KTM 65 SX 2022 Owner Manual
โฆษณา
โฆษณา
OWNER'S MANUAL 2022
65 SX
Art. no. 3214407en
DEAR KTM CUSTOMER
DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports vehicle that will continue to give you and your child pleasure for a long time if you maintain it properly.
We hope your child has many safe and enjoyable rides!
Enter the serial numbers of your vehicle below.
Vehicle identification number ( p. 13)
Dealer's stamp
The Owner's Manual contained the latest information for this model series at the time of publication. However, minor differences due to further developments in design cannot be ruled out completely.
All specifications contained herein are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2021 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard.
Issued by: TÜV Management Service
KTM Sportmotorcycle GmbH
Stallhofnerstraße 3
5230 Mattighofen, Austria
This document is valid for the following models:
65 SX (F6001V6)
*3214407en*
3214407en
03/2021
TABLE OF CONTENTS
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ...................... 5
Symbols used .................................... 5
Formats used..................................... 5
2 SAFETY ADVICE............................................ 6
Use definition – intended use.............. 6
Misuse.............................................. 6
Safety advice..................................... 6
Degrees of risk and symbols ................ 6
Tampering warning............................. 7
Safe operation ................................... 7
Protective clothing ............................. 8
Work rules......................................... 8
Environment...................................... 8
Owner's Manual ................................. 8
3 IMPORTANT NOTES.................................... 10
Manufacturer warranty, implied warranty.......................................... 10
Fuel, auxiliary substances ................. 10
Spare parts, accessories ................... 10
Service ........................................... 10
Figures ........................................... 10
Customer service.............................. 10
4 VIEW OF VEHICLE ...................................... 11
View of vehicle, front left (example) ... 11
(example)........................................ 12
5 SERIAL NUMBERS ..................................... 13
Vehicle identification number............ 13
Type label ....................................... 13
Engine number ................................ 13
Fork article number.......................... 13
Shock absorber article number .......... 14
6 CONTROLS................................................. 15
Clutch lever..................................... 15
Hand brake lever.............................. 15
Throttle grip .................................... 15
Stop button ..................................... 15
Opening the fuel tank filler cap ......... 16
Closing the fuel tank filler cap........... 16
Fuel tap .......................................... 17
Choke ............................................. 17
Shift lever ....................................... 17
Kick starter lever.............................. 18
Foot brake lever ............................... 18
Plug-in stand................................... 18
Service hour counter ........................ 18
7 PREPARING FOR USE................................. 19
Advice on preparing for first use ........ 19
Running in the engine ...................... 21
8 RIDING INSTRUCTIONS.............................. 22
Checks and maintenance measures when preparing for use ..................... 22
Starting the vehicle .......................... 22
Starting off...................................... 23
Shifting, riding ................................ 23
Applying the brakes.......................... 24
Stopping, parking............................. 24
Transporting .................................... 25
Refueling ........................................ 25
9 SERVICE SCHEDULE .................................. 27
Additional information...................... 27
Required work ................................. 27
Recommended work ......................... 28
10 TUNING THE CHASSIS ............................... 29
Checking the basic chassis setting with rider's weight............................ 29
Air suspension XACT 5235 ............... 29
Compression damping of the shock absorber.......................................... 30
Adjusting the rebound damping of the shock absorber........................... 31
Measuring the dimension of the unloaded rear wheel ......................... 32
Checking the static sag of the shock absorber.......................................... 33
Checking the riding sag of the shock absorber.......................................... 33
10.10 Adjusting the spring preload of the shock absorber ............................. 34
10.11 Adjusting the riding sag ................ 35
10.12 Checking the basic setting of the fork ................................................ 35
10.13 Adjusting the fork air pressure........... 36
10.14 Adjusting the rebound damping of the fork........................................... 37
10.15 Handlebar position........................... 37
10.16 Adjusting the handlebar position .... 38
11 SERVICE WORK ON THE CHASSIS............... 39
Raising the motorcycle with a lift stand .............................................. 39
Removing the motorcycle from the lift stand ......................................... 39
Bleeding the fork legs....................... 39
2
TABLE OF CONTENTS
Cleaning the dust boots of the fork legs ................................................ 40
Removing the fork protector .............. 40
Installing the fork protector............... 41
Removing the fork legs .................. 41
Installing the fork legs .................. 42
Removing the lower triple clamp .... 43
11.10 Installing the lower triple clamp ..... 44
11.11 Checking the steering head bearing play ................................................ 46
11.12 Adjusting the steering head bearing play ............................................ 46
11.13 Lubricating the steering head bearing ........................................ 47
11.14 Removing the start number plate....... 47
11.15 Installing the start number plate........ 47
11.16 Removing front fender ...................... 48
11.17 Installing front fender....................... 48
11.18 Removing the shock absorber ........ 49
11.19 Installing the shock absorber ......... 49
11.20 Removing the seat ........................... 49
11.21 Mounting the seat ............................ 50
11.22 Removing the air filter .................. 50
11.23 Installing the air filter ................... 51
11.24 Cleaning the air filter and air filter box ............................................. 51
11.25 Removing the main silencer .............. 52
11.26 Installing the main silencer............... 52
11.27 Changing the glass fiber yarn filling of the main silencer ...................... 53
11.28 Removing the fuel tank ................. 53
11.29 Installing the fuel tank .................. 55
11.30 Checking the chain for dirt................ 56
11.31 Cleaning the chain ........................... 56
11.32 Checking the chain tension ............... 57
11.33 Adjusting the chain tension............... 58
11.34 Checking the chain, rear sprocket, engine sprocket, and chain guide ...... 58
11.35 Checking the frame ...................... 61
11.36 Checking the link fork ................... 61
11.37 Checking the throttle cable routing .... 61
11.38 Checking the rubber grip .................. 62
11.39 Additionally securing the rubber grip ................................................ 62
11.40 Adjusting the basic position of the clutch lever ..................................... 62
11.41 Checking the fluid level of the hydraulic clutch............................... 62
11.42 Correcting the fluid level of the hydraulic clutch............................... 63
11.43 Changing the hydraulic clutch fluid ............................................ 64
12 BRAKE SYSTEM ......................................... 66
Checking the free travel of the hand brake lever ...................................... 66
Adjusting the basic position of the hand brake lever .............................. 66
Checking the brake discs .................. 66
Checking the front brake fluid level ... 67
Adding front brake fluid ................ 68
Checking the front brake linings ........ 69
Changing the brake linings of the front brake ................................... 69
Checking the free travel of the foot brake lever ...................................... 72
Adjusting the free travel of the foot brake lever ................................... 72
12.10 Adjusting the basic position of the foot brake lever ............................ 73
12.11 Checking the rear brake fluid level..... 73
12.12 Adding rear brake fluid ................. 74
12.13 Checking the rear brake linings ......... 75
12.14 Changing the rear brake linings ...... 76
13 WHEELS, TIRES ......................................... 79
Removing the front wheel .............. 79
Installing the front wheel .............. 79
Removing the rear wheel ............... 80
Installing the rear wheel ................ 81
Checking the tire condition ............... 82
Checking tire pressure ...................... 83
Checking spoke tension .................... 84
14 COOLING SYSTEM ...................................... 85
Cooling system ................................ 85
Checking the antifreeze and coolant level ............................................... 85
Checking the coolant level ................ 86
Draining the coolant ..................... 86
Refilling with coolant .................... 87
Changing the coolant .................... 88
15 TUNING THE ENGINE................................. 90
Checking the play in the throttle cable .............................................. 90
Adjusting the play in the throttle cable ........................................... 90
Carburettor – idle speed.................... 91
Carburetor – adjusting the idle speed .......................................... 91
Emptying the carburetor float chamber ...................................... 92
16 SERVICE WORK ON THE ENGINE ................ 94
Checking the gear oil level ................ 94
Changing the gear oil .................... 94
Adding the gear oil ....................... 95
3
TABLE OF CONTENTS
17 CLEANING, CARE ....................................... 97
Cleaning the motorcycle ................... 97
18 STORAGE................................................... 99
Storage ........................................... 99
Preparing for use after storage......... 100
19 TROUBLESHOOTING ................................ 101
20 TECHNICAL DATA..................................... 103
Engine .......................................... 103
Engine tightening torques ............... 103
Carburetor ..................................... 105
Carburetor tuning....................... 105
Capacities ..................................... 106
Gear oil..................................... 106
Coolant ..................................... 106
Fuel ......................................... 106
Fork.............................................. 106
Shock absorber .............................. 106
Chassis ......................................... 107
Tires ............................................. 108
Chassis tightening torques .............. 108
21 SUBSTANCES .......................................... 110
22 AUXILIARY SUBSTANCES ......................... 112
23 STANDARDS ............................................ 114
24 LIST OF ABBREVIATIONS.......................... 115
INDEX ............................................................. 117
4
MEANS OF REPRESENTATION 1
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g., of a work step or a function).
Indicates an unexpected reaction (e.g., of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of the safety of your child, have these jobs performed in an authorized KTM workshop. Your motorcycle will be optimally cared for there by specially trained experts using the special tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Indicates the end of an activity, including potential reworking.
Indicates a voltage measurement.
Indicates a current measurement.
1.2
Formats used
The typographical formats used in this document are explained below.
Proprietary name Indicates a proprietary name.
Name ®
Brand™
Underlined terms
Indicates a protected name.
Indicates a brand available on the open market.
Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.
5
2 SAFETY ADVICE
2.1
Use definition
–
intended use
This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.
Info
Only operate this vehicle in closed-off areas remote from public road traffic.
2.2
Misuse
The vehicle must only be used as intended.
Dangers can arise for people, property and the environment through use not as intended.
Any use of the vehicle beyond the intended and defined use constitutes misuse.
Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.
2.3
Safety advice
A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.
2.4
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Note
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
6
SAFETY ADVICE 2
2.5
Tampering warning
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:
1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
1 Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.
2 Removal or puncturing of parts of the intake system.
3 Lack of proper maintenance.
4 Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.
2.6
Safe operation
Danger
Danger of accidents A rider who is not fit to ride poses a danger to him or herself and others.
– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.
– Do not operate the vehicle if you are physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner.
The vehicle should only be used by trained persons.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
7
2 SAFETY ADVICE
2.7
Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.
– Alway use protective clothing for your child that is in good condition and meets the legal requirements.
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing suitable protective clothing.
2.8
Work rules
Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).
Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000)
During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers).
In the case of certain screws, a screw adhesive (e.g.
Loctite ® ) is required. Observe the manufacturer's instructions.
If thread locker (e.g., Precote ® ) has already been applied to a new part, do not apply any additional thread locker.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After completing a repair or service work, check the operating safety of the vehicle.
2.9
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2.10
Owner's Manual
It is important that you read this Owner's Manual carefully and completely before your child makes his or her first trip. The Owner's Manual contains useful information and many tips for you and your child on how to operate, handle, and service your motorcycle. This is the only way for you to find out how to ideally tune the vehicle and how to protect your child from injury.
Tip
Store the Owner's Manual on your terminal device, for example, so that you can read it whenever you need to.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle. If the vehicle is sold, the Owner's Manual must be downloaded again by the new owner.
The Owner's Manual can be downloaded several times using the QR code or the link on the delivery certificate.
8
SAFETY ADVICE 2
The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website. A printed copy can also be ordered from your authorized KTM dealer.
International KTM Website: KTM.com
9
3 IMPORTANT NOTES
3.1
Manufacturer warranty, implied warranty
The work prescribed in the service schedule must only be carried out in an authorized KTM workshop and confirmed in the KTM Dealer.net
, as otherwise all warranty claims will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the manufacturer warranty.
3.2
Fuel, auxiliary substances
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: KTM.com
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. An incorrect suspension setting can lead to damage and breakage of chassis components.
Use of the vehicle under difficult conditions, such as on sand or on wet, dusty and muddy surfaces, can result in significantly increased wear of components, such as the drive train, brake system, air filter or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.
The relevant mileage or time interval is whichever occurs first.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: KTM.com
10
4.1
View of vehicle, front left (example)
VIEW OF VEHICLE 4
1
2 Valve for fork airpump
3
4 Quick release for seat lock
5 Shock absorber rebound adjuster
6
7
8
V02015-10
11
4 VIEW OF VEHICLE
4.2
View of vehicle, rear right (example)
1 Fuel tank filler cap
2
3 Fork rebound adjustment
4
5
Vehicle identification number ( p. 13)
6
7
8 Shock absorber compression adjuster
9 Level viewer for brake fluid, rear
V02000-10
12
SERIAL NUMBERS 5
5.1
Vehicle identification number
The vehicle identification number of the steering head.
1 is stamped on the right side
5.2
Type label
401945-10
The type label 1 is located on the front frame tube.
5.3
Engine number
402154-10
The engine number 1 is located on the left side of the engine under the engine sprocket.
5.4
Fork article number
401949-10
The fork article number clamp.
1 is stamped on the outside of the axle
401947-10
13
5 SERIAL NUMBERS
5.5
Shock absorber article number
The shock absorber article number 1 is stamped on the top of the shock absorber above the adjusting ring towards the left-hand side.
