reconfigure the special tool. Rivet the rivet link until the edges of the pins are visibly flattened.
Timing chain separating and riveting tool (59029020000) (
P. 209)
600349-10
Insert dowels. Grease the sealing area. Apply the sealing compound.
Loctite5910
600350-10
0
7
0
7
00
4
5
Mount the cylinder head. Mount screw with the new seal ring but do not tighten
yet.
Specification
0
2
0
3
M6x75
10Nm (7.4lbfft)
M6x45
10Nm (7.4lbfft)
6
00
4
600350-01
M6x30
10Nm (7.4lbfft)
M6x50
10Nm (7.4lbfft)
M6x45
10Nm (7.4lbfft)
With the special tool inserted, press end caps in the direction of the arrow to
adjust the axial clearance.
Specification
Rocker arm - axial clearance
Feeler gauge (59029041100) (
600351-10
M6x55 10.9
10Nm (7.4lbfft)
135
With timing chain tensioner in the installation position, install it with a new seal.
Mount and tighten screws.
Specification
Screw, timing-chain tensioner
M6
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
600352-10
Mount rotor. Mount spring washer and nut. Tighten the nut.
600354-10
Specification
Ignition rotor nut
M12x1
60Nm
(44.3lbfft)
600355-10
Set the engine to ignition top dead center again and screw in special tool.
Crankshaft locking bolt (113080802) (
P. 207)
600210-11
On all valves, check valve clearance between the valve and rocker arm using special
tool.
Specification
Valve clearance, cold, intake
P. 209)
P. 136)
136
Set the valve clearance by turning adjusting screw between the valve and rocker
arm using special tool.
Specification
Valve clearance, cold, intake
M6x0,75
11Nm (8.1lbfft)
600353-10
Position valve cover with the seal. Mount and tighten the screws.
Specification
Screw, valve cover
M6
10Nm (7.4lbfft)
600356-10
M6
10Nm (7.4lbfft)
600219-11
Mount and tighten banjo bolt and jet screw with the seal rings.
Specification
Banjo bolt, oil line
M8
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
600218-11
600207-10
M12x1,25
P. 210)
17Nm
(12.5lbfft)
137
Slide the primary gearwith the free-wheel onto free-wheel-gear and mount them
both on the crankshaft.
600357-10
Info
The free-wheel-gear must rotate counterclockwise when it is mounted.
600358-10
M20LHx1,5
150Nm
(110.6lbfft)
Loctite 243
Mount external rotor and internal rotor with marking facing inward.
The marking should not be visible after installation.
Insert pin in the second drill hole of the oil pump shaft.
Insert the oil pump shaft into the engine case. Ensure that the pin engages in the
internal rotor.
600359-10
600360-10
Specification
Screw, oil pump cover
600361-10
M5
6Nm
(4.4lbfft)
Loctite 222
138
Mount external rotor and internal rotor with marking facing inward.
Insert pin.
600362-10
600363-10
Specification
Screw, oil pump cover
M5
6Nm
(4.4lbfft)
Loctite 222
6Nm
(4.4lbfft)
Loctite 243
600364-10
Position the cable and insert cable support sleeve into the engine case.
600365-10
600367-11
M5
139
M8
10Nm (7.4lbfft)
600366-10
600369-10
Specification
Screw, gear sensor
M5
6Nm
(4.4lbfft)
Loctite 243
600368-10
Position locking shaft lever. Mount and tighten screw with the washer.
Specification
Screw, locking shaft lever
M5
6Nm
(4.4lbfft)
Loctite 243
600370-10
600371-10
M5
6Nm
(4.4lbfft)
Loctite 243
140
Push locking lever away from the shift drum locatingand position shift drum
locating.
Info
The flat surfaces of the shift drum locating are not symmetric.
600372-10
M6
10Nm
(7.4lbfft)
Loctite 243
Slide the premounted shift shaft with the washer into the bearing seat.
Press the sliding plate away from the shift drum locating. Insert the shift shaft all
the way.
600373-10
600374-10
600375-10
P. 207)
600384-10
M8
10Nm (7.4lbfft)
141
Mount outer clutch hub and insert the two half washers into the main shaft
with grease.
Position stepped washer with the recess facing the half washers.
Slide on inner clutch hub. Position the new lock washer and mount nut.
Mount the inner clutch hub sleeves and attach special tool.
600376-10
600377-10
600378-10
600379-10
P. 208)
Tighten nut.
Clutch holder (59029003100) (
P. 208)
Beginning with a thin clutch disc, place all further clutch facing discs and clutch
discs alternately into the outer clutch hub.
600380-10
bl
Info
The two outer clutch discs are thinner than the four inner clutch
discs.
bm
bn
bm
600439-01
142
Mount the pressure cap. Mount screws with washers and springs. Tighten all
screws in a crisscross pattern.
600381-10
Specification
Screw, clutch spring
M6
8Nm
(5.9lbfft)
Loctite 243
600382-10
600385-10
Specification
30ml (1.01fl.oz.)
Mount the clutch cover. Position spring holder. Mount and tighten screws.
600386-10
Specification
Screw, clutch cover
600387-10
M6
10Nm (7.4lbfft)
143
P. 205)
M6
10Nm (7.4lbfft)
600388-10
Mount oil drain plug with seal ring and tighten it.
Specification
Oil drain plug with magnet
M12x1,5
20Nm
(14.8lbfft)
600393-10
Oil the O-rings, mount them on oil screen and using a long hexagon socket
wrench insert them carefully until the O-ring is seated in the housing with the oil
screen.
600391-10
Specification
Locking screw, oil sieve, long
M20x1,5
15Nm
(11.1lbfft)
Insert oil screen with the O-rings into plug and tighten.
Specification
Locking screw, oil sieve,
short
M16x1,5
10Nm
(7.4lbfft)
lubricated with
engine oil
600392-10
600389-10
Tilt the engine sideways and fill the oil filter housing about full with engine oil.
Fill the oil filter with engine oil and place it in the oil filter container.
144
Oil the O-rings of oil filter covers and mount them with the oil filter covers.
M5
6Nm (4.4lbfft)
600390-10
Remove screw cap on the clutch cover and fill up with engine oil.
Engine oil
2.00l (2.11qt.)
External temperature: 0C
(32F)
Engine oil
(SAE 10W/50)
( P. 203)
Engine oil
(SAE 5W/40)
( P. 203)
600187-11
Specification
Screw, shift lever
M6
10Nm
(7.4lbfft)
600394-10
600395-10
600441-01
P. 215)
Loctite 243
31/CARBURETOR
145
31/CARBURETOR
21
Choke
21.1
Info
If the engine is warm, the choke function must be deactivated.
100014-10
Possible states
Choke function activated The choke lever is pulled out to the stop.
Choke function deactivated The choke lever is pushed in to the stop.
The hot start button (red) is fitted on the left side of the carburetor.
Activating the hot start function frees an opening in the carburetor through which the
engine can draw extra air. This gives a leaner fuel-air mixture, which is needed for a
hot start.
Info
If the engine is cold, the hot start function must be deactivated.
100015-10
Possible states
Hot start function activated The hot start button is pulled out to the stop.