H01141-10
14
6.1
Clutch lever
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
CONTROLS 6
6.2
Hand brake lever
S02397-10
Hand brake lever 1 is fitted on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
6.3
Throttle grip
F03098-10
Throttle grip 1 is fitted on the right side of the handlebar.
6.4
Stop button
F03098-11
S02397-11
The stop button 1 is fitted on the left side of the handlebar.
Possible states
• The stop button is in the basic position – In this position, the ignition circuit is closed and the engine can be started.
• Stop button pressed – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.
15
6 CONTROLS
6.5
Opening the fuel tank filler cap
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
– Press release button 1 clockwise, and lift it off.
, turn the fuel tank filler cap counter-
6.6
V00189-10
Closing the fuel tank filler cap
– Mount the fuel tank filler cap and turn it clockwise until release button 1 engages.
Info
Route fuel tank breather hose 2 without kinks.
V00190-10
16
CONTROLS 6
6.7
Fuel tap
6.8
Choke
6.9
Shift lever
Fuel tap 1 is on the left of the fuel tank.
Possible states
• Fuel tap is closed – The knurled screw is turned all the way clockwise. Fuel cannot flow out of the fuel tank.
• Fuel tap is open – The knurled screw is turned all the way counterclockwise. Fuel can flow out of the fuel tank.
V00191-10
V00192-10
Choke lever 1 is fitted on the left side of the carburetor.
Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel. This results in a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated – The choke lever is pushed down all the way to the stop.
• Choke function deactivated – The choke lever is pushed up all the way to the stop.
Shift lever 1 is mounted on the left of the engine.
401950-10
The gear positions can be seen in the figure.
The neutral or idle position N is between the first and second gear.
401950-11
17
6 CONTROLS
6.10
Kick starter lever
Kick starter lever 1 is fitted on the right side of the engine.
The kick starter lever can be swiveled.
Info
Before riding, swing the kick starter lever inwards towards the engine.
6.11
Foot brake lever
401954-10
Foot brake lever 1 is located in front of the right footrest.
The rear brake is engaged with the foot brake lever.
401956-10
6.12
Plug-in stand
The fixture for plug-in stand 1 is located on the frame on the left side of the vehicle.
The plug-in stand is used to park the motorcycle.
Info
Remove the plug-in stand before riding.
6.13
Service hour counter
402581-10
V00490-10
The service hour counter 1 is fitted on the right side of the frame.
It shows the total number of service hours of the engine.
The service hour counter begins counting when the engine is started and stops when the engine is switched off.
Info
The value indicated by the service hour counter cannot be cleared or adjusted.
18
PREPARING FOR USE 7
7.1
Advice on preparing for first use
Warning
Danger of accidents A lack of physical and mental readiness on the part of the child poses a major risk.
Children often underestimate or fail to recognize dangerous situations.
– Your child must already be able to ride a bicycle.
– Your child must be able to put the vehicle upright independently after a fall.
– Your child must understand that regulations and instructions from you or from other guardians must be followed.
– Make it clear to your child that he or she should not, under any circumstances, operate the vehicle without supervision.
– Make it clear to your child that he or she may only drive at speeds commensurate with the child's riding abilities and the road conditions.
– Do not ask too much of your child.
Do not consider participation in competitive activities until your child's stamina, riding techniques and motivation are at the necessary levels.
– Only let your child ride on the vehicle if he or she is physically and mentally ready.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Ensure your child wears appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.
– Alway use protective clothing for your child that is in good condition and meets the legal requirements.
– When you ride a motorcycle, set an example for your child and wear suitable protective clothing.
Warning
Danger of crashing Different tire tread patterns on the front and rear wheel impair the handling characteristic.
Different tire tread patterns can make the vehicle significantly more difficult to control.
– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.
Warning
Danger of accidents An unadapted riding style constitutes a major risk.
– Ensure that your child adapts the riding speed to the road conditions and to his or her riding abilities.
Warning
Danger of accidents The vehicle is not designed to carry passengers.
– Do not ride with a passenger.
Warning
Danger of accidents The brake system fails in the event of overheating.
If the foot brake lever is not released, the brake linings drag continuously.
– Ensure that your child raises his or her foot from the foot brake lever if he or she does not want to brake.
Warning
Danger of accidents The suspension components will become damaged or destroyed if overloaded.
– Do not exceed the maximum permissible weight of the rider.
19
7 PREPARING FOR USE
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.
You will receive a delivery certificate when the vehicle is handed over.
– Carefully read the entire Owner's Manual together with your child before going for the first ride.
Info
Pay particular attention to the safety instructions and risks of injury.
Explain to your child the techniques of riding and falling, e.g. how shifting weight can influence handling characteristics.
– Familiarize your child with the controls.
–
Adjust the basic position of the clutch lever. ( p. 62)
–
Adjust the basic position of the hand brake lever. ( p. 66)
– Adjust the basic position of the foot brake lever.
– Before using the vehicle for the first time, ensure that the basic settings of the chassis are suitable for the weight of your child.
– Allow your child to become accustomed to the handling of the motorcycle on suitable terrain, preferably on a large, open meadow.
Info
To give your child a feeling for the brake system, you should push your child at first. Do not start the engine until your child is able to apply the necessary front brake pressure.
Initially, let your child ride to another person who can help your child stop and turn.
– Erect obstacles for your child to navigate around to accustom your child to handling the vehicle.
– Your child should also try to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle.
– Do not let your child ride on terrain that exceeds your child's capabilities and experience.
– Your child should hold the handlebar firmly with both hands and keep his or her feet on the footrests when riding.
– Make sure the maximum permissible weight of the rider is not exceeded.
Guideline
Maximum rider weight 50 kg (110 lb.)
–
Check the spoke tension. ( p. 84)
Info
The spoke tension must be checked after half an hour of operation.
–
20
7.2
Running in the engine
– During the running-in phase, do not exceed the specified engine performance.
Guideline
Maximum engine performance
During the first 3 operating hours
During the first 5 operating hours
< 70 %
< 100 %
– Avoid fully opening the throttle!
PREPARING FOR USE 7
21
8 RIDING INSTRUCTIONS
8.1
Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is safe to operate.
The vehicle must be in perfect technical condition when it is being operated.
H02217-01
–
Check the gear oil level. ( p. 94)
–
Check the front brake fluid level. ( p. 67)
–
Check the rear brake fluid level. ( p. 73)
–
Check the front brake linings. ( p. 69)
–
Check the rear brake linings. ( p. 75)
– Check that the brake system is functioning properly.
–
Check the coolant level. ( p. 86)
–
Check the chain for dirt. ( p. 56)
– Check the chain, rear sprocket, engine sprocket, and chain
–
Check the chain tension. ( p. 57)
–
Check the tire condition. ( p. 82)
–
–
Check the spoke tension. ( p. 84)
Info
The spoke tension must be checked regularly as incorrect spoke tension will strongly impair riding safety.
–
Clean the dust boots of the fork legs. ( p. 40)
–
– Check the air filter.
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check all screws, nuts, and hose clamps regularly for tightness.
– Check the fuel level.
8.2
Starting the vehicle
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
Note
Engine damage High revving speed with a cold engine negatively impacts the lifespan of the engine.
– Always run the engine warm at a low speed.
22
RIDING INSTRUCTIONS 8
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
The motorcycle has been out of use for more than 1 week
– Empty the carburetor float chamber.
– Turn the knurled screw on the fuel tap all the way counterclockwise.
Fuel can flow from the fuel tank to the carburetor.
– Remove the motorcycle from the stand.
– Shift the transmission into neutral.
The engine is cold
– Push down the choke lever all the way to the stop.
– Press the kick starter lever robustly through its full range.
Info
Do not open the throttle.
8.3
Starting off
Info
The plug-in stand must be removed prior to riding.
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
8.4
Shifting, riding
Warning
Danger of accidents If you change down at high engine speed, the rear wheel blocks and the engine races.
– Make it clear to your child that he or she must not change into a low gear at high engine speed.
Info
If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized
KTM workshop.
First-gear is used for starting off and for steep inclines.
– When conditions allow (incline, road situation, etc.), your child can shift into a higher gear. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.
– If the choke function was activated, deactivate it after the engine has warmed up.
– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower.
– Your child should always open the throttle only as much as the engine can handle – abruptly opening the throttle increases fuel consumption.
– To shift down, apply the brakes and close the throttle at the same time.
23
8 RIDING INSTRUCTIONS
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.
– Your child should switch off the engine if prolonged operation at idle speed or while stationary is imminent.
Guideline
≥ 2 min
– Your child should avoid frequent or extended slipping of the clutch. This heats the engine oil, the engine, and the cooling system.
– Insist that your child ride with a low rpm instead of with a high rpm and a slipping clutch.
8.5
Applying the brakes
Warning
Danger of accidents Excessively forceful application of the brakes blocks the wheels.
– Explain to your child that he or she must adapt the braking to the traffic situation and the road conditions.
Warning
Danger of accidents A spongy pressure point on the front or rear brake reduces braking efficiency.
– Check the brake system and do not allow your child to continue riding until the problem is eliminated.
(Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– On sandy, wet, or slippery surfaces, use the rear brake.
– Always finish braking before you go into a bend. Your child should change down to a lower gear appropriate to the road speed.
– Insist that your child take advantage of the braking action of the engine when riding on long downhills. To do so, shift back one or two gears, but do not overrev the engine. Your child will need to apply the brakes far less often and the brake system will not overheat.
8.6
Stopping, parking
Warning
Risk of misappropriation People who act without authorization endanger themselves and others.
– Do not leave the vehicle unattended if the engine is running.
– Protect the vehicle against access by unauthorized persons.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.
– Let the vehicle parts cool down before you perform any work on the vehicle.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
24
RIDING INSTRUCTIONS 8
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Apply the brakes on the motorcycle.
– Shift the transmission into neutral.
– Press and hold the stop button while the engine is idling until the engine stops.
– Turn the knurled screw on the fuel tap all the way clockwise.
– Park the motorcycle on firm ground.
8.7
Transporting
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
Note
Fire hazard Hot vehicle components pose a fire hazard and explosion risk.
– Do not park the vehicle near to materials which are highly flammable or explosive.
– Allow the vehicle to cool down before covering it.
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.
401475-01
8.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
25
8 RIDING INSTRUCTIONS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
400382-10
– Switch off the engine.
–
Open the fuel tank filler cap. ( p. 16)
–
Fill the fuel tank with fuel up to measurement A .
Guideline
Measurement of A 35 mm (1.38 in)
Fuel tank capacity, approx.
3.5 l (3.7 qt.) Super unleaded
(95 octane) mixed with 2-stroke engine oil (1:60)
Engine oil, 2-stroke ( p. 110)
–
Close the fuel tank filler cap. ( p. 16)
26
SERVICE SCHEDULE 9
9.1
Additional information
Any further work that results from the compulsory work or from the recommended work must be ordered separately and invoiced separately.
Different service intervals may apply in your country, depending on the local operating conditions.
Individual service intervals and scopes may change in the course of technical developments. The most up-to-date service schedule can always be found on KTM Dealer.net. Your authorized KTM dealer will be happy to advise you.
9.2
Required work
Every 80 operating hours
Every 40 operating hours
Every 20 operating hours
After 10 operating hours
Check the front brake linings. (
Check the rear brake linings. (
Check the brake discs. ( p. 66)
Check the brake lines for damage and leakage.
Change the foot brake cylinder sealing cup.
Check the rear brake fluid level. (
Check the frame.
Check the free travel of the foot brake lever. ( p. 72)
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
● ● ●
○ ● ● ●
○ ● ● ●
● ● ●
● ● ● Check the link fork.
Check the fork bearing for play.
Check the shock absorber heim joint for play.
Check the wheel bearing for play.
Check the wheel hubs.
● ● ●
● ● ●
○ ● ● ●
○ ● ● ●
● ● ●
● ● ●
○ ● ● ● Check the rim run-out.
Check the chain, rear sprocket, engine sprocket, and chain guide. (
Grease all moving parts (e.g., hand lever, chain, ...) and check for smooth operation.
Check the fluid level of the hydraulic clutch. (
Check the front brake fluid level. ( p. 67)
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
Check the free travel of the hand brake lever. ( p. 66)
Check the steering head bearing play. ( p. 46)
Change the spark plug and spark plug connector.
Change the gear oil.
○ ● ● ●
● ● ●
○ ● ●
Check the clutch.
●
● ● ●
○ ● ● ● Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.
Check the antifreeze and coolant level. ( p. 85)
○ ● ● ●
Check the cables for damage and routing without sharp bends.
○ ● ● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
○ ● ● ●
27
9 SERVICE SCHEDULE
Clean the air filter and air filter box.
Service the fork.
Perform the shock absorber service.
Final check: Check the vehicle for safe operation and take a test ride.
Make a service entry in the KTM Dealer.net
.
Change the glass fiber yarn filling of the main silencer.
Check the tightness of the easily accessible, safety-relevant screws and nuts.
Check the idle speed.
Every 80 operating hours
Every 40 operating hours
Every 20 operating hours
After 10 operating hours
○ ● ● ●
● ● ●
● ●
●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ ● ● ●
○ One-time interval
● Periodic interval
9.3
Recommended work
Change the front brake fluid.