Hot start function deactivated The hot start button is pushed in as far as possible.
Remove the air filter box lid with the carburetor connection boot. (
Remove screw. Take off the holder for the carburetor vent hoses.
P. 53)
600158-10
600442-10
600159-10
P. 51)
31/CARBURETOR
146
Take carburetor out of the frame toward the rear and set it on the frame.
Loosen nut. Detach the gas Bowden cable and hang it to one side.
Remove screws and detach all vent hoses from the carburetor.
Remove screws. Take off the throttle slide cover and seal.
600160-10
600161-10
600162-10
600163-10
P. 145)
700034-10
700035-10
31/CARBURETOR
147
Remove screw.
Pull up throttle slide arm. Take throttle slide out of the carburetor along with
throttle slide roller and the throttle slide plate.
Remove screws. Take off the accelerator pump cover with the seal ring.
Remove fulcrum pin. Take off the float and float needle valve.
Remove idling jet, cold start jet, needle jet and buffer plate.
Screw in mixture control screw to the stop, counting and noting down the number of rotations.
Remove the mixture control screw with the spring, washer and O-ring.
600444-10
700037-10
700038-10
700039-10
700044-12
700045-12
31/CARBURETOR
148
700046-11
700047-12
Info
Only remove the throttle valve sensor if necessary. If screw is loosened,
the throttle valve sensor must be readjusted.
Clean all jets and other parts thoroughly and blow out with compressed air.
600398-11
Carburetor cleaner (
Clean the carburetor housing and blow out all channels in the carburetor with compressed air.
Carburetor cleaner (
700049-12
P. 205)
P. 205)
Info
Do not use nitro thinner to clean the carburetor.
31/CARBURETOR
149
600397-02
P. 146)
P. 149)
P. 150)
P. 150)
P. 150)
P. 151)
P. 151)
P. 151)
P. 153)
P. 153)
P. 152)
P. 153)
700051-10
P. 205)
31/CARBURETOR
150
P. 153)
Info
Adjusting the play of the accelerator pump changes the time at which injection starts and does not influence the injection rate or the intensity of the
accelerator pump.
700065-10
P. 157)
600400-01
P. 205)
If the rubber sleeve is damaged or brittle, or if the lock does not function:
600399-01
P. 205)
If the rubber sleeve is damaged or brittle, or if the lock does not function:
Check the jet needle for bending and wear of the coating.
700052-10
31/CARBURETOR
151
If the throttle slide rollers do not turn easily, are worn or have flat areas:
Except for throttle slide roller (removable), all rollers must rest flush against the
throttle slide.
700055-10
Check membrane of the throttle slide plate for damage, brittleness and tightness.
Check the coating of the throttle slide and throttle slide plate for damage and
wear.
700056-10
Use a new jet needle as a gauge. Apply a marking on the jet needle above
step at a distance of.
Specification
Distance
3mm (0.12in)
Info
The marking should come off completely when cleaned away.
700053-10
Insert the marked jet needle into the needle jet being tested. Push the two pieces
together carefully.
If marking on the jet needle is not visible on top edge of the needle jet:
700054-10
Check the float needle valve including the valve seat for deposits or wear.
Clean the valve seat. Clean or change the float needle valve.
Carburetor cleaner (
Check the float needle valve for wear and the sealing areas of indentations.
700057-10
P. 205)
31/CARBURETOR
152
Info
The value in the figure is an example only!
P. 145)
P. 151)
Condition
Component temperature: 20C (68F)
Connect the positive wire of the multimeter to the blue (bu) cable and the
ground wire to the black(bl) cable of the connector of throttle valve sensorTPS.
Measure the total resistanceRtot of the throttle valve sensor.
Specification
Total resistanceRtot of the throttle
valve sensor
4 6k
700063-10
Connect the positive wire of the multimeter to the yellow(ye) cable and the
ground wire to the black(bl) cable of the connector of throttle valve sensorTPS.
Slowly open the throttle slide and measure the variable resistanceRvar of the
throttle valve sensor.
Variable resistanceRvar of the throttle valve sensor (throttle slide fully
opened)
700064-10
3 4.5k
P. 152)
P. 156)
Info
The value in the figure is an example only!
P. 145)
P. 153)
Conditions
Component temperature: 20C (68F)
Connect the positive wire of the multimeter to the blue(bu) cable and the
ground wire to the black(bl) cable of the connector of throttle valve sensorTPS.
Measure the total resistanceRtot of the throttle valve sensor.
Specification
Total resistanceRtot of the throttle
valve sensor
4 6k
700063-10
700064-10
Multiply the total resistanceRtot of the throttle valve sensor by 0.17. This generates the variable resistanceRvar for the setting of the throttle valve sensor.
31/CARBURETOR
153
Connect the positive wire of the multimeter to the yellow(ye) cable and the
ground wire to the black(bl) cable of the connector of throttle valve sensorTPS.
Info
The throttle slide must be in the neutral position.
700066-10
Tighten screw.
Specification
Screw, throttle valve sensor
3.5Nm
(2.58lbfft)
M5
P. 156)
Info
The basic setting of the throttle slide controls the time at which injection begins at the accelerator pump and the basic setting
of the throttle valve sensor.
P. 145)
1mm (0.04in)
If the throttle slide opening does not equal the specified value:
700062-10
Hold the carburetor at a slant, securing the pin against falling out of the float.
Hold the carburetor at a slant so that the float lies against the float needle valve
but does not press it together.
In this position, if the edge on the float is not parallel to the sealing area of the
float chamber:
700061-10
700049-11
M4,5x0.75
2Nm (1.5lbfft)
31/CARBURETOR
154
Mount and tighten the choke slide and hot start slide.
Specification
Choke slide
M12
2.5Nm
(1.84lbfft)
Position throttle valve sensor. Mount screw with the spring ring and washer
but do not tighten yet.
Info
When installing the throttle valve sensor, ensure that the flat area of the
inner clutch hub engages in the recess of the throttle valve sensor.
600398-10
M4
2Nm
(1.5lbfft)
Loctite 243
Info
The hose connection must be easy to turn when it is mounted.
700047-11
Screw in mixture control screw together with the spring, washer and O-ring to
the stop.
Specification
Mixture control screw
M6x0.5
1Nm (0.7lbfft)
Unscrew mixture control screw again by the number of turns that was noted
down earlier when it was disassembled or to the specified basic setting.
Specification
Idle mixture adjusting screw
700045-11
Open
1.0turn
Info
The mixture control screw may be open by no more than 2 turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
Position buffer plate. Mount and tighten needle jet, cold start jet and
idling jet.
Specification
Needle jet
M7x0.75
3.5Nm
(2.58lbfft)
M5x0.75
2Nm (1.5lbfft)
Idling jet
M6x0.75
2Nm (1.5lbfft)
M5x0.75
2Nm (1.5lbfft)
700044-11
Position the float and float needle valve, and mount fulcrum pin.
P. 153)
31/CARBURETOR
155
Insert throttle slide with throttle slide roller and the throttle slide plate into
throttle slide arm and position them in the carburetor.
700067-10
Specification
Needle position (450 XC ATV)
Jet needle(OBEKR)
700037-12
M8
3.5Nm
(2.58lbfft)
M4
2Nm
(1.5lbfft)
Loctite 243
600444-11
Position the throttle slide cover with the seal. Mount and tighten screws.
Specification
Other screws, carburetor
M4
2Nm (1.5lbfft)
P. 153)
700035-12
P. 149)
Info
The label on the membrane must be visible when mounted.
700060-10
700059-10
Position seal ring in the accelerator pump cover with the rounded side facing
outward.
31/CARBURETOR
156
M4
2Nm (1.5lbfft)
700038-12
Position the hose holder. Mount the screws and tighten all screws in a crisscross
pattern.
Specification
Other screws, carburetor
M4
2Nm (1.5lbfft)
Set the carburetor on the frame and attach the gas Bowden cable.
P. 152)
P. 156)
700034-12
Info
Ensure that the gas Bowden cable has been laid correctly.
600163-11
600162-11
600161-11
600160-11
M5
5Nm (3.7lbfft)
31/CARBURETOR
157
Info
Ensure that the engine breather hose has been laid correctly.
600159-11
Lay the engine breather hose toward the bottom and secure with a retaining
bracket. Mount and tighten screw.
600158-11
Specification
Screw, vent hose bracket
M6
10Nm
(7.4lbfft)
Loctite 243
Install the air filter box lid and the carburetor connection boot. (
Screw in the idle adjusting screw until it stops and then to the prescribed basic
setting.
P. 51)
P. 54)
P. 16)
600442-11
Specification
Idle mixture adjusting screw
Open
1.0turn
P. 209)
600145-10
Warm-up time
5min
1,500 1,600rpm
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.
Turn the idle adjusting screw slowly until the idle speed begins to fall.
Note the position and turn the idle adjusting screw slowly counterclockwise until
the idle speed falls.
31/CARBURETOR
158
Adjust to the point between these two positions with the highest idle speed.
Info
If there is a big engine speed rise, reduce the idle speed to a normal level
and repeat the above steps.
The extremely sporty rider will set the mixture about 1/4 of a turn back from
this ideal value (leaner, in a clockwise direction) since the engine becomes
hotter in sporting use.
If the procedure described here does not lead to satisfactory results, the
cause may be a wrongly dimensioned idling jet.
If you can turn the idle adjusting screw to the end without any change of
engine speed, you have to fit a smaller idling jet.
The idle adjusting screw must not be opened more than two turns. If more
than two turns are necessary (rich mixture), use a larger idling jet.
After changing the idling jet, start from the beginning with the adjusting
steps.
1,500 1,600rpm
Info
Following extreme air temperature or altitude changes, adjust the idle speed
again.
P. 53)
600401-10
P. 215)
Connect the positive cable of the multimeter to the yellow cable and the ground
wire to the black cable of the special tool. Measure the throttle valve sensor voltage.
Variable throttle valve sensor
voltageVvar (throttle slide closed)
600403-10
P. 157)
P. 152)
0.505 0.855V
P. 215)
P. 54)
31/CARBURETOR
159
Danger
Fire hazardFuel can easily catch fire.
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 fuel immediately.
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See specifications on filling up with fuel.
Warning
Danger of poisoningFuel 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 doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Warning
Environmental hazardImproper handling of fuel is a danger to the environment.
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Info
Carry out this work with a cold engine.
Guide the hose coming down behind the engine into a suitable container.
P. 55)
Info
Water in the float chamber results in malfunctioning.
100051-10
Undo the screw (turn it counterclockwise) a few turns and drain the fuel from
the float chamber.
Tighten screw.
32/CLUTCH
160
32/CLUTCH
22
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.
Remove screws.
100037-10
4mm (0.16in)
P. 204)
Check parts for damage and wear. Replace damaged or worn parts.
Position the cover with the membrane. Mount and tighten screws.
33/TRANSMISSION
161
33/TRANSMISSION
23
23.1
Press the rear brake and remove screw with spring washer.
Pull engine sprocket with chain off of the countershaft. Remove the engine
sprocket.
With the collar facing the engine, mount engine sprocket in the chain and
slide both onto the countershaft.
Press the rear brake. Mount and tighten screw with spring washer.
600164-10
600165-10
Specification
Screw, engine sprocket
M10
60Nm
(44.3lbfft)
Loctite 243
600165-11
600164-11
M6
10Nm (7.4lbfft)
M8
25Nm
(18.4lbfft)
162
24.1
Warning
Danger of scaldingThe coolant gets very hot and is under high pressure when the vehicle is driven.
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningCoolants 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
contact 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. Keep coolants out of the reach of children.
P. 56)
Completely fill the radiator with coolant and close the radiator cap.
600123-12
600125-12
P. 204)
Alternative 2
Coolant (mixed ready to use) (
P. 204)
P. 57)
Warning
Danger of scaldingThe coolant gets very hot and is under high pressure when the vehicle is driven.
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningCoolants 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
contact 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. Keep coolants out of the reach of children.
163
Condition
The radiator must be completely full.
Open the compensating tank cover and correct the coolant level.
Alternative 1
Coolant (
P. 204)
Alternative 2
600125-11
P. 204)
Draining coolant
24.3
Warning
Danger of scaldingThe coolant gets very hot and is under high pressure when the vehicle is driven.
Do not open the radiator, radiator hoses or other cooling system components when the engine is hot. Allow the engine and
cooling system to cool down. If you scald yourself, hold the affected area under cold water immediately.
Warning
Danger of poisoningCoolants 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
contact 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. Keep coolants out of the reach of children.
Remove screw.
Remove screw.
P. 56)
600118-10
600119-10
600123-11
164
Check parts for damage and wear. Replace damaged or worn parts.
600124-10
M6
10Nm (7.4lbfft)
Mount and tighten the screws and with new seal rings.
Specification
Remaining screws, chassis
M6
10Nm (7.4lbfft)
Warning
Danger of poisoningCoolants 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
contact 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. Keep coolants out of the reach of children.
Position the vehicle as shown and secure it against rolling away. The height difference must be achieved.
Specification
Height difference
0
A
50cm (19.7in)
Pull handbrake lever, push the locking pawl downwards, and release the handbrake lever. (Figure100006-10 P. 74)
The front wheels are blocked.
400360-10
1.50l (1.59qt.)
1.30l (1.37qt.)
P. 204)
600120-10
Coolant (
Coolant (
P. 204)
Open the screw to bleed the cylinder head. Tighten the screw when coolant
emerges from the opening.
Specification
Remaining screws, chassis
M6
10Nm (7.4lbfft)
Info
Ensure that the radiator is always filled with a sufficient amount of coolant.
600121-10
Open the screw to bleed the radiator. Tighten the screw when coolant
emerges from the opening.
Specification
Remaining screws, chassis
600122-10
M6
10Nm (7.4lbfft)
165
600123-10
600125-10
P. 57)
P. 162)
38/LUBRICATION SYSTEM
166
38/LUBRICATION SYSTEM
25
25.1
P. 166)
P. 167)
P. 168)
P. 168)
Warning
Danger of scaldingEngine 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 hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
Drain the engine oil only when the engine is warm.