Change the rear brake fluid.
Change the hydraulic clutch fluid.
Lubricate the steering head bearing.
every 48 months every 12 months
Every 80 operating hours
Every 40 operating hours
After 20 operating hours / Every 20 operating hours
After 10 operating hours
● ●
● ●
● ●
● ●
Service the fork.
○
Perform the shock absorber service.
Check/set the carburetor components.
Change the coolant.
Perform minor engine service. Check the cylinder and piston. Check the inlet membrane. Check the exhaust control for functioning and smooth operation.)
○
● ● ● ●
●
● ● ●
● Perform major engine service including removing and installing the engine. (Change the spring of the exhaust control. Change the piston. Change the connecting rod, conrod bearing and crank pin. Change the crankshaft bearing. Check the transmission and shift mechanism. Change all engine bearings.)
○ One-time interval
● Periodic interval
28
TUNING THE CHASSIS 10
10.1
Checking the basic chassis setting with rider's weight
Info
When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.
– For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider's weight.
– In the delivered condition, this vehicle is adjusted for an average rider's weight (with full protective clothing).
Guideline
Standard rider weight 35 … 45 kg (77 … 99 lb.)
– If the rider's weight is above or below this range, the basic setting of the suspension components must be adjusted accordingly.
– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.
401030-01
10.2
Air suspension XACT 5235
Air suspension WP XACT 5235 is used in the fork.
In this system, suspension is located in the left fork leg and damping in the right fork leg.
As fork springs are no longer required, a significant weight advantage is achieved when compared to conventional forks. The response on slightly uneven surfaces is significantly improved.
In normal driving mode, suspension is provided exclusively by an air cushion. A steel spring is located in the left fork leg as an end stop.
Info
If the fork is frequently overloaded, then the air pressure in the fork must be increased to avoid damage to the fork and frame.
The air pressure in the fork can be quickly adjusted to the rider's weight, surface conditions and the rider's preference using a fork airpump. The fork does not have to be dismantled. The time consuming mounting of harder or softer fork springs is not required.
If the air chamber loses air due to a damaged seal, the fork will still not sag. In this case the air is retained in the fork. The suspension travel is maintained as far as possible. The damping becomes harder and the riding comfort reduces.
The rebound damping can be adjusted.
The rebound adjustment is located at the upper end of the right fork leg.
29
10 TUNING THE CHASSIS
10.3
Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed compression adjuster has an effect, for example, when landing after a jump: the rear wheel suspension compresses quickly.
The low-speed compression adjuster has an effect, for example, when riding over long ground swells: the rear wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.
10.4
Adjusting the low-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed compression adjuster can be seen in slow to normal compression of the shock absorber.
F02172-10
– Turn adjusting screw 1 the last perceptible click.
clockwise with a screwdriver as far as
Info
Do not loosen fitting 2 !
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Low-speed compression damping
Comfort
Standard
Sport
18 clicks
15 clicks
12 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
30
TUNING THE CHASSIS 10
10.5
Adjusting the high-speed compression damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed compression adjuster can be seen in fast compression of the shock absorber.
F02172-11
– Turn adjusting screw wrench.
1 all the way clockwise with a socket
Info
Do not loosen fitting 2 !
– Turn counterclockwise by the number of turns corresponding to the shock absorber type.
Guideline
High-speed compression damping
Comfort
Standard
Sport
2.5 turns
2 turns
1.5 turns
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.6
Adjusting the rebound damping of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
F02173-10
– Turn adjusting screw click.
1 clockwise up to the last perceptible
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Rebound damping
Comfort
Standard
Sport
18 clicks
15 clicks
12 clicks
31
10 TUNING THE CHASSIS
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.7
Measuring the dimension of the unloaded rear wheel
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Position the sag gage in the rear axle and measure the distance to marking SAG on the rear fender.
Sag gauge (00029090000)
Pin, sag scale (00029990010)
– Note the value as dimension A .
402415-10
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
32
TUNING THE CHASSIS 10
10.8
Checking the static sag of the shock absorber
– Measure dimension A
– Hold the motorcycle upright with aid of an assistant.
– Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage.
– Note the value as dimension B .
Info
The static sag is the difference between measurements A and B .
– Check the static sag.
Static sag 30 mm (1.18 in)
» If the static sag is less or more than the specified value:
– Adjust the spring preload of the shock absorber.
402416-10
10.9
Checking the riding sag of the shock absorber
–
Measure dimension A
of rear wheel unloaded. ( p. 32)
– With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.
The rear wheel suspension levels out.
– Another person again measures the distance between the rear axle and marking SAG on the rear fender using the sag gage.
– Note the value as dimension C .
402417-10
Info
The riding sag is the difference between measurements A and C .
– Check riding sag.
Guideline
Riding sag 70 mm (2.76 in)
» If the riding sag differs from the specified measurement:
– Adjust the riding sag.
33
10 TUNING THE CHASSIS
10.10
Adjusting the spring preload of the shock absorber
Caution
Risk of injury Parts of the shock absorber will move around if the shock absorber is detached incorrectly.
The shock absorber is filled with highly compressed nitrogen.
– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)
F02171-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
– Remove the shock absorber.
– After removing the shock absorber, clean it thoroughly.
Main work
– Measure the full spring length while it is under tension and note down the value.
– Loosen retaining ring
– Turn adjusting ring sion.
1 .
2 until the spring is no longer under ten-
Combination wrench (50329080000)
Hook wrench (T106S)
Info
If the spring cannot be fully released, the spring must be removed to accurately measure the spring length.
– Measure the total spring length while the spring is not under tension.
– Tension the spring by turning adjusting ring dimension A .
2 to specified
Guideline
Spring preload 5 mm (0.2 in)
Info
The spring preload is the difference between the relaxed spring length and the tensioned spring length.
Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.
– Tighten retaining ring 1 .
Finishing work
– Install the shock absorber.
–
Remove the motorcycle from the lift stand. ( p. 39)
34
TUNING THE CHASSIS 10
10.11
Adjusting the riding sag
B00292-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
– Remove the shock absorber.
– After removing the shock absorber, clean it thoroughly.
Main work
– Choose and mount a suitable spring.
Guideline
Spring rate
Weight of rider: 35 kg
(77 lb.)
35 N/mm (200 lb/in)
Weight of rider: 40 kg
(88 lb.)
Weight of rider: 45 kg
(99 lb.)
40 N/mm (228 lb/in)
45 N/mm (257 lb/in)
Info
The spring rate is shown on the outside of the spring.
Smaller weight differences can be compensated by changing the spring preload.
Finishing work
– Install the shock absorber.
–
Remove the motorcycle from the lift stand. ( p. 39)
–
Check the static sag of the shock absorber. ( p. 33)
–
Check the riding sag of the shock absorber. ( p. 33)
–
Adjust the rebound damping of the shock absorber. ( p. 31)
10.12
Checking the basic setting of the fork
Info
For various reasons, no exact riding sag can be determined for the fork.
– Smaller differences in the rider's weight can be compensated for by the fork air pressure.
– However, if the fork frequently bottoms out (hard end stop on compression), the fork air pressure must be increased, within the specified values, to avoid damage to the fork and frame.
401000-01
35
10 TUNING THE CHASSIS
10.13
Adjusting the fork air pressure
Warning
Danger of accidents Modifications to the suspension setting may seriously alter the handling characteristic.
Extreme modifications to the suspension setting may cause a serious deterioration in the handling characteristic and overload components.
– Only make adjustments within the recommended range.
– Make sure your child rides slowly to start with after making adjustments in order that he or she can assess the new handling characteristic.
Info
Check or adjust the air pressure under the same conditions at the earliest 5 minutes after switching off the engine.
The air suspension is located in the left fork leg. The rebound damping is located in the right fork leg.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Remove protection cap 1 .
– Push together fork airpump 2 fully.
Fork airpump (79412966100)
F02177-10
Info
The fork airpump is included as part of the motorcycle's accessory pack.
– Connect the fork airpump to the left fork leg.
The fork airpump switches on automatically.
A little air escapes from the fork leg when connecting.
Info
This is due to the volume of the hose and not due to a defect in the fork airpump or the fork.
Read the accompanying KTM PowerParts instructions.
– Adjust the air pressure as specified.
Guideline
Air pressure
Gradual changing of the air pressure in steps of
3 bar (44 psi)
0.2 bar (3 psi)
Minimum air pressure
Maximum air pressure
1.4 bar (20 psi)
4 bar (58 psi)
Info
Never adjust the air pressure to a value outside the stated range.
– Disconnect the fork airpump from the left fork leg.
36
TUNING THE CHASSIS 10
When disconnecting, excess pressure will escape from the hose – the fork leg does not lose any air.
The fork pump airpump switches off automatically after
80 seconds.
– Mount the protection cap.
Info
Only mount the protection cap by hand.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
10.14
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
F02178-10
– Turn adjuster 1 clockwise all the way.
Info
Adjuster fork leg.
1 is located at the upper end of the right
– Turn counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
Comfort
Standard
Sport
15 clicks
12 clicks
10 clicks
Info
Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.
10.15
Handlebar position
C00248-10
On the upper triple clamp, there are 2 holes at a distance of each other.
A to
Hole distance A 15 mm (0.59 in)
The holes on the handlebar supports are placed at a distance of B from the center.
Hole distance B 3.5 mm (0.138 in)
The handlebar supports can be mounted in four different positions. This allows the handlebar to be mounted in the most comfortable position for the rider.
37
10 TUNING THE CHASSIS
10.16
Adjusting the handlebar position
Warning
Danger of accidents A repaired handlebar poses a safety risk.
If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.
– Change the handlebar if the handlebar is damaged or bent.
C00249-10
– Remove screws 1 . Take off the handlebar clamps. Remove the handlebar and lay it to one side.
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
– Remove screws 2 . Take off handlebar supports.
– Place handlebar supports in required position. Mount and tighten screws 2 .
Guideline
Screw, handlebar support
M10 40 Nm (29.5 lbf ft)
Loctite ® 243™
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
– Position the handlebar clamps. Mount screws evenly.
1 and tighten
Guideline
Screw, handlebar clamp
M8 20 Nm (14.8 lbf ft)
Info
Make sure the installed gaps are even.
38
SERVICE WORK ON THE CHASSIS 11
11.1
Raising the motorcycle with a lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Raise the motorcycle at the frame underneath the engine.
Lift stand (78929955100)
Neither wheel is in contact with the ground.
– Secure the motorcycle against falling over.
401942-01
11.2
Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle can roll away or fall over.
– Park the vehicle on a firm and level surface.
– Remove the motorcycle from the lift stand.
– Remove the lift stand.
–
To park the motorcycle, insert plug-in stand 1 in stand bracket on the left side of the vehicle.
into the plug-
Info
Remove the plug-in stand before riding.
402581-10
11.3
Bleeding the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
–
Release bleeder screws 1 .
Any excess pressure escapes from the interior of the fork.
– Tighten the bleeder screws.
F02179-10
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
39
11 SERVICE WORK ON THE CHASSIS
11.4
Cleaning the dust boots of the fork legs
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
–
Remove the fork protector. ( p. 40)
Main work
– Push dust boots 1 of both fork legs downward.
Info
The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumulate behind the dust boots. If this dirt is not removed, the seals rings behind can start to leak.
V00199-10
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
– Clean and oil the dust boots and inside fork tubes of both fork legs.
– Press the dust boots back into the installation position.
– Remove the excess oil.
Finishing work
–
Install the fork protector. ( p. 41)
–
Remove the motorcycle from the lift stand. ( p. 39)
11.5
Removing the fork protector
– Remove screws 1 and take off the clamp.
– Remove screws tector.
2 on the left fork leg. Take off the fork pro-
V00200-10
40
SERVICE WORK ON THE CHASSIS 11
– Remove screws tector.
3 on the right fork leg. Take off the fork pro-
V00201-10
11.6
Installing the fork protector
– Position fork protector on the right fork leg. Mount and tighten screws 1 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
V00201-11
V00200-11
– Position fork protector on left fork leg. Mount and tighten screws 2 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
– Position the brake line and the clamp. Mount and tighten screws 3 .
Guideline
Screw, brake hose bracket
EJOT 1.7 Nm
(1.25 lbf ft)
11.7
Removing the fork legs
V00227-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
– Remove the front wheel.
Main work
–
Remove screws
– Remove screws
1
2 and take off the clamp.
and take off the brake caliper.
– Allow the brake caliper and brake line to hang loosely to the side.
Info
Do not kink the brake line.
41
11 SERVICE WORK ON THE CHASSIS
– Loosen screws
– Loosen screws
3 . Remove the left fork leg.
4 . Remove the right fork leg.
11.8
F02907-10
Installing the fork legs
Main work
– Position the fork legs.
Bleeder screws 1 are positioned toward the rear.
Info
The second milled groove in the fork leg must be flush with the upper edge of the upper triple clamp.
F02179-10
F02907-11
V00227-11
– Tighten screws 2 .
Guideline
Screw, top triple clamp
– Tighten screws 3 .