Remove the plug screw and small oil screen with both O-rings.
Remove the plug screw and large oil screen with both O-rings.
P. 18)
600134-10
600135-10
600136-10
38/LUBRICATION SYSTEM
167
Check parts for damage and wear. Replace damaged or worn parts.
Oil the O-rings, mount them on the oil screen and using a long hexagon key
insert them until the O-ring is seated in the housing with the oil screen.
Fit the plug screw with seal ring and tighten it.
Specification
Locking screw, oil sieve, long
M20x1,5
15Nm
(11.1lbfft)
600144-10
Insert the oil screen with the O-rings into the plug screw and tighten.
Specification
Locking screw, oil sieve,
short
M16x1,5
10Nm
(7.4lbfft)
lubricated with
engine oil
600140-10
Fit oil drain plug with seal ring and tighten it.
Specification
Oil drain plug with magnet
M12x1,5
20Nm
(14.8lbfft)
P. 18)
600134-11
Warning
Danger of scaldingEngine 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 hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
600137-10
Remove screws and. Take off the oil filter cover with the O-ring.
38/LUBRICATION SYSTEM
168
Pull the oil filters and out of the engine housing.
Circlip pliers reverse (51012011000)
Check parts for damage and wear. Replace damaged or worn parts.
Fill the oil filters and with engine oil and place in the oil filter container.
Oil the O-rings of the oil filter covers and mount them with the oil filter covers.
Mount and tighten screws and.
600138-10
600147-10
Specification
Screw, oil filter cover
M5
6Nm (4.4lbfft)
Connect the ground cable on the engine and tighten the screw.
Specification
Screw, starter engine
M6
10Nm (7.4lbfft)
600137-10
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
Remove the screw cap on the clutch cover and fill up with engine oil.
Engine oil
600132-10
2.00l (2.11qt.)
External temperature: 0C
(32F)
Engine oil
(SAE 10W/50)
( P. 203)
Engine oil
(SAE 5W/40)
( P. 203)
Danger
Danger of poisoningExhaust 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.
P. 169)
38/LUBRICATION SYSTEM
169
Info
The engine oil level can be checked on a cold or hot engine.
Condition
The engine is at operating temperature.
Info
After switching off the engine, wait one minute before checking the
level.
The engine oil reaches the middle of the viewer.
600131-10
When the engine oil does not reach the middle of the viewer:
P. 169)
Condition
Engine is cold.
When the engine oil does not reach the bottom of the viewer:
P. 169)
600131-11
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
Remove the screw cap on the clutch cover and fill up with engine oil.
Condition
External temperature: 0C (32F)
Engine oil (SAE 10W/50) (
P. 203)
Condition
External temperature: <0C (<32F)
Engine oil (SAE 5W/40) (
600132-10
P. 203)
Info
To ensure optimal engine oil performance, it is advisable to not use different
engine oils.
We recommend making an oil change in this case.
39/IGNITION SYSTEM
170
39/IGNITION SYSTEM
26
26.1
P. 53)
600408-10
black - black
0.0 1.0
Ground - black
600407-10
Disconnect the plug-in connector of the ignition pulse generator coil to the CDI
unit.
P. 53)
Pulse generator
600432-10
red - green
80 120
Ground - red
Condition
All plug connectors must be in corrosion-free condition and the plug-in connectors
must be tight-fitting.
P. 52)
Primary coil
ground - ignition coil input at:
20C (68F)
600456-10
0.25 0.35
39/IGNITION SYSTEM
171
5.0 7.5k
600434-01
Use a multimeter to check the power supply of the ignition coil. Measurement
between the positive terminal of the battery and the unplugged connector of the
ignition coil.
Battery voltage
unloaded:
600476-01
12.4 12.8V
P. 72)
700085-01
3.75 6.25k
172
Toe, checking
27.1
P. 59)
P. 59)
Specification
Standard rider weight
P. 211)
500228-01
400333-10
P. 173)
0mm (0in)
Info
The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when
driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange.
P. 173)
173
Check the chassis parts for damage, play and wear. Replace damaged or worn
parts.
P. 59)
P. 59)
Specification
Standard rider weight
P. 211)
500228-01
400333-11
Adjust the distances and to the same value by rotating the tie rods.
Adjust the distances and to the specified value by evenly rotating the tie rods.
Specification
Toe
Front
0mm (0in)
Info
The toe is the difference in length between distances and by which the wheels are spaced at the front or rear when
driving straight ahead. The distance is measured at the height of the wheel center from rim flange to rim flange.
M12x1,25
20Nm (14.8lbfft)
M12LHx1,25
20Nm (14.8lbfft)
Info
The tie rods must still be freely movable.
174
Checking/adjusting camber
27.3
Info
The left and right camber should have the same settings.
The operations are the same on the left and right.
Loosen nuts.
Check parts for damage and wear. Replace damaged or worn parts.
Insert the tool in the heim joint and clip onto the A-arm.
P. 14)
600128-10
600126-10
P. 211)
If the marking is not aligned with the top edge of the A-arm:
Turn the tool with the heim joint in steps of 180 until the marking is in
line with the top edge of the A-arm.
Position the A-arm with the bushings. Mount and tighten screws.
600127-10
Specification
Screw, A-arm top
M10x52
45Nm
(33.2lbfft)
600126-10
Align the heim joint at right angles to the screws and tighten the nut.
Specification
Nut, A-arm top
M12x1,25
30Nm
(22.1lbfft)
Info
All four heim joints must be checked and adjusted if necessary.
600128-10
P. 14)
175
Info
The left and right fork offset should have the same settings.
The operations are the same on the left and right.
Check parts for damage and wear. Replace damaged or worn parts.
Place the A-arm with the bushings in the desired position. Mount and tighten
screws.
P. 14)
Specification
Screw, A-arm top
M10x52
45Nm
(33.2lbfft)
P. 14)
600126-11
Info
The operations are the same on the left and right sides.
P. 59)
600445-10
Locking pawl moves into its basic position, parking brake is deactivated.
Remove screws. Press the brake caliper by hand on to the brake disc in order to
press back the brake piston.
Info
600446-10
Do not operate the hand brake lever when the brake caliper has been
removed.
176
Hang the brake caliper and the brake line loosely to one side.
Remove nut and take the tie rod out of the wheel carrier.
Remove nuts.
Position special tool. Press the lower ball head out of the wheel carrier.
400401-10
600447-10
600449-10
P. 212)
600450-10
600451-10
Turn and position special tool. Press the upper ball head out of the wheel carrier.
177
Info
The operations are the same on the left and right sides.
Insert the wheel carrier between the A-arms. Mount and tighten nuts.
Specification
Nut, ball head, A-arm bottom
M12x1,5
40Nm
(29.5lbfft)
M10x1,25
35Nm
(25.8lbfft)
600449-11
Insert the tie rod in the wheel carrier. Mount and tighten nut.