Guideline
Screw, bottom triple clamp
M8
M8
20 Nm (14.8 lbf ft)
15 Nm (11.1 lbf ft)
– Position the brake caliper, and mount and tighten screws 4 .
Guideline
Screw, front brake caliper
M8 20 Nm (14.8 lbf ft)
Loctite ® 243™
– Position the brake line and the clamp. Mount and tighten screws 5 .
Guideline
Screw, brake hose bracket
EJOT 1.7 Nm
(1.25 lbf ft)
Finishing work
– Install the front wheel.
42
SERVICE WORK ON THE CHASSIS 11
11.9
Removing the lower triple clamp
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
– Remove the front wheel.
– Remove the fork legs.
–
Remove the start number plate. ( p. 47)
–
Main work
– Pull fuel tank breather
– Remove nut 2 .
1 out of the steering stem.
– Release screw 3 , take off the upper triple clamp with the handlebar and set aside.
F03101-10
Info
Cover the components to protect them against damage.
Do not kink the cables and lines.
– Remove protective ring 4 .
– Remove the lower triple clamp with the steering stem.
– Remove the upper steering head bearing.
F03102-10
43
11 SERVICE WORK ON THE CHASSIS
11.10
Installing the lower triple clamp
Main work
– Clean the bearing and sealing elements, check for damage, and grease.
High viscosity grease ( p. 112)
– Insert the lower triple clamp with the steering stem. Mount upper steering head bearing 1 .
– Check whether upper steering head seal tioned.
2 is correctly posi-
– Push on protective ring 3 .
F02885-10
– Position the upper triple clamp with the handlebar.
– Mount nut 4 , but do not tighten yet.
Guideline
Nut, steering head M20x1.5
10 Nm (7.4 lbf ft)
F03103-10
– Position the fork legs.
Bleeder screws 5 are positioned toward the rear.
Info
The upper milled groove in the fork leg must be flush with the upper edge of the upper triple clamp.
F02179-11
44
SERVICE WORK ON THE CHASSIS 11
– Tighten screws 6 .
Guideline
Screw, bottom triple clamp
M8 15 Nm (11.1 lbf ft)
F02908-10
– Tighten nut 4 .
Guideline
Nut, steering head M20x1.5
10 Nm (7.4 lbf ft)
– Position the fuel tank breather 7 in the steering stem.
F03105-10
F03106-10
V00227-12
– Tighten bolt 8 .
Guideline
Screw, steering stem M8 20 Nm (14.8 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
– Tighten screws 9 .
Guideline
Screw, top triple clamp
M8 20 Nm (14.8 lbf ft)
– Position the brake caliper, and mount and tighten screws bk .
Guideline
Screw, front brake caliper
M8 20 Nm (14.8 lbf ft)
Loctite ® 243™
– Position the brake line and the clamp. Mount and tighten screws bl .
Guideline
Screw, brake hose bracket
EJOT 1.7 Nm
(1.25 lbf ft)
Finishing work
– Check that the wiring harness, throttle cable, and brake and clutch lines can move freely and are routed correctly.
–
Install front fender. ( p. 48)
–
Install the start number plate. ( p. 47)
– Install the front wheel.
–
Check the steering head bearing play. ( p. 46)
–
Remove the motorcycle from the lift stand. ( p. 39)
45
11 SERVICE WORK ON THE CHASSIS
11.11
Checking the steering head bearing play
Warning
Danger of accidents Incorrect steering head bearing play impairs the handling characteristic and damages components.
– Correct incorrect steering head bearing play immediately. (Your authorized KTM workshop will be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the frame can become damaged over time.
H01167-01
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.
Play should not be detectable on the steering head bearing.
» If there is detectable play:
– Adjust the steering head bearing play.
– Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire steering range. There should be no detectable detent positions.
» If detent positions are detected:
– Adjust the steering head bearing play.
– Check the steering head bearing and replace if required.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
11.12
Adjusting the steering head bearing play
F02909-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Pull fuel tank breather 1 out of the steering stem.
– Loosen screws
–
Loosen screw
2
3 .
.
– Loosen and retighten nut 4 .
Guideline
Nut, steering head M20x1.5
10 Nm (7.4 lbf ft)
– Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.
– Tighten screw 3 .
46
SERVICE WORK ON THE CHASSIS 11
Guideline
Screw, steering stem M8
– Tighten screws 2 .
Guideline
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
– Position the fuel tank breather 1 in the steering stem.
Finishing work
–
Check the steering head bearing play. ( p. 46)
–
Remove the motorcycle from the lift stand. ( p. 39)
11.13
Lubricating the steering head bearing
– Remove the lower triple clamp.
– Install the lower triple clamp.
Info
The steering head bearing is cleaned and lubricated in the course of removal and installation of the lower triple clamp.
H02387-01
11.14
Removing the start number plate
– Remove screw 1 .
– Unhook the start number plate from the brake line and remove it.
F02902-10
11.15
Installing the start number plate
– Attach the start number plate to the brake line.
– Position the start number plate.
Holding lugs 1 engage in the fender.
F02911-10
47
11 SERVICE WORK ON THE CHASSIS
– Mount and tighten screw 2 .
Guideline
Start number plate screw
M6 4 Nm (3 lbf ft)
F02912-10
11.16
Removing front fender
–
Remove screws 1 . Take off the front fender.
F02913-11
11.17
Installing front fender
– Position start number plate on the fender.
The holding lugs of the start number plate engage in drill holes 1 of the fender.
F02914-10
– Position fender on the lower triple clamp, mount and tighten screws 2 .
Guideline
Screw, fender M6 6 Nm (4.4 lbf ft)
F02913-10
48
SERVICE WORK ON THE CHASSIS 11
11.18
Removing the shock absorber
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Pull brake line
–
1 out of the holder.
Remove screw 2 and lower the rear wheel with the link fork as far as possible without blocking the rear wheel. Secure the rear wheel in this position.
– Remove screw 3 , push splash protector remove the shock absorber.
4 to the side, and
V02027-10
11.19
Installing the shock absorber
V02028-10
Main work
– Push splash protector 1 to the side and position the shock absorber. Mount and tighten screw 2 .
Guideline
Screw, top shock absorber
M10 45 Nm (33.2 lbf ft)
Loctite ® 243™
– Raise the link fork, mount and tighten the shock absorber with screw 3 .
Guideline
Screw, bottom shock absorber
M10 45 Nm (33.2 lbf ft)
Loctite ® 243™
– Attach brake line 4 to the holder.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
11.20
Removing the seat
– Open quick release 1 and raise the rear of the seat.
– Pull back the seat and remove it.
H00122-10
49
11 SERVICE WORK ON THE CHASSIS
11.21
Mounting the seat
– Hook seat onto screw push it forward.
1 and lower the seat at the rear and
Holding lug 2 hooks into the fuel tank.
V00208-10
– Close quick release 3 .
H00122-11
11.22
Removing the air filter
Note
Engine damage Unfiltered intake air has a negative effect on the service life of the engine.
Dust and dirt will enter the engine without an air filter.
– Only operate the vehicle if it is equipped with an air filter.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Preparatory work
–
Main work
– Detach air filter holding bracket 1 at the bottom and swing it to one side. Remove the air filter with the air filter support.
– Remove the air filter from the air filter support.
V00209-10
50
SERVICE WORK ON THE CHASSIS 11
11.23
Installing the air filter
Main work
– Mount the clean air filter on the air filter support.
–
Grease the air filter in area A .
100818-10
– Insert both parts together, position them, and secure them using air filter holding bracket 1 .
Info
If the air filter is not mounted correctly, dust and dirt may enter the engine and result in damage.
V00209-10
Finishing work
–
11.24
Cleaning the air filter and air filter box
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Do not clean the air filter with fuel or petroleum since these substances attack the foam.
M01456-01
Preparatory work
–
– Remove the air filter.
Main work
– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.
Info
Only press the air filter to dry it, never wring it out.
– Oil the dry air filter with a high-grade air filter oil.
Oil for foam air filter ( p. 112)
– Clean the air filter box.
– Check intake flange for damage and looseness.
51
11 SERVICE WORK ON THE CHASSIS
Finishing work
– Install the air filter.
–
11.25
Removing the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
–
Remove screw 1 .
– Pull off the main silencer from the manifold at exhaust sleeve 2 .
V00210-10
11.26
Installing the main silencer
– Mount the main silencer with intake sleeve 1 .
– Position wide collar bushing bushing 3 .
2 and narrow collar
V00211-10
– Mount and tighten screw 4 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
V00210-11
52
SERVICE WORK ON THE CHASSIS 11
11.27
Changing the glass fiber yarn filling of the main silencer
Warning
Danger of burns The exhaust system gets very hot when the vehicle is driven.
– Allow the exhaust system to cool down before performing any work on the vehicle.
Info
Over time, the fibers of the glass fiber yarn filling escape and the damper "burns" out.
Not only is the noise level higher, but the performance characteristics change.
V00212-10
Preparatory work
–
Remove main silencer. ( p. 52)
Main work
– Remove screws with toothed washers cap 2 .
1 from the silencer
– Remove end cap and outer tube
– Remove glass fiber yarn filling
3 .
4 from the inner tube.
– Clean the parts that need to be reinstalled and check for damage.
– Mount the new glass fiber yarn filling on the inner tube.
– Slide the outer tube over the glass fiber yarn filling.
– Insert the end cap into the outer tube.
– Mount and tighten the screws with the toothed washers.
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
Finishing work
–
Install the main silencer. ( p. 52)
11.28
Removing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
53
11 SERVICE WORK ON THE CHASSIS
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Preparatory work
–
– Turn the knurled screw on the fuel tap all the way clockwise.
Main work
– Remove screw 1 .
F02916-10
– Remove screws 2 .
F02915-10
– Pull off fuel hose 3 .
Info
Remaining fuel may flow out of the fuel hose.
– Pull fuel tank breather out of the steering stem.
– Pull both spoilers off laterally from the radiator bracket and lift off the fuel tank.
K00216-10
54
SERVICE WORK ON THE CHASSIS 11
11.29
Installing the fuel tank
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Main work
–
Check the throttle cable routing. ( p. 61)
– Position the fuel tank and fit the two spoilers to the sides of the radiator mount.
– Make sure that no cables or throttle cables are trapped or damaged.
– Mount fuel hose 1 .
K00216-11
– Mount and tighten screws 2 .
Guideline
Screw, fuel tank spoiler on radiator
M6 6 Nm (4.4 lbf ft)
F02915-10
55
11 SERVICE WORK ON THE CHASSIS
– Mount and tighten screw 3 .
Guideline
Remaining screws, chassis
M6 10 Nm (7.4 lbf ft)
– Position the fuel tank breather in the steering stem.
F02916-11
Finishing work
–
11.30
Checking the chain for dirt
– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
–
400678-01
11.31
Cleaning the chain
Warning
Danger of accidents Lubricants on the tires reduces the road grip.
– Remove lubricants from the tires using a suitable cleaning agent.
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
56
SERVICE WORK ON THE CHASSIS 11
Main work
– Rinse off loose dirt with a soft jet of water.
– Remove old grease residue with chain cleaner.
– After drying, apply chain spray.
Off-road chain spray ( p. 112)
400725-01
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
11.32
Checking the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
V00235-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Press the chain upward at the end of the chain sliding piece and determine chain tension A .
Info
Top chain section 1 must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Chain tension 5 … 8 mm (0.2 … 0.31 in)
» If the chain tension does not meet the specification:
–
Adjust the chain tension. ( p. 58)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
57
11 SERVICE WORK ON THE CHASSIS
11.33
Adjusting the chain tension
Warning
Danger of accidents Incorrect chain tension damages components and results in accidents.
If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.
If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.
– Check the chain tension regularly.
– Set the chain tension in accordance with the specification.
V00251-10
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
–
Check the chain tension. ( p. 57)
Main work
–
Loosen nut 1 .
– Loosen nuts 2 .
– Adjust the chain tension by turning adjusting screws and right.
3 left
Guideline
Chain tension 5 … 8 mm (0.2 … 0.31 in)
Turn the adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters 4 are in the same position relative to the reference marks A . The rear wheel is then correctly aligned.
– Tighten nuts 2 .
– Make sure that chain adjusters adjusting screws 3 .
4 are fitted correctly on
– Tighten nut 1 .
Guideline
Nut, rear wheel spindle
M14x1.5
40 Nm (29.5 lbf ft)
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
11.34
Checking the chain, rear sprocket, engine sprocket, and chain guide
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
58
SERVICE WORK ON THE CHASSIS 11
400227-01
H00130-10
Main work
– Shift the transmission into neutral.
– Check the chain, rear sprocket and engine sprocket for wear.
» If the chain, rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.
Info
The engine sprocket, rear sprocket and chain should always be replaced together.
When fitting the chain joint, always make sure that the closed side of the joint faces forward
(direction of travel).
– Check the engine sprocket cover for wear.
» If the engine sprocket cover is worn through in the marked area A :
– Change the engine sprocket cover.
– Check the engine sprocket cover for tightness.
» If the engine sprocket cover is loose:
– Tighten the engine sprocket cover.