Specification
Nut, tie rod end
M10x1,25
45Nm
(33.2lbfft)
600447-11
400401-11
Specification
Screw, front brake caliper
600446-11
M8
20Nm
(14.8lbfft)
Loctite 243
When both Brake calipers have been mounted, activate the hand brake lever several
times until the brake linings are in contact with brake disc and there is a pressure
point.
178
Info
Note the holding lug of the brake line guide.
P. 60)
P. 172)
600445-11
Info
The operations are the same on the left and right sides.
P. 175)
Info
When removing screws, make sure that bushings remain in place.
600453-10
600454-10
Info
The operations are the same on the left and right sides.
M10x70
45Nm
(33.2lbfft)
Position the shock absorber in the lower A-arm. Mount and tighten screw.
Specification
Screw, front shock absorber
M10
45Nm
(33.2lbfft)
600454-11
Insert tool in the heim joint and clip onto the A-arm.
Camber gauge (83019014000) (
600127-10
P. 211)
If the marking is not flush with the top edge of the A-arm:
Turn tool with the heim joint in steps of 180 until the marking is in line
with the top edge of the A-arm.
Remove tool.
179
M10x52
45Nm
(33.2lbfft)
Info
The fork offset is set using the bushings.
600453-11
When the nuts on the heim joint have been released, align the heim joint at right
angles to the screws and tighten nut.
Specification
Nut, A-arm top
M12x1,25
P. 177)
600128-11
Info
The operations are the same on the left and right sides.
P. 178)
600467-10
600468-10
600469-01
P. 212)
P. 212)
P. 212)
30Nm
(22.1lbfft)
180
Info
When mounting the lock ring, do not damage the rubber boot.
600467-10
Loosen nuts. Remove heim joint. Screw the nuts off of the heim joints.
Screw the nuts on the new heim joints. Mount the heim joints.
Insert the tool in the heim joint and clip onto the A-arm.
600470-10
600471-10
P. 211)
Align marking with the upper edge of the A-arm by rotating the heim joint.
Info
Nuts are tightened when the A-arm is installed.
600472-10
Info
The operations are the same on the left and right sides.
P. 178)
P. 178)
181
6
7
600457-01
Info
The spacing washers are only installed at the front pivot point.
Press out needle bearing using the thin long side of the special tool.
Press mandrel (83019020170) (
P. 212)
P. 212)
Press in a new needle bearing on all pivot points using the thick end of the special
tool.
600458-01
P. 212)
Info
The needle bearing cannot be pushed through from one side.
600459-01
Install the new shaft seal rings. Lightly grease the sealing lips of the shaft seal
rings.
182
600464-10
P. 212)
600465-10
P. 212)
P. 212)
600466-01
Info
When mounting the lock ring, do not damage the rubber boot.
600464-10
P. 178)
183
Design
448cm (27.34cuin)
510cm (31.12cuin)
Stroke
72mm (2.83in)
89mm (3.5in)
95mm (3.74in)
Compression ratio
11:1
Idle speed
1,500 1,600rpm
Control
35mm (1.38in)
30mm (1.18in)
Crankshaft bearing
Conrod bearing
Needle bearing
Bronze bush
Piston rings
Engine lubrication
Primary transmission
Clutch
Transmission ratio
1st gear
14:35
2nd gear
17:33
3rd gear
19:30
4th gear
21:28
5th gear
23:26
Reverse gear
14:19:34
Generator
12V, 200W
Ignition
Contactless controlled fully electronic ignition with digital ignition adjustment, type Kokusan
Spark plug
NGK DCPR8E
0.6mm (0.024in)
Cooling
Starting aid
Electric starter
Engine oil
2.00l (2.11qt.)
External temperature: 0C
(32F)
184
Capacity - coolant
28.2
Coolant
With compensating tank
1.50l (1.59qt.)
Coolant (
P. 204)
1.30l (1.37qt.)
Coolant (
P. 204)
P. 204)
P. 204)
Valves
Sealing seat width, intake
1.50mm (0.0591in)
2.00mm (0.0787in)
0.05mm (0.002in)
Valve springs
Minimum length of outside spring
39.20mm (1.5433in)
36.45mm (1.435in)
0.10mm (0.0039in)
Size II
Size II
Diameter size II
Diameter size II
Size II
Wear limit
0.120mm (0.00472in)
Size II
Wear limit
0.120mm (0.00472in)
<0.80mm (<0.0315in)
<1.00mm (<0.0394in)
0.06mm (0.0024in)
0.12mm (0.0047in)
650.05mm (2.560.002in)
1.10mm (0.0433in)
0.05mm (0.002in)
>1.90mm (>0.0748in)
23.5mm (0.925in)
0.20mm (0.0079in)
0.20mm (0.0079in)
0.15mm (0.0059in)
Shift fork
Thickness at leaf
0.06mm (0.0024in)
185
186
Loctite 243
M4
M5
2Nm (1.5lbfft)
M5
6Nm (4.4lbfft)
Loctite 243
M5
6Nm (4.4lbfft)
Loctite 243
M5
6Nm (4.4lbfft)
Loctite 243
M5
6Nm (4.4lbfft)
Loctite 243
M5
6Nm (4.4lbfft)
M5
6Nm (4.4lbfft)
Loctite 243
M5
6Nm (4.4lbfft)
Loctite 222
M5
6Nm (4.4lbfft)
M5
6Nm (4.4lbfft)
Loctite 243
M5
6Nm (4.4lbfft)
Loctite 243
M6x0,75
11Nm (8.1lbfft)
M6x0,75
4Nm (3lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
Loctite 243
M6
6Nm (4.4lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
M6
10Nm (7.4lbfft)
M6
8Nm (5.9lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
Loctite 243
M6x30
10Nm (7.4lbfft)
M6x45
10Nm (7.4lbfft)
M6x60
10Nm (7.4lbfft)
M6x65
10Nm (7.4lbfft)
M6x75
10Nm (7.4lbfft)
M6
10Nm (7.4lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
Loctite 243
M6
6Nm (4.4lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
M6
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
M6x30
10Nm (7.4lbfft)
M6x45
10Nm (7.4lbfft)
M6x50
10Nm (7.4lbfft)
M6x55 10.9
10Nm (7.4lbfft)
M6x75
10Nm (7.4lbfft)
M6
10Nm (7.4lbfft)
M6
10Nm (7.4lbfft)
M6
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
M8
10Nm (7.4lbfft)
M8
28Nm (20.7lbfft)
Loctite 243
M10
60Nm (44.3lbfft)
Loctite 243
M10
Step 1
40Nm (29.5lbfft)
Step 2
50Nm (36.9lbfft)
187
M12x1
60Nm (44.3lbfft)
Spark plug
M12x1,25
17Nm (12.5lbfft)
M12x1,5
M12x1,5
20Nm (14.8lbfft)
M12x1.5
20Nm (14.8lbfft)
M16x1,5
10Nm (7.4lbfft)
M18x1,5
120Nm (88.5lbfft)
Loctite 243
M20LHx1,5
150Nm (110.6lbfft)
Loctite 243
M20x1,5
M20x1,5
Loctite 243
Loctite 577
15Nm (11.1lbfft)
188
450/525XCATV
31.1
Carburetor type
KEIHIN FCR-MX 39
3925H
1.0turn
2.15mm (0.0846in)
Main jet
170
Jet needle
OBEKR
40
42
200
100
85
Throttle slide
15
189
M4
2Nm (1.5lbfft)
Loctite 243
M4
2Nm (1.5lbfft)
Loctite 243
M4
2Nm (1.5lbfft)
M4,5x0.75
2Nm (1.5lbfft)
Main jet
M5x0.75
2Nm (1.5lbfft)
M5x0.75
2Nm (1.5lbfft)
M5
3.5Nm (2.58lbfft)
M5
5Nm (3.7lbfft)
Idling jet
M6x0.75
2Nm (1.5lbfft)
Needle jet
M7x0.75
3.5Nm (2.58lbfft)
Needle screw
M8
3.5Nm (2.58lbfft)
Choke slide
M12
2.5Nm (1.84lbfft)
M12
2.5Nm (1.84lbfft)
190
Frame
Wheel suspension
Front
Rear
Rigid axle
Suspension travel
Front
257mm (10.12in)
Rear
265mm (10.43in)
Fork offset
Front
46mm (1.81in)
Front
0mm (0in)
Toe
Camber
Front
Toe width
Front
1,115mm (43.9in)
Rear
1,148mm (45.2in)
Wheelbase
1,28010mm (50.390.39in)
Turning radius
5,625mm (221.46in)
Fording depth
330mm (12.99in)
820mm (32.28in)
290mm (11.42in)
Weight
fuel tank empty
163kg (359lb.)