Guideline
Screw, engine sprocket cover
M6 8 Nm (5.9 lbf ft)
– Check the chain sliding guard for wear.
» If the lower edge of the chain pins is in line with, or below, the chain sliding guard:
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
Guideline
Remaining screws, chassis
M6 10 Nm
(7.4 lbf ft)
V00214-10
59
11 SERVICE WORK ON THE CHASSIS
– Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below the chain sliding piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten the chain sliding piece.
Guideline
Screw, chain sliding piece
M8 15 Nm
(11.1 lbf ft)
V00215-10
– Check the chain guide for wear.
Info
Wear can be seen on the front of the chain guide.
» If the light part of the chain guide is worn:
– Change the chain guide.
400985-01
– Check that the chain guide is firmly seated.
» If the chain guide is loose:
– Tighten the chain guide.
Guideline
Remaining screws, chassis
M6 10 Nm
(7.4 lbf ft)
H00131-01
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
60
SERVICE WORK ON THE CHASSIS 11
11.35
Checking the frame
– Check the frame for damage, cracks, and deformation.
» If the frame shows signs of damage, cracks, or deformation:
– Change the frame.
Guideline
Repairs on the frame are not permitted.
601599-01
11.36
Checking the link fork
– Check the link fork for damage, cracks, and deformation.
» If the link fork shows signs of damage, cracks, or deformation:
– Change the link fork.
Guideline
Repairs on the link fork are not permitted.
V00216-01
11.37
Checking the throttle cable routing
Warning
Danger of accidents The throttle cable may slip out of the guide if routed incorrectly.
The throttle slide will then no longer be closed and the speed can no longer be controlled.
– Make sure that the throttle cable routing and the play in throttle cable complies with the specification.
Preparatory work
–
– Turn the knurled screw on the fuel tap all the way clockwise.
– Remove the fuel tank.
Main work
– Check the throttle cable routing.
The throttle cable must be routed behind the handlebar, behind the coolant hose and on the left of the frame.
» If the throttle cable is not routed as specified:
– Correct the throttle cable routing.
V02023-01
Finishing work
– Install the fuel tank.
–
61
11 SERVICE WORK ON THE CHASSIS
11.38
Checking the rubber grip
– Check the rubber grips on the handlebar for damage, wear, and looseness.
» If a rubber grip is damaged, worn, or loose:
– Change the rubber grip.
Rubber grip adhesive (00062030051) ( p. 113)
–
Additionally secure the rubber grip. ( p. 62)
401197-01
11.39
Additionally securing the rubber grip
Preparatory work
–
Check the rubber grip. ( p. 62)
Main work
– Secure the rubber grip at two locations with the retaining wire.
Securing wire (54812016000)
Wire twister forceps (U6907854)
The twisted wire ends face away from the palms and are bent in toward the rubber grip.
401198-01
11.40
Adjusting the basic position of the clutch lever
– Adjust the basic position of the clutch lever to the size of the rider's hand using adjusting screw 1 .
S02399-10
Info
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.
11.41
Checking the fluid level of the hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch facing discs.
62
SERVICE WORK ON THE CHASSIS 11
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Check the fluid level in viewer 1 .
» If the fluid has dropped below marking viewer:
A in the level
– Correct the fluid level of the hydraulic clutch.
S02400-10
11.42
Correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
V00236-10
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
– Remove cover
1 .
2 with membrane 3 .
– Correct the fluid up to level A .
Guideline
Level A (fluid level below container rim)
4 mm (0.16 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 110)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
63
11 SERVICE WORK ON THE CHASSIS
11.43
Changing the hydraulic clutch fluid
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws 1 .
– Remove cover 2 with membrane 3 .
V00236-11
– Fill bleeding syringe 4 with the appropriate hydraulic fluid.
Syringe (50329050000)
Brake fluid DOT 4 / DOT 5.1 ( p. 110)
– On the slave cylinder, remove the bleeder screw and mount bleeding syringe 4 .
V00237-10
64
SERVICE WORK ON THE CHASSIS 11
S02401-10
– Inject the liquid into the system only until it emerges from drill hole 5 of the master cylinder without bubbles.
– Now and then, extract fluid from the master cylinder reservoir to prevent overflow.
– Remove the bleeding syringe. Mount and tighten screws bleeder screw.
– Correct the fluid level of the hydraulic clutch.
Guideline
Fluid level below container rim
4 mm (0.16 in)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
65
12 BRAKE SYSTEM
12.1
Checking the free travel of the hand brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the hand brake lever, pressure builds up on the front brake circuit.
– Set the free travel on the hand brake lever in accordance with the specification.
– Push the hand brake lever forward and check free travel A .
Free travel of hand brake lever
≥ 3 mm ( ≥ 0.12 in)
» If the free travel does not match the specification:
– Adjust the basic position of the hand brake lever.
12.2
F03098-13
Adjusting the basic position of the hand brake lever
–
Check the free travel of the hand brake lever. ( p. 66)
– Adjust the basic position of the hand brake lever using adjusting screw 1 .
F03098-12
Info
Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the hand brake 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.
12.3
Checking the brake discs
Warning
Danger of accidents Worn-out brake discs reduce the braking effect.
– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.)
66
BRAKE SYSTEM 12
400257-10
– Check the front and rear brake disc thickness at multiple points for the dimension A .
Info
Wear reduces the thickness of the brake disc around the contact surface of the brake linings.
Brake discs - wear limits front rear
2.5 mm (0.098 in)
2.5 mm (0.098 in)
» If the brake disc thickness is less than the specified value:
– Change the front brake disc.
– Change the rear brake disc.
– Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc exhibits damage, cracking, or deformation:
– Change the front brake disc.
– Change the rear brake disc.
12.4
Checking the front brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in level viewer 1 .
» If the brake fluid level has dropped below marking the level viewer:
– Add front brake fluid.
A in
F03081-10
67
12 BRAKE SYSTEM
12.5
Adding front brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized
KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
–
Check the front brake linings. ( p. 69)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
–
Take off cover
1 .
2 with membrane 3 .
F03082-10
68
BRAKE SYSTEM 12
309386-11
– Add brake fluid up to level A .
Guideline
Level A (brake fluid level below reservoir rim)
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 110)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Use water to immediately clean up any brake fluid that has overflowed or spilled.
12.6
Checking the front brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
B02059-10
– Check the brake linings for minimum thickness A .
Minimum thickness A ≥ 1 mm ( ≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the brake linings of the front brake.
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the brake linings of the front brake.
12.7
Changing the brake linings of the front brake
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
69
12 BRAKE SYSTEM
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
– Take off cover
1 .
2 with membrane 3 .
F03082-10
– Remove screw 4 and 5 .
– Press back the brake linings by slightly tilting the brake caliper laterally on the brake disc. Carefully pull the brake caliper backward from the brake disc.
– Press the brake piston back into the basic position and ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.
E00754-10
70
BRAKE SYSTEM 12
E00756-10
E00754-10
F03082-10
– Remove lock ring
– Remove screw 7 .
6 .
– Remove the brake linings.
– Clean the brake caliper.
– Position new brake linings.
Info
Always change the brake linings in pairs.
Ensure that the brake linings are correctly positioned in the holding spring.
– Mount and tighten screw
Guideline
7 .
Screw, front brake linings
M6
– Mount lock ring 6 .
10 Nm (7.4 lbf ft)
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
–
Check the brake discs. ( p. 66)
– Position the brake caliper.
– Mount screw 4 and 5 but do not tighten yet.
– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Secure the hand brake lever in the activated position.
The brake caliper straightens.
– Tighten screw 4 and 5 .
Guideline
Screw, front brake caliper
M8 20 Nm (14.8 lbf ft)
Loctite ® 243™
– Remove the locking piece of the hand brake lever.
– Correct the brake fluid level.
Guideline
Brake fluid level under top level of container
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 110)
– Position cover 2 with membrane
– Mount and tighten screws 1 .
3 .
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
71
12 BRAKE SYSTEM
12.8
Checking the free travel of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
402026-10
– Detach spring 1 .
– Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A .
Guideline
Free travel of foot brake lever 3 … 5 mm (0.12 … 0.2 in)
» If the free travel does not match the specification:
– Adjust the free travel of the hand brake lever.
– Attach spring 1 .
12.9
Adjusting the free travel of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
H00161-10
– Detach the foot brake lever spring.
– Loosen nut 1 .
– Turn push rod 2 accordingly until you have free travel A .
Guideline
Free travel of foot brake lever 3 … 5 mm (0.12 … 0.2 in)
–
Hold push rod 2 and tighten nut
– Attach the foot brake lever spring.
1 .
– Check whether the basic position of the foot brake lever is suitable for the rider.
» When the basic position of the foot brake lever needs to be adjusted:
– Adjust the basic position of the foot brake lever.
72
BRAKE SYSTEM 12
12.10
Adjusting the basic position of the foot brake lever
Warning
Danger of accidents The brake system fails in the event of overheating.
If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.
– Set the free travel on the foot brake lever in accordance with the specification.
F03115-10
– Detach spring 1 .
– Loosen nut 2 and, with push rod have maximum free travel.
3 , turn it back until you
– To adjust the basic position of the foot brake lever to individual requirements, loosen nut 4 and turn screw 5 accordingly.
Info
The range of adjustment is limited.
– Turn push rod 3 accordingly until you have free travel A necessary, adjust the basic position of the foot brake lever.
. If
Guideline
Free travel of foot brake lever 3 … 5 mm (0.12 … 0.2 in)
– Hold screw 5 and tighten nut 4 .
Guideline
Nut, foot brake lever stop
M8 20 Nm (14.8 lbf ft)
– Hold push rod 3 and tighten nut 2 .
Guideline
Remaining nuts, chassis
M6
– Attach spring 1 .
10 Nm (7.4 lbf ft)
12.11
Checking the rear brake fluid level
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated.
(Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
73
12 BRAKE SYSTEM
– Stand the vehicle upright.
– Check the brake fluid level in level viewer 1 .
» If an air bubble is visible in viewer 1
– Add rear brake fluid.
:
V00245-10
12.12
Adding rear brake fluid
Warning
Danger of accidents An insufficient brake fluid level will cause the brake system to fail.
If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.
– Check the brake system and ensure that nobody drives the vehicle before the problem is eliminated.
(Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
–
Check the rear brake linings. ( p. 75)
74
BRAKE SYSTEM 12
Main work
–
Remove screws
– Take off cover
1 .
2 with washer 3 and membrane 4 .
V00244-10
H00115-10
– Add brake fluid up to level A .
Guideline
Level A (brake fluid level below reservoir rim)
10 mm (0.39 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 110)
– Position the cover with the washer and membrane.
– Mount and tighten the screws.
Info
Clean up overflowed or spilled brake fluid immediately with water.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
12.13
Checking the rear brake linings
Warning
Danger of accidents Worn-out brake linings reduce the braking effect.
– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)
– Check the brake linings for minimum thickness A .
Minimum thickness A ≥ 1 mm ( ≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings.
– Check the brake linings for damage and cracking.
» If damage or wear is encountered:
– Change the rear brake linings.
S00885-10
75
12 BRAKE SYSTEM
12.14
Changing the rear brake linings
Warning
Skin irritation Brake fluid causes skin irritation.
– Keep brake fluid out of the reach of children.
– Wear suitable protective clothing and safety glasses.
– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.
– Consult a doctor immediately if brake fluid has been swallowed.
– Rinse the affected area with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.
– If brake fluid spills on to your clothing, change the clothing.
Warning
Danger of accidents Old brake fluid reduces the braking effect.
– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Incorrect servicing will cause the brake system to fail.
– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
–
Main work
– Remove lock ring 1 .
Remove screw 2 .
H00143-10
76
BRAKE SYSTEM 12
F02161-10
F02162-10
– Remove the brake linings.
– Remove screw 3 .
– Remove screw 4 and take off the brake caliper.
Info
Cover the components to protect them against damage.
Do not kink the brake line.
– Clean the brake caliper and the brake caliper bracket.
– Remove screws
–
Take off cover
5 .
6 with washer 7 and membrane 8 .
– Press the brake piston back to its basic position and make sure that no brake fluid overflows from the brake fluid reservoir, extract brake fluid if necessary.
– Position the brake caliper.
–
Mount and tighten screw 4 .
Guideline
Screw, rear brake caliper
M8x20 18 Nm (13.3 lbf ft)
Loctite ® 243™
– Mount and tighten screw
Guideline
3 .
Screw, rear brake caliper
M8x40 18 Nm (13.3 lbf ft)
Loctite ® 243™
H00144-01
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
Warning
Danger of accidents Brake linings which have not been approved alter the braking efficiency.
Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.
If brake linings are used that differ from the original equipment, compliance with the original homologation is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the manufacturer warranty shall be void.
– Only use brake linings approved and recommended by KTM.
– Position the new brake linings.
77
12 BRAKE SYSTEM
H00143-10
H00115-10
Info
Always change the brake linings in pairs.
Ensure that the brake linings are correctly positioned in the holding spring.
–
Mount and tighten screw 2 .
Guideline
Screw, rear brake lining
M6 10 Nm (7.4 lbf ft)
– Mount lock ring 1 .