173kg (381lb.)
144kg (317lb.)
Rear
149kg (328lb.)
293kg (646lb.)
Vehicle length
1,810mm (71.26in)
Vehicle width
1,148mm (45.2in)
Vehicle height
1,125mm (44.29in)
Brake system
Front
Rear
180mm (7.09in)
Rear
200mm (7.87in)
3.5mm (0.138in)
Rear
3.5mm (0.138in)
0.3bar (4psi)
Rim
Front
5x10"DWTAl 6061
Rear
8x9"DWTAl6601
14:38
Chain
5/8 x 1/4"
4Ah battery
YTX5L-BS
191
Lighting equipment
33.1
Headlight
BA20d
12V
35/35W
Parking light
W2,1x9,5d
12V
5W
Indicator lights
W2x4,6d
12V
1.2W
LED
Tires
33.2
Front tire
Rear tire
21x7.00-10
MAXXIS RazrM931
20x11.00-9
MAXXIS RazrM932
Capacity - fuel
33.3
Tank capacity
Fuel reserve
13.4l (3.54USgal)
P. 204)
36PRC
Setting number
KT 7702
Compression damping
Standard
14clicks
5 5clicks
Rebound damping
Standard
20clicks
5 5clicks
Cross over
171.5mm (0.670.059in)
5mm (0.2in)
Spring preload
5mm (0.2in)
30N/mm (171lb/in)
275mm (10.83in)
60mm (2.36in)
Fitted length
463mm (18.23in)
192
46PRCQ
Setting number
KT 7710
Compression damping
Standard
15clicks
5 5clicks
Rebound damping
Standard
15clicks
5 5clicks
Spring preload
Standard
3mm (0.12in)
Spring rate
62N/mm (354lb/in)
Spring length
250mm (9.84in)
Fitted length
457mm (17.99in)
193
194
M6
15Nm (11.1lbfft)
M6
10Nm (7.4lbfft)
M6
6Nm (4.4lbfft)
M6
10Nm (7.4lbfft)
Loctite 243
M6
7Nm (5.2lbfft)
Loctite 243
M6
10Nm (7.4lbfft)
M8
30Nm (22.1lbfft)
M8
25Nm (18.4lbfft)
M8
25Nm (18.4lbfft)
Loctite 243
M8
25Nm (18.4lbfft)
Loctite 243
M8
20Nm (14.8lbfft)
Loctite 243
M8
20Nm (14.8lbfft)
Loctite 243
M8
25Nm (18.4lbfft)
M8
20Nm (14.8lbfft)
M8
20Nm (14.8lbfft)
Screw, subframe
M8
35Nm (25.8lbfft)
Loctite 243
M8
20Nm (14.8lbfft)
M10x1,25
35Nm (25.8lbfft)
M10x1,25
45Nm (33.2lbfft)
Loctite 243
M10x1,25
45Nm (33.2lbfft)
Wheel nut
M10x1,25
45Nm (33.2lbfft)
M10
45Nm (33.2lbfft)
M10
50Nm (36.9lbfft)
M10
45Nm (33.2lbfft)
M10
60Nm (44.3lbfft)
M10x52
45Nm (33.2lbfft)
M10x70
45Nm (33.2lbfft)
M10
45Nm (33.2lbfft)
Screw, footrest
M10
45Nm (33.2lbfft)
M10
25Nm (18.4lbfft)
M10
60Nm (44.3lbfft)
M12x1,25
30Nm (22.1lbfft)
M12x1,25
20Nm (14.8lbfft)
M12LHx1,25
20Nm (14.8lbfft)
M12x1,5
40Nm (29.5lbfft)
M12
70Nm (51.6lbfft)
M12
60Nm (44.3lbfft)
M12
70Nm (51.6lbfft)
M16x1,5
100Nm (73.8lbfft)
M18x1,5
130Nm (95.9lbfft)
M20x1,5
25Nm (18.4lbfft)
M20x1,5
40Nm (29.5lbfft)
2"-10UNS-2B-LH
25Nm (18.4lbfft)
CLEANING
195
CLEANING
37
37.1
Note
Material damageDamage 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 hazardProblem materials cause environmental damage.
Dispose of oil, grease, filters, fuel, cleaning substances, brake fluid, batteries, etc. according to regulations.
Info
If you clean the vehicle regularly, its value and appearance are maintained over a long period.
Avoid direct sunshine on the vehicle during cleaning.
Info
Do not place the vehicle onto the rear frame bracket to clean it since it could fall over.
Never raise the vehicle on your own, even if a gear is engaged.
Fuel can leak out of the fuel tank.
Before you clean the vehicle, seal the exhaust system to prevent penetration by water.
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner (
P. 206)
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
After rinsing the vehicle with a gentle water spray, allow it to dry thoroughly.
P. 159)
Warning
Danger of accidentsReduced braking due to wet or dirty brakes.
After cleaning, ride the vehicle a short distance until the engine warms up, and then apply the brakes.
Info
The heat produced causes water at inaccessible positions in the engine and the brakes to evaporate.
Push back the protection covers on the handlebar instruments to allow water to evaporate.
After the vehicle has cooled off, oil or grease all moving parts and bearings.
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials.
P. 61)
P. 206)
P. 206)
To prevent electrical problems, treat electric contacts and switches with contact spray.
Contact spray (
P. 206)
STORAGE
196
STORAGE
38
Storage
38.1
Warning
Danger of poisoningFuel 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 doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according
to regulations and keep it out of the reach of children.
Info
If you want to store the vehicle for a longer period, take the following actions.
Info
Before storing the vehicle, check all parts for function and wear. If service, repairs or replacements are necessary, you should
do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start
of the new season.
Change the engine oil and oil filter, clean the oil screens. (
P. 195)
P. 166)
P. 162)
P. 159)
P. 59)
P. 69)
P. 70)
Specification
Storage temperature of battery without direct sunshine.
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.
Info
Avoid running the engine of a vehicle in storage for a short time only. Since the engine cannot warm up properly, the water
vapor produced during combustion condenses and causes valves and exhaust system to rust.
P. 69)
197
39.1
Engine
Change the engine oil and oil filter, clean the oil screens. (
P. 166)
S3N
S15A
S30A
Carburetor
Attachments
Check idle.
P. 162)
P. 160)
P. 50)
Check the steering column bearing for wear and smooth operation.
Check tie rods and tie rod ends for damage and play.
P. 60)
Chassis
P. 74)
P. 77)
P. 59)
P. 61)
P. 59)
P. 62)
P. 61)
198
S15A: Every 15 service hours - corresponds to about 105 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 order)
39.2
Competition use
S15A
S30A
Hobby use
S45A
S30A
S60A
J1A
J2A
S90A
Check valves.
hours
hours
hours
hours
hours
corresponds
corresponds
corresponds
corresponds
corresponds
to
to
to
to
to
about
about
about
about
about
105
210
315
420
630
liters
liters
liters
liters
liters
of
of
of
of
of
NB1A
Check the engine oil level. (
P. 169)
P. 61)
P. 62)
199
NB1A
P. 61)
P. 61)
P. 50)
P. 59)
P. 59)
P. 162)
Check all screws, nuts and hose clamps regularly for tightness.
29
40
30
42
HI
LO
-S9
-S2
C_CV/4
C_BY/4
-X4
1,2,3,4
-X3
34,19,35
-M2
M
C_BI/2
-X2
-X1
-S4
16,17,25,31,32
72
C_AV/2
24
26
-X102
-S3
C_AK/2
-X200
C_AH/2
C_CU/4
-X24
C_AT/2
C_AY/1
C_AL/2
-X23
ACC1
-S6
C_AY/1
-X22
C_AY/1
C_AY/1
-M1
ACC2
-X21
-K1
C_AT/2
C_AL/2
C_AE/4
20
A
C_AU/2
20,21,28,29,30
13
41,42
2.1
10 11 12 13 14 15 16 17 18
70
C_BK/4
C_BR/4
34,38,37
19
-X201
22
C_BC/6
22
C_AC/6
-X6
1
C_BO/2
12
2
-X300
C_EI/1
C_EH/1
-G1
5,6,7,10,8,9
38
10
44
48
57
49
56,57
C_BI/2
-S5
35
C_DG/4
28
56
36,39
-X101
C_BV/2
2.2 2.1
47,49
-X5
C_BG/3
43,44
C_AH/2
51
36
51,52
-X302
45,46
-X301
-H5
-G2
-N1
-S10
C_AU/2
C_AK/2
45
54
50
53
1
4
-L2
37
23
25
C_AR/3
68
5
15
C_EJ/2
C_EK/2
C_AM/3
14
-B1
67
55
1
C_CA/4
C_BU/18
16
2
14
23
15
-A1
69
70
17
71
4
N
71
6
11
50,48
2
46
C_CE/4
GND
-L1
69
32
58
27
27
66
33
60
31
67
68
24
66
18
41
1st
-S1
59
21
R
61
33
58
3
13
47
-S7
43
26
65
63
64
65
63
53
52
20
62
-H1
-H2
-H3
12
64
54,55
C_AK/2
11
40
18
39
C_AH/2
4
3
2
1
C_BC/4
1
2
1
-S8
low
high
pos.
-H6
-H4
60
61
62
200
WIRING DIAGRAM
WIRING DIAGRAM
40
40.1
450/525XCATV
C_AJ/3
600146-10
WIRING DIAGRAM
Components
A1
CDI controller
ACC1
ACC2
B1
G1
Battery
G2
Generator
H1
H2
H3
H4
H5
H6
Headlight
K1
L1
Ignition coil
L2
Pulse generator
M1
Starter motor
M2
Radiator fan
N1
Voltage regulator/rectifier
S1
S2
Ignition switch
S3
S4
S5
Light switch
S6
Clutch switch
S7
S8
S9
S10
X201
Cable colors
1
green
green
green
green
white-red
white-red
white-red
white-red
white-red
10
white-red
11
red
12
yellow
13
white-black
14
yellow-red
15
black-red
16
brown
17
brown
18
yellow-red
19
brown
20
orange
21
orange
201
WIRING DIAGRAM
22
yellow
23
blue-red
24
orange
25
brown
26
yellow-green
27
black-yellow
28
orange
29
orange
30
orange
31
brown
32
brown
33
black
34
brown
35
brown
36
brown
37
brown
38
brown
39
brown
40
black-green
41
yellow-green
42
yellow-green
43
brown
44
brown
45
brown
46
brown
47
yellow
48
white
49
yellow
50
white
51
yellow
52
yellow
53
green
54
blue
55
blue
56
white-green
57
white-green
58
white-blue
59
brown
60
white
61
blue-red
62
green
63
white-red
64
white-black
65
yellow-green
66
black-yellow
67
red
68
green
69
blue
70
yellow
71
black
202
SUBSTANCES
203
SUBSTANCES
41
Specification
Only use oils from hlins with the appropriate properties (see specifications on container).
Viscosity at 40C
14.0cSt
Supplier
hlins
ShockAbsorberFluid
Long-life grease
according to
NLGI
Specification
Use only grease that complies with the specified standards (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex products.
Supplier
Motorex
LongTherm2000
SAE (
P. 216)
Specification
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
CrossPower4T
SAE (
P. 216)
Specification
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
PowerSynt4T
SUBSTANCES
204
Coolant
Specification
Use only suitable coolant (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
KTM recommends Motorex products.
Mixture ratio
Antifreeze: 25 45C (13 49F)
50% Anti-corrosion/antifreeze
50% distilled water
40C (40F)
Supplier
Motorex
AntiFreeze
AUXILIARY SUBSTANCES
AUXILIARY SUBSTANCES
42
Lubricant (T158)
Specification
KTM recommends Lubcon products.
Supplier
Lubcon
TurmogreasePP300
Lubricant (T625)
Specification
KTM recommends Molykote products.
Supplier
Molykote
33Medium
Chain cleaner
Specification
KTM recommendsMotorex products.
Supplier
Motorex
ChainClean611
Long-life grease
Specification
KTM recommendsMotorex products.
Supplier
Motorex
LongTherm2000
Carburetor cleaner
Specification
KTM recommends Motorex products.
Supplier
Motorex
Carburetor
205
AUXILIARY SUBSTANCES
Motorcycle cleaner
Specification
KTM recommendsMotorex products.
Supplier
Motorex
MotoClean900
Contact spray
Specification
KTM recommendsMotorex products.