–
Check the brake discs. ( p. 66)
– Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
– Add brake fluid up to level A .
Guideline
Level A (brake fluid level below reservoir rim)
10 mm (0.39 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 110)
– Position the membrane and the cover with the washer. Mount and tighten the screws.
Info
Immediately clean up any brake fluid that has overflowed or spilled with water.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
78
WHEELS, TIRES 13
13.1
Removing the front wheel
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
Main work
– Remove screw 1 .
V00219-10
V00246-10
– Loosen screws 2 .
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Hold the front wheel and pull out wheel spindle front wheel out of the fork.
3 . Take the
Info
Do not actuate the hand brake lever when the front wheel is removed.
– Remove spacers 4 .
H00934-13
13.2
Installing the front wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
79
13 WHEELS, TIRES
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change front wheel bearing.
– Clean and grease shaft seal rings of the spacers.
1 and contact surfaces A
– Insert the spacers.
H00935-10
V00247-10
– Clean and grease wheel spindle 2 .
– Position the front wheel.
The brake linings are correctly positioned.
– Insert the wheel spindle.
– Tighten screws 3 .
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
– Mount and tighten screw 4 .
Guideline
Screw, front wheel spindle
M10 40 Nm (29.5 lbf ft)
Loctite ® 243™
–
Remove the motorcycle from the lift stand. ( p. 39)
V00219-11
V00248-10
– Operate the hand brake lever several times until the brake linings are seated correctly against the brake disc.
– Loosen screws 3 .
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
– Tighten screws 3 .
Guideline
Screw, fork stub M6 10 Nm (7.4 lbf ft)
13.3
Removing the rear wheel
Preparatory work
–
Raise the motorcycle with a lift stand. ( p. 39)
80
WHEELS, TIRES 13
Main work
–
Remove nut 1 .
– Take off chain adjuster 2 .
H00116-10
– Pull out wheel spindle to be pushed forward.
3 far enough to allow the rear wheel
– Push the rear wheel forward as far as possible. Remove the chain from the rear sprocket.
Info
Cover the components to protect them against damage.
H00117-10
Warning
Danger of accidents Damaged brake discs reduce the braking effect.
– Always lay the wheel down in such a way that the brake disc is not damaged.
– Hold the rear wheel and remove the wheel spindle. Take the rear wheel out of the link fork.
Info
Do not operate the foot brake lever when the rear wheel is removed.
– Remove spacers 4 .
F02175-10
13.4
Installing the rear wheel
Warning
Danger of accidents Oil or grease on the brake discs reduces the braking effect.
– Always keep the brake discs free of oil and grease.
– Clean the brake discs with brake cleaner when necessary.
81
13 WHEELS, TIRES
F02176-10
Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease shaft seal rings of the spacers.
1 and contact surfaces A
– Insert the spacers.
Info
Insert the wide spacer on the left in the direction of travel.
– Clean and grease wheel spindle 2 .
– Position the rear wheel and insert wheel spindle.
The brake linings are correctly positioned.
– Mount the chain.
– Position chain adjuster spindle in all the way.
3 on both sides and push the wheel
H00117-12
H00116-11
– Mount nut 4 , but do not tighten yet.
– Make sure that the chain adjusters are fitted correctly on the adjusting screws.
–
Check the chain tension. ( p. 57)
– Tighten nut 4 .
Guideline
Nut, rear wheel spindle
M14x1.5
40 Nm (29.5 lbf ft)
– Operate the foot brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point.
Finishing work
–
Remove the motorcycle from the lift stand. ( p. 39)
13.5
Checking the tire condition
Info
Only mount tires approved and/or recommended by KTM.
Other tires could have a negative effect on handling characteristics.
The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.
The tires mounted on the front and rear wheels must have a similar profile.
Worn tires have a negative effect on handling characteristics, especially on wet surfaces.
82
WHEELS, TIRES 13
– Check the front and rear tires for cuts, embedded objects, and other damage.
» If the tires have cuts, run-in objects, or other damage:
– Change the tires.
400602-10
H01144-10
– Check the tire age.
Info
The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the
DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture.
KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.
» If the tires are more than five years old:
– Change the tires.
13.6
Checking tire pressure
Info
Low tire pressure leads to abnormal wear and overheating of the tire.
Correct tire pressure ensures optimal riding comfort and maximum tire service life.
400695-01
– Remove protection cap.
– Check tire pressure when the tires are cold.
Offroad tire pressure front rear
1.0 bar (15 psi)
1.0 bar (15 psi)
» If the tire pressure does not meet specifications:
– Correct tire pressure.
– Mount the protection cap.
83
13 WHEELS, TIRES
13.7
Checking spoke tension
Warning
Danger of accidents Incorrectly tensioned spokes impair the handling characteristic and result in secondary damage.
The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.
– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.)
400694-01
– Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound depends on the spoke length and spoke diameter.
If you hear different tone frequencies from different spokes of equal length and diameter, this is an indication of different spoke tensions.
You should hear a high note.
» If the spoke tension differs:
– Correct the spoke tension.
– Check the spoke torque.
Guideline
Spoke nipple M3.5
Torque wrench kit (58429094000)
3 Nm (2.2 lbf ft)
84
COOLING SYSTEM 14
14.1
Cooling system
V00220-10
The water pump 1 in the engine forces the coolant to flow.
The pressure resulting from the warming of the cooling system is regulated by a valve in the radiator cap 2 . This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
120 °C (248 °F)
Cooling is effected by the air stream.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
14.2
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
– Stand the motorcycle upright on a horizontal surface.
–
Take off radiator cap 1 .
– Check the antifreeze in the coolant.
− 25 … − 45 °C ( − 13 … − 49 °F)
» If the antifreeze in the coolant does not match the specified value:
– Correct the antifreeze in the coolant.
V00221-10
– Check the coolant level in the radiator.
Coolant level radiator fins
A above the 10 mm (0.39 in)
» If the coolant level does not match the specified value:
– Correct the coolant level.
– Mount the radiator cap.
400243-10
85
14 COOLING SYSTEM
14.3
Checking the coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
400243-10
– Stand the motorcycle upright on a horizontal surface.
– Remove the radiator cap.
– Check the coolant level in the radiator.
Coolant level radiator fins
A above the 10 mm (0.39 in)
» If the coolant level does not match the specified value:
– Correct the coolant level.
– Mount the radiator cap.
14.4
Draining the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
86
COOLING SYSTEM 14
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
– Remove screw 1 . Take off the radiator cap.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Drain plug, water pump cover
M6 6 Nm (4.4 lbf ft)
H00119-10
14.5
Refilling with coolant
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
K00211-10
Main work
– Make sure that screw 1 is tightened.
– Position the motorcycle upright.
– Add coolant to level A .
Guideline
Distance ator fins
A above the radi10 mm (0.39 in)
Coolant 0.55 l
(0.58 qt.)
87
14 COOLING SYSTEM
400677-11
– Move the vehicle into the position shown and prevent it from rolling away. Height difference B must be reached.
Guideline
Height difference B 50 cm (19.7 in)
Info
For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front. If the cooling system is poorly de-aerated, its cooling power will be reduced and the engine may overheat.
– Return the vehicle to the horizontal position.
–
Add coolant to level A .
– Mount the radiator cap.
Finishing work
– Go for a short test ride.
– Check the cooling system for leaks.
–
Check the coolant level. ( p. 86)
14.6
Changing the coolant
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.
– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Warning
Danger of poisoning Coolant is toxic and a health hazard.
– Keep coolant out of the reach of children.
– Do not allow coolant to come into contact with the skin, the eyes and clothing.
– Consult a doctor immediately if coolant is swallowed.
– Rinse the affected area immediately with plenty of water in the event of contact with the skin.
– Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.
– Change clothing if coolant spills onto your clothing.
Condition
The engine is cold.
– Position the motorcycle upright.
– Place an appropriate container under the water pump cover.
88
COOLING SYSTEM 14
– Remove screw 1 . Take off the radiator cap.
– Completely drain the coolant.
– Mount and tighten screw 1 with a new seal ring.
Guideline
Drain plug, water pump cover
M6 6 Nm (4.4 lbf ft)
H00119-10
– Make sure that screw
–
Add coolant to level
1
A .
is tightened.
Guideline
Distance ator fins
A above the radi10 mm (0.39 in)
Coolant 0.55 l
(0.58 qt.)
K00211-10
400677-11
– Move the vehicle into the position shown and secure it against rolling away. Height difference B must be reached.
Guideline
Height difference B 50 cm (19.7 in)
Info
For all of the air to be able to escape from the cooling system, the vehicle must be raised at the front. If the cooling system is poorly de-aerated, its cooling power will be reduced and the engine may overheat.
– Return the vehicle to the horizontal position.
– Add coolant to level A .
– Mount the radiator cap.
Finishing work
– Go for a short test ride.
– Check the cooling system for leaks.
–
Check the coolant level. ( p. 86)
89
15 TUNING THE ENGINE
15.1
Checking the play in the throttle cable
– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable A .
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
» If the throttle cable play does not meet the specified value:
– Adjust the play in the throttle cable.
400192-11
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Start the engine and let it run at idle speed. Move the handlebar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
– Adjust the play in the throttle cable.
15.2
Adjusting the play in the throttle cable
Preparatory work
–
– Turn the knurled screw on the fuel tap all the way clockwise.
– Remove the fuel tank.
–
Check the throttle cable routing. ( p. 61)
Main work
– Move the handlebar to the straight-ahead position.
– Push back sleeve 1 .
–
– Ensure that the throttle cable sleeve is pushed all the way into barrel adjuster 2 .
Loosen nut 3 .
F02917-10
90
TUNING THE ENGINE 15
– Turn barrel adjuster 2 cable at the throttle grip.
so that there is play A in the throttle
Guideline
Play in throttle cable 3 … 5 mm (0.12 … 0.2 in)
– Tighten nut
–
3
Slide on sleeve
.
1 .
400192-11
Finishing work
– Install the fuel tank.
–
–
Check the play in the throttle cable. ( p. 90)
15.3
Carburettor
–
idle speed
The idle setting of the carburetor has a big influence on the starting behavior, stable idle speed, and the response to throttle opening. This means that an engine with a correctly set idle speed will be easier to start than one with an incorrectly set idle speed.
Info
The carburetor and its components are subject to increased wear caused by engine vibration. Wear can result in malfunctioning.
V00222-10
The idle speed is adjusted using the idle speed adjusting screw 1 .
The idle mixture is adjusted using the idle air adjusting screw 2 .
15.4
Carburetor
–
adjusting the idle speed
– Screw in idle air adjusting screw the specified basic setting.
2 all the way and turn it to
Guideline
Idle air adjusting screw
Open 3.5 turns
V00222-10
– Run the engine until warm.
Guideline
Warming-up phase
– Connect the special tool.
Tachometer (45129075000)
≥ 5 min
91
15 TUNING THE ENGINE
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
–
Adjust the idle speed using idle speed adjusting screw 1 .
Guideline
Choke function deactivated – The choke lever is pushed up
all the way to the stop. ( p. 17)
Idle speed 1,400 … 1,500 rpm
–
Turn idle air adjusting screw 2 slowly in a clockwise direction until the idle speed begins to fall.
– Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall.
– 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.
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 air adjusting screw to the end without any change of engine speed, mount a smaller idling jet.
After changing the idling jet, start from the beginning with the adjusting steps.
Following extreme air temperature or altitude changes, adjust the idle speed again.
15.5
Emptying the carburetor float chamber
Danger
Fire hazard Fuel is highly flammable.
The fuel in the fuel tank expands when warm and can escape if overfilled.
– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.
– Switch off the engine for refueling.
– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.
– If any fuel is spilled, wipe it off immediately.
– Observe the specifications for refueling.
92
TUNING THE ENGINE 15
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Note
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to enter the groundwater, the soil, or the sewage system.
Info
Carry out work with a cold engine.
Water in the float chamber results in malfunctioning.
Preparatory work
– Turn the knurled screw on the fuel tap all the way clockwise.
No more fuel flows from the tank to the carburetor.
Main work
– Place a cloth under the carburetor to capture the draining fuel.
–
Remove screw plug 1 .
– Fully drain the fuel.
– Mount and tighten the screw plug.
V00223-10
93
16 SERVICE WORK ON THE ENGINE
16.1
Checking the gear oil level
300661-10
–
Condition
The engine is cold.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Remove screw 1 .
– Check the gear oil level.
A small quantity of gear oil must run out of the drilled hole.
» If no gear oil runs out:
– Add the gear oil.
Mount and tighten screw 1 .
Guideline
Screw, gear oil level monitoring
M6 6 Nm (4.4 lbf ft)
16.2
Changing the gear oil
Warning
Danger of scalding Engine and gear oil get very hot when the motorcycle is ridden.
– Wear suitable protective clothing and safety gloves.
– In the event of scalding, rinse the area affected immediately with lukewarm water.
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Drain gear oil with engine at operating temperature.
601967-10
Preparatory work
– Stand the motorcycle on the plug-in stand on a horizontal surface.
Main work
– Position an appropriate container under the engine.
– Remove oil drain plug 1 with the magnet.