Supplier
Motorex
AccuContact
206
SPECIAL TOOLS
207
SPECIAL TOOLS
43
400035-01
Spring hooks
ART. NO.: 50305017000
400363-01
400059-01
400067-01
Extractor
ART. NO.: 58012009000
400073-01
SPECIAL TOOLS
208
Assembly ring
ART. NO.: 58012015095
Feature
95mm (3.74in)
400074-01
400082-01
Clutch holder
ART. NO.: 59029003100
400098-01
Mounting sleeve
ART. NO.: 59029005010
400095-01
400101-01
SPECIAL TOOLS
209
400102-01
400104-01
Extractor
ART. NO.: 59029033000
400105-01
400106-01
Feeler gauge
ART. NO.: 59029041100
35
30
25
20
15
12
5
10
400110-01
SPECIAL TOOLS
210
400170-01
200224-10
Hook wrench
ART. NO.: 83019002000
200225-10
500172-01
Hook wrench
ART. NO.: 83019011000
600430-01
SPECIAL TOOLS
211
Press mandrel
ART. NO.: 83019012000
600421-01
Press mandrel
ART. NO.: 83019013000
600476-01
Camber gauge
ART. NO.: 83019014000
500229-01
200424-10
Extractor
ART. NO.: 83019020000
600477-01
SPECIAL TOOLS
212
Mounting sleeve
ART. NO.: 83019020100
600461-01
Press mandrel
ART. NO.: 83019020130
600462-01
Disassembly/assembly holder
ART. NO.: 83019020150
600463-01
Press mandrel
ART. NO.: 83019020170
600460-01
Push-out tool
ART. NO.: 83019021000
600452-01
SPECIAL TOOLS
213
Mounting sleeve
ART. NO.: 83019050001
200217-10
200218-10
Disassembly/assembly tool
ART. NO.: 83019050004
200220-10
Disassembly/assembly tool
ART. NO.: 83019050005
200221-10
Disassembly fork
ART. NO.: 83019050006
200222-10
SPECIAL TOOLS
214
Mounting sleeve
ART. NO.: 83019050007
200223-10
Mounting sleeve
ART. NO.: 83019050012
200228-10
Mounting sleeve
ART. NO.: 83019050013
200229-10
Press drift
ART. NO.: 83019050014
200230-10
Press drift
ART. NO.: 83019050015
200231-10
SPECIAL TOOLS
215
Filling adapter
ART. NO.: 83019050016
200276-10
Adapter cable
ART. NO.: 83029043000
600402-01
Engine holder
ART. NO.: 83112001050
600422-01
Vacuum pump
ART. NO.: T1240S
200273-10
STANDARDS
216
STANDARDS
44
JASOT903MA
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 engines. With most motorcycles, the gearbox and the clutch are lubricated with the oil as the engine. The JASO
MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
INDEX
217
checking the choke slide . . . . . . . . . . .
checking the float needle valve . . . . . . .
checking the hot start slide . . . . . . . . .
checking the jet needle . . . . . . . . . . . .
checking the needle jet . . . . . . . . . . . .
checking/adjusting the accelerator pump
checking/adjusting the float level . . . . .
INDEX
A
A-Arm bottom
changing the bearing . . . . . . . . . . . . . . . . . . . . . . . . 180
A-arm top
changing the bearing . . . . . . . . . . . . . . . . . . . . . . . . 179
A-arms
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Air filter
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Air filter box lid with carburetor connection boot
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
B
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Battery voltage
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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.
150
151
150
150
151
149
153
Carburetor components
checking/adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 149
Chain
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Chain wear
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Charging voltage
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Closed-circuit current
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Clutch
checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . 160
Clutch lever
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 15
Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Cooling system
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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77
76
76
76
81
79
80
80
C
Camber
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Carburetor
adjusting idle . . . . . . . . .
assembling . . . . . . . . . .
disassembling . . . . . . . .
emptying the float chamber
installing . . . . . . . . . . . .
removing . . . . . . . . . . . .
....
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...
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157
153
146
159
156
145
. . . . . . . . . . . . . . . . . . . . . . . 113
E
Engine
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Engine - Work on individual parts
assembling the autodecompressor . . . . . . . . . . . . .
assembling the countershaft . . . . . . . . . . . . . . . .
assembling the main shaft . . . . . . . . . . . . . . . . . .
changing the camshaft bearing . . . . . . . . . . . . . . .
changing the conrod bearing . . . . . . . . . . . . . . . .
changing the crankshaft seal ring in the clutch cover
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
checking electric starter operation . . . . . . . . . . . .
checking the clutch . . . . . . . . . . . . . . . . . . . . . .
checking the countershaft . . . . . . . . . . . . . . . . . .
checking the crankshaft run-out on the bearing pin .
checking the free-wheel . . . . . . . . . . . . . . . . . . . .
checking the lower valve spring retainer . . . . . . . . .
checking the main shaft . . . . . . . . . . . . . . . . . . .
checking the oil pumps for wear . . . . . . . . . . . . . .
checking the piston ring end gap . . . . . . . . . . . . .
checking the piston/cylinder mounting clearance . . .
checking the rocker arm and rocker arm shafts . . . .
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104
124
121
105
110
102
109
126
118
123
111
127
108
120
115
114
115
106
INDEX
218
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116
101
110
108
108
113
114
125
112
113
103
122
119
117
127
101
109
102
112
118
110
127
101
107
100
136
135
144
128
133
142
144
128
132
132
134
139
138
138
129
139
139
143
136
137
143
141
131
137
135
129
140
129
144
129
140
136
140
143
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131
131
135
128
136
136
143
140
144
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87
91
87
99
94
88
88
99
95
95
94
97
91
92
90
96
87
93
90
93
89
96
91
92
98
90
88
90
98
91
90
87
96
96
94
99
94
97
Engine guard
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine oil
changing .
draining .
refilling . .
topping up
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166
166
168
169
INDEX
219
Engine sprocket
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Ignition curve
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
plug connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fender, rear
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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19
20
19
20
32
25
31
24
22
34
23
21
33
22
Front trim
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fuel, oils, etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuse
changing fuses of individual power-consuming components 71
changing the main fuse . . . . . . . . . . . . . . . . . . . . . . . 71
G
M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main silencer
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Manifold
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Oil screens
cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P
Parking brake
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ignition coil
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Generator
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Greasing and service table
. . . . . . . . . . . . . . . . . . . . 197-199
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
adjusting basic position . . . . . . . . . . . . . . . . . . . . . . . 74
checking free play . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Handlebar position
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hot start button
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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34
35
35
44
40
42
38
37
47
37
36
46
37
INDEX
220
Wheel/wheels
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
shock absorber
bleeding and filling . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shock absorber
setting number, front . . . . . . . . . . . . . . . . . . . . . . . . 12
setting number, rear . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spare parts, accessories
.......................... 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
T
Technical data
carburetor . . . . . . . . . . . . .
carburetor tightening torques
chassis . . . . . . . . . . . . . . .
chassis tightening torques . .
engine . . . . . . . . . . . . . . .
engine - tolerance, wear limits
engine tightening torques . .
front shock absorber . . . . . .
rear shock absorber . . . . . . .
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. . . . 188
. . . . 189
. 190-191
. . . . 194
. 183-184
. . . . 185
. 186-187
. . . . 192
. . . . 193
*3206058en*
3206058en
12/2007
Photo Mitterbauer
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com