– Let the gear oil drain fully.
– Thoroughly clean the oil drain plug with magnet.
– Clean the sealing surface on the engine.
– Mount and tighten the oil drain plug with the magnet and new seal ring.
Guideline
Oil drain plug with magnet
M12x1.5
20 Nm (14.8 lbf ft)
94
SERVICE WORK ON THE ENGINE 16
V00224-11
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
– Remove filler plug 2 with the O-ring, and fill up with gear oil.
Gear oil 0.50 l
(0.53 qt.)
Engine oil
(15W/50)
– Mount and tighten filler plug 2 with the O-ring.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Start the engine and check for leaks.
Finishing work
–
Check the gear oil level. ( p. 94)
16.3
Adding the gear oil
Info
Too little gear oil or poor-quality gear oil results in premature wear to the transmission.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Remove screw 1 .
300661-10
V00224-11
–
Remove filler plug 2 with the O-ring.
– Add gear oil until it flows out of the hole of the gear oil level plug.
– Mount and tighten screw 1 .
Guideline
Screw, gear oil level monitoring
M6 6 Nm (4.4 lbf ft)
– Mount and tighten filler plug 2 with the O-ring.
95
16 SERVICE WORK ON THE ENGINE
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and death.
– Always make sure there is sufficient ventilation when running the engine.
– Use effective exhaust extraction when starting or running the engine in an enclosed space.
– Start the engine and check for leaks.
96
CLEANING, CARE 17
17.1
Cleaning the motorcycle
Note
Material damage Components become damaged or destroyed if a pressure cleaner is used incorrectly.
The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.
Pressure which is too high causes malfunctions and destroys components.
– Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.
– Maintain a minimum distance between the nozzle of the pressure cleaner and the component.
Minimum clearance 60 cm (23.6 in)
Note
Environmental hazard Hazardous substances cause environmental damage.
– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.
Info
Clean the motorcycle regularly to maintain its value and appearance over a long period.
Avoid direct sunshine when cleaning the motorcycle.
– Close off exhaust system to keep water from entering.
– Remove loose dirt first with a soft jet of water.
– Spray the heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush.
401061-01
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.
– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Remove the closure of the exhaust system.
– Empty the carburetor float chamber.
Warning
Danger of accidents Moisture and dirt impair the brake system.
– Explain to your child that he or she must brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.
– After cleaning, your child should ride the vehicle a short distance until the engine warms up and until the brakes system has dried through careful application of the brakes.
97
17 CLEANING, CARE
Info
The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.
– Push back the protection caps on the handlebar controls to allow water to evaporate.
– After the motorcycle has cooled down, lubricate all moving parts and pivot points.
–
– Treat bare metal (except for brake discs and the exhaust system) with a corrosion inhibitor.
Preserving materials for paints, metal and rubber
– Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal
and plastic surfaces ( p. 113)
98
STORAGE 18
18.1
Storage
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid skin, eye and clothing contact with fuel.
– Immediately consult a doctor if you swallow fuel.
– Do not inhale fuel vapors.
– In case of skin contact, rinse the affected area with plenty of water.
– Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.
– Change your clothing in case of fuel spills on them.
– Keep fuels correctly in a suitable canister, and out of the reach of children.
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
Before storing the motorcycle, 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.
401058-01
– When refueling for the last time before taking the motorcycle out of service, add fuel additive.
–
–
Clean the motorcycle. ( p. 97)
– Change the gear oil.
–
Check the antifreeze and coolant level. ( p. 85)
– Empty the carburetor float chamber.
–
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.
–
Raise the motorcycle with a lift stand. ( p. 39)
– Cover the vehicle with a tarp or similar cover that is permeable to air.
Info
Do not use non-porous materials since they prevent humidity from escaping, thus causing corrosion.
Avoid running the engine for a short time only. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, causing engine parts and the exhaust system to rust.
99
18 STORAGE
18.2
Preparing for use after storage
–
Remove the motorcycle from the lift stand. ( p. 39)
– Perform checks and maintenance measures when preparing for
– Take a test ride.
401059-01
100
TROUBLESHOOTING 19
Faults
Engine turns but does not start
Engine has no idle speed
Engine does not speed up
Engine has too little power
Possible cause
Operating error
Motorcycle was out of use for a long time and there is old fuel in the float chamber
Action
– Carry out the start procedure.
–
Empty the carburetor float chamber.
Fuel supply interrupted
Spark plug sooty or wet
Fault in ignition system
Short-circuit cable in wiring harness frayed, stop button faulty
– Check the fuel tank breather.
– Clean the fuel tap.
– Check/set the carburetor components.
– Clean and dry the spark plug and spark plug connector, or change if necessary.
Plug gap of spark plug too wide – Adjust plug gap.
Guideline
Spark plug electrode gap
0.60 mm (0.0236 in)
– Check the ignition system.
– Adjust the ignition.
– Check the stop button.
The connector or ignition coil is loose or oxidized
Water in carburetor or jets blocked
Idling jet blocked
Adjusting screws on carburetor distorted
Spark plug defective
Ignition system defective
Carburetor running over because float needle dirty or worn
Loose carburetor jets
– Clean the plug-in connection and treat it with contact spray.
– Check/set the carburetor components.
– Check/set the carburetor components.
– Carburetor – adjust the idle speed.
– Change spark plug.
– Check the ignition coil.
– Check the spark plug connector.
– Check/set the carburetor components.
Fault in ignition system
Fuel supply interrupted
Air filter very dirty
Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer
– Check/set the carburetor components.
– Check the ignition system.
– Adjust the ignition.
– Check the fuel tank breather.
– Clean the fuel tap.
– Check/set the carburetor components.
– Clean the air filter and air filter box.
– Check exhaust system for damage.
– Change the glass fiber yarn filling of the main silencer.
101
19 TROUBLESHOOTING
Faults
Engine has too little power
Engine stalls or is popping into the carburetor
Engine overheats
White smoke emission (steam in exhaust gas)
Gear oil exits at the vent hose
Water in the gear oil
Possible cause
Fault in ignition system
Diaphragm or reed valve housing damaged
Noticeable wear
Lack of fuel
Engine takes in bad air
The connector or ignition coil is loose or oxidized
Too little coolant in cooling system
Too little air stream
Radiator fins very dirty
Foam formation in cooling system
Damaged cylinder head or cylinder head gasket
Bent radiator hose
Incorrect ignition point due to loose stator
Damaged cylinder head or cylinder head gasket
Too much gear oil added
Damaged radial shaft seal ring or water pump
Action
– Check the ignition system.
– Adjust the ignition.
– Check the diaphragm and reed valve housing.
– Overhaul the engine.
– Turn the knurled screw on the fuel tap all the way counterclockwise.
–
– Check the intake flange and carburetor for tightness.
– Clean the plug-in connection and treat it with contact spray.
– Check the cooling system for leakage.
–
Check the coolant level. ( p. 86)
– Switch off engine when standing.
– Clean radiator fins.
– Drain the coolant.
– Refill with coolant.
– Check the cylinder head or cylinder head gasket.
– Change the radiator hose.
– Adjust the ignition.
– Check the cylinder head or cylinder head gasket.
–
Check the gear oil level. ( p. 94)
– Check the radial shaft seal ring and the water pump.
102
TECHNICAL DATA 20
20.1
Engine
Design
Displacement
Stroke
Bore
Idle speed
Control
Crankshaft bearing
Conrod bearing
Piston pin bearing
Pistons
Piston rings
Engine lubrication
Primary transmission
Clutch
Gearbox
Transmission ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Ignition
Spark plug
Spark plug electrode gap
Cooling
Starting aid
20.2
Engine tightening torques
Nut, exhaust control diaphragm
Screw, clutch line holder
Screw, diaphragm cover of exhaust control
Screw, ignition system/stator
M5
M5
M5
M5
Screw, main shaft bearing retainer M5
Screw, reed valve housing of exhaust control
Screw, retaining bracket for return spring of shift shaft
M5
M5
1-cylinder 2-stroke engine, water-cooled, with reed intake and exhaust control
64.85 cm³ (3.9574 cu in)
40.8 mm (1.606 in)
45 mm (1.77 in)
1,400 … 1,500 rpm
Exhaust control PCEV (Pneumatic Controlled Exhaust
Valve)
2 grooved ball bearings
Needle bearing
Needle bearing
Aluminum cast
1 rectangular ring
Mixed lubrication
23:75 straight cut spur gear wheel drive
Multidisc clutch in oil bath/hydraulically activated
6-gear transmission, claw shifted
13:37
16:34
18:31
21:30
23:28
24:26
Non-contact controlled fully electronic ignition system with digital ignition adjustment
NGK LR 8 B
0.60 mm (0.0236 in)
Water-cooled
Kick starter lever
4 Nm (3 lbf ft)
5 Nm (3.7 lbf ft)
4 Nm (3 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
103
20 TECHNICAL DATA
Screw, shift drum locating
Screw, water pump impeller
M5
M5
Drain plug, water pump cover
Screw, alternator cover
Screw, clutch cover
Screw, clutch slave cylinder
Screw, clutch springs
Screw, engine case
Screw, engine sprocket cover
Screw, exhaust flange
Screw, gear oil level monitoring
Screw, intake flange
M6
M6
Screw, kick starter lever stop piece M6
Screw, outer clutch cover
Screw, reed valve housing of exhaust control
M6
M6
Screw, shift drum bearing retainer M6
Screw, shift drum locating
Screw, shift lever
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
Screw, water pump cover
Vacuum connection/vent connection
Screw, cylinder head
Nuts, cylinder base
Screw, kick starter lever
M6
M6
M7
M8
M8
Stud, cylinder base (left section of the engine case)
M8
M8 Stud, cylinder base (right section of the engine case)
Screw, inner clutch hub M10
Spark plug
Nut, rotor
Oil drain plug with magnet
Nut, primary gear wheel
M10x1
M12x1
M12x1.5
M14x1.25
104
6 Nm (4.4 lbf ft)
2 Nm (1.5 lbf ft)
6 Nm (4.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
Loctite
Loctite
Loctite
Loctite
Loctite
®
®
®
®
®
243™
243™
243™
243™
243™
5 Nm (3.7 lbf ft)
Loctite ® 243™
10 Nm (7.4 lbf ft)
Loctite ® 243™
14 Nm (10.3 lbf ft)
Loctite ® 243™
8 Nm (5.9 lbf ft)
4 Nm (3 lbf ft)
Loctite ® 243™
18 Nm (13.3 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
Loctite ® 243™
Tightening sequence:
Screw in up to 27 mm projection
Loctite ® 243™
Tightening sequence:
Screw in up to 29 mm projection
Loctite ® 243™
60 Nm (44.3 lbf ft)
Loctite ® 243™
10 … 12 Nm (7.4 … 8.9 lbf ft)
50 Nm (36.9 lbf ft)
20 Nm (14.8 lbf ft)
40 Nm (29.5 lbf ft)
Loctite ® 243™
TECHNICAL DATA 20
20.3
Carburetor
Carburetor type
Needle position
Idle air adjusting screw
Open
Main jet
Jet needle
Idling jet
Needle jet
Throttle slide
MIKUNI TM 24
2nd position from top
3.5 turns
210
5IPL43 (5N17)
20
Q-O (454)
2.5
20.3.1
Carburetor tuning
MIKUNI TM 24
ASL
2,301 …
3,000 m
(7,549 …
9,843 ft)
1,501 …
2,300 m
(4,925 …
7,546 ft)
751 …
1,500 m
(2,464 …
4,921 ft)
301 …
750 m
(988 …
2,461 ft)
0 …
300 m (0
… 984 ft)
TEMP
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
ASO
IJ
NDL
POS
MJ
− 20 … − 7 °C
( − 4 … 19 °F)
3.5
20
5N17
3
210
3.5
20
5N17
3
210
3
25
5N17
3
215
3
30
5N17
3
220
3
30
5N17
3
225
− 6 … 5 °C
(21 …
41 °F)
3.5
20
5N17
2
210
3.5
20
5N17
2
210
3.5
20
5N17
3
210
3
25
5N17
3
215
3
25
5N17
3
215
6 … 15 °C
(43 …
59 °F)
3.5
15
5N17
2
205
3.5
20
5N17
2
210
3.5
20
5N17
2
210
3.5
20
5N17
3
210
3.5
20
5N17
3
210
16 … 24 °C
(61 …
75 °F)
3.5
15
5N17
2
200
3.5
15
5N17
2
205
3.5
20
5N17
2
210
3,5
20
5N17
2
210
3.5
20
5N17
2
210
25 … 36 °C
(77 …
97 °F)
2.5
15
5N17
1
200
3.5
15
5N17
2
200
3.5
15
5N17
2
205
3.5
20
5N17
2
210
3.5
20
5N17
2
210
37 … 49 °C
(99 …
120 °F)
2.5
15
5N17
1
200
3.5
15
5N17
2
200
3.5
15
5N17
2
205
3.5
15
5N17
2
205
ASL
TEMP
ASO
IJ
NDL
POS
MJ
Above sea level
Temperature
Open (rotations) idle air adjusting screw
Idling jet
Jet needle
Needle position from top
Main jet
The carburetor tuning depends on the defined ambient and operating conditions.
105
20 TECHNICAL DATA
20.4
Capacities
20.4.1
Gear oil
Gear oil
20.4.2
Coolant
Coolant
0.50 l (0.53 qt.)
0.55 l (0.58 qt.)
20.4.3
Fuel
Fuel tank capacity, approx.
3.5 l (3.7 qt.) Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
20.5
Fork
Fork article number
Fork
Rebound damping
Comfort
Standard
Sport
Air pressure
Fork length
Spring length with preload spacer(s)
Oil capacity external mechanism left
Oil capacity, right cartridge
07.18.6U.03
WP XACT 5235
15 clicks
12 clicks
10 clicks
3 bar (44 psi)
735 mm (28.94 in)
377.5 mm (14.862 in)
40 + 15
10 ml (1.35
+ 0.51
0.34
fl. oz.)
240 ml (8.11 fl. oz.)
Grease capacity, left cartridge 6 g (0.21 oz)
Fork oil (SAE 4) (48601166S1)
Fork oil (SAE 4) (48601166S1)
Special grease (00062010053)
20.6
Shock absorber
Shock absorber article number
Shock absorber
Low-speed compression damping
Comfort
Standard
Sport
High-speed compression damping
Comfort
Standard
Sport
Rebound damping
Comfort
Standard
03.18.7T.03
WP XACT 5735
18 clicks
15 clicks
12 clicks
2.5 turns
2 turns
1.5 turns
18 clicks
15 clicks
106
Sport
Spring preload
Spring rate
Weight of rider: 35 kg (77 lb.)
Weight of rider: 40 kg (88 lb.)
Weight of rider: 45 kg (99 lb.)
Spring length
Gas pressure
Static sag
Riding sag
Fitted length
Shock absorber fluid ( p. 111)
20.7
Chassis
Frame
Fork
Shock absorber
Suspension travel front rear
Fork offset
Brake system front rear
Brake disc diameters front rear
Brake discs - wear limits front rear
Offroad tire pressure front rear
Secondary drive ratio
Chain
Rear sprockets available
Steering head angle
Wheelbase
Seat height unloaded
Ground clearance unloaded
Weight without fuel approx.
Maximum rider weight
TECHNICAL DATA 20
12 clicks
5 mm (0.2 in)
35 N/mm (200 lb/in)
40 N/mm (228 lb/in)
45 N/mm (257 lb/in)
210 mm (8.27 in)
10 bar (145 psi)
30 mm (1.18 in)
70 mm (2.76 in)
347 mm (13.66 in)
SAE 2.5
Central tube frame of chrome molybdenum steel tubing, powder-coated
WP XACT 5235
WP XACT 5735
215 mm (8.46 in)
270 mm (10.63 in)
22 mm (0.87 in)
Disc brake with 4-piston brake caliper
Disc brake with 4-piston brake caliper
198 mm (7.8 in)
160 mm (6.3 in)
2.5 mm (0.098 in)
2.5 mm (0.098 in)
1.0 bar (15 psi)
1.0 bar (15 psi)
14:48
1/2 x 1/4” O ‑ ring
46, 48, 50
64.5°
1,137 mm (44.76 in)
750 mm (29.53 in)
280 mm (11.02 in)
53 kg (117 lb.)
50 kg (110 lb.)
107
20 TECHNICAL DATA
20.8
Tires
Front tire Rear tire
60/100 - 14 M/C 30M TT
MAXXIS MAXX CROSS SI
80/100 - 12 41M TT
MAXXIS MAXX CROSS SI
The tires specified represent one of the possible series production tires. Additional information is available in the Service section under:
KTM.com
20.9
Chassis tightening torques
Hose clip, carburetor
Screw, brake hose bracket
Stop button screw
Spoke nipple
Screw, throttle slide cover
Remaining nuts, chassis
Remaining screws, chassis
Nut, push rod, foot brake lever
Remaining nuts, chassis
Remaining screws, chassis
Screw, ball joint of push rod on foot brake cylinder
Screw, clutch master cylinder
Screw, fender
Screw, foot brake cylinder
Screw, fork stub
Screw, front brake disc
M6
M6
M6
M6
M6
-
EJOT
M3
M3.5
M4
M5
M5
M6
M6
M6
M6
Screw, front brake linings M6
Screw, fuel tank spoiler on radiator M6
Screw, hand brake cylinder
Screw, rear brake disc
M6
M6
Screw, rear brake lining
Screw, throttle grip
Start number plate screw
Fitting, engine mounting bracket
Nut, foot brake lever stop
Nut, rim lock
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom triple clamp
Screw, chain sliding piece
Screw, engine bracket
Screw, engine sprocket cover
M8
M8
M8
M8
M6
M6
M6
M8
M8
M8
M8
M8
2.8 Nm (2.07 lbf ft)
1.7 Nm (1.25 lbf ft)
0.4 Nm (0.3 lbf ft)
3 Nm (2.2 lbf ft)
2 Nm (1.5 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
Loctite ® 243™
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
14 Nm (10.3 lbf ft)
Loctite ® 243™
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
14 Nm (10.3 lbf ft)
Loctite ® 243™
10 Nm (7.4 lbf ft)
4.5 Nm (3.32 lbf ft)
4 Nm (3 lbf ft)
30 Nm (22.1 lbf ft)
20 Nm (14.8 lbf ft)
10 Nm (7.4 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
15 Nm (11.1 lbf ft)
30 Nm (22.1 lbf ft)
Loctite ® 2701™
15 Nm (11.1 lbf ft)
108
Screw, front brake caliper
Screw, handlebar clamp
Screw, rear brake caliper
Screw, rear brake caliper
Screw, rear sprocket
Screw, steering stem
Screw, subframe
Screw, top triple clamp
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom shock absorber
Screw, foot brake lever
Screw, front wheel spindle
Screw, handlebar support
Screw, top shock absorber
Nut, swingarm pivot
Nut, rear wheel spindle
Nut, steering head
M8
M8
M8x20
M8x40
M8
M8
M8
M8
M10
M10
M10
M10
M10
M10
M10
M12x1
M14x1.5
M20x1.5
TECHNICAL DATA 20
20 Nm (14.8 lbf ft)
Loctite ® 243™
20 Nm (14.8 lbf ft)
18 Nm (13.3 lbf ft)
Loctite ® 243™
18 Nm (13.3 lbf ft)
Loctite ® 243™
25 Nm (18.4 lbf ft)
Loctite ® 243™
20 Nm (14.8 lbf ft)
35 Nm (25.8 lbf ft)
Loctite ® 2701™
20 Nm (14.8 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
Loctite ® 243™
35 Nm (25.8 lbf ft)
Loctite ® 243™
40 Nm (29.5 lbf ft)
Loctite ® 243™
40 Nm (29.5 lbf ft)
Loctite ® 243™
45 Nm (33.2 lbf ft)
Loctite ® 243™
40 Nm (29.5 lbf ft)
40 Nm (29.5 lbf ft)
10 Nm (7.4 lbf ft)
109
21 SUBSTANCES
Brake fluid DOT 4 / DOT 5.1
Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties.
Recommended supplier
Castrol
– REACT PERFORMANCE DOT 4
MOTOREX ®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.
– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protection and lubrication properties.
– Only use coolant that complies with the requirements stated (see specifications on the container) and that has the relevant properties.
Antifreeze protection to at least − 25 °C ( − 13 °F)
The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted.
The use of premixed coolant is recommended.
Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.
Recommended supplier
MOTOREX ®
– COOLANT M3.0
Engine oil (15W/50)
Standard/classification
–
–
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
Recommended supplier
MOTOREX ®
– Top Speed 4T
Engine oil, 2-stroke
Standard/classification
–
Guideline
– Only use high-grade 2-stroke engine oil from a reputable brand.
fully synthetic
110
SUBSTANCES 21
Recommended supplier
MOTOREX ®
– Cross Power 2T
Fork oil (SAE 4) (48601166S1)
Standard/classification
–
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
–
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Super unleaded (ROZ 95)
Standard/classification
– DIN EN 228 (ROZ 95)
Guideline
– Only use super unleaded fuel that matches or is equivalent to the specified standard.
– Fuel with an ethanol content of up to 10% (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e.g., M15, M85, M100) or more than 10% ethanol (e.g., E15,
E25, E85, E100).
Super unleaded (95 octane) mixed with 2-stroke engine oil (1:60)
Standard/classification
– DIN EN 228
–
Mixture ratio
1:60
Engine oil, 2-stroke ( p. 110)
Super unleaded (ROZ 95) ( p. 111)
Recommended supplier
MOTOREX ®
– Cross Power 2T
111
22 AUXILIARY SUBSTANCES
Air filter cleaner
Recommended supplier
MOTOREX ®
– Racing Bio Dirt Remover
Chain cleaner
Recommended supplier
MOTOREX ®
– Chain Clean
Fuel additive
Recommended supplier
MOTOREX ®
– Fuel Stabilizer
High viscosity grease
Recommended supplier
SKF ®
– LGHB 2
Long-life grease
Recommended supplier
MOTOREX ®
– Bike Grease 2000
Motorcycle cleaner
Recommended supplier
MOTOREX ®
– Moto Clean
Off-road chain spray
Recommended supplier
MOTOREX ®
– Chainlube Offroad
Oil for foam air filter
Recommended supplier
MOTOREX ®
– Racing Bio Liquid Power
Preserving materials for paints, metal and rubber
Recommended supplier
MOTOREX ®
– Moto Protect
112
AUXILIARY SUBSTANCES 22
Rubber grip adhesive (00062030051)
Recommended supplier
KTM AG
– GRIP GLUE
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
MOTOREX ®
– Quick Cleaner
Special grease (00062010053)
Recommended supplier
Klüber Lubrication ®
– KLÜBERFOOD NH1 34 ‑ 401
Universal oil spray
Recommended supplier
MOTOREX ®
– Joker 440 Synthetic
113
23 STANDARDS
JASO T903 MA2
Different technical development directions required a separate specification for motorcycles – the JASO T903 MA2 standard.
Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.
In most motorcycle engines, the transmission and clutch are lubricated with the same oil.
The JASO T903 MA2 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.
JASO FD
JASO FD is a classification for a 2-stroke engine oil that was specifically developed for the extreme demands of racing. Thanks to first-rate synthetic esters and specially designed additives, superb combustion is achieved even under extreme operating conditions.
114
Art. no.
ca.
cf.
e.g.
etc.
i.a.
no.
poss.
Article number circa compare for example et cetera inter alia number possibly
LIST OF ABBREVIATIONS 24
115
For the rider training location nearest you, call: (877) 288-7093
dirtbikeschool.com
© 2015 Motorcycle Safety Foundation, Inc.
2 Jenner, Suite 150 • Irvine, CA 92618
(949) 727-3227 • msf-usa.org
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Use for TEXT ONLY P1-to 44
The information contained in this publication is offered for the benefit of those who have an interest in riding off-highway motorcycles. The information has been compiled from publications, interviews and observations of individuals and organizations familiar with the use of off-highway motorcycles. Because there are many differences in product design, riding terrain and riding styles, there may be organizations and individuals who hold differing opinions.
Consult your local motorcycle dealers or experienced off-highway motorcycle riders about appropriate riding locations in your area. Although the Motorcycle Safety
Foundation will continue to publish responsible viewpoints on this subject, it must disclaim specific or general liability for the views expressed herein.
The Motorcycle Safety Foundation ® (MSF) is a national not-for-profit organization promoting the safety of motorcyclists with programs in rider training, operator licensing and public information. The MSF is sponsored by BMW, BRP, Ducati, Harley-
Davidson, Honda, Kawasaki, KTM, Piaggio, Polaris Motorcycles,
Suzuki, Triumph and Yamaha.
Motorcycle Safety Foundation
2 Jenner, Suite 150
Irvine, CA 92618
949.727.3227 msf-usa.org
Copyright 2015
Printed: March 2015
Parents...Be Cautious
Riding Off-Highway Motorcycles (OHMs) can be an enjoyable form of outdoor recreation when done properly. With preparation, practice, and parental supervision your youngster can safely develop and expand his or her riding skills. Remember, off-highway motorcycles are not toys.
This manual is designed to assist you in the important task of teaching your youngster the safe and responsible use of an off-highway motorcycle. We urge you to read this booklet thoroughly. Also read other information provided with the motorcycle. The owner’s manual contains important warnings and features of the motorcycle.
Deciding if your youngster is ready to ride an off-highway motorcycle is an important decision. The
MSF strongly urges you to carefully determine your youngster’s readiness to ride. There is a Readiness
Checklist in Part 4 of this booklet. Do not permit youngsters to ride an off-highway motorcycle if you doubt that they will operate the motorcycle safely.
1
2
INTRODUCTION
• Purpose of the Booklet
• Important Note to Parents
• Other Sources of Information
PART 1: Determining Your
Youngster’s Readiness to Ride an
Off-Highway Motorcycle
• Readiness Guidelines
• Steps for Safe and
Responsible OHM Riding
PART 2: Pre-Operating
Procedures and Practice
• Protective Gear and Clothing
• Mounting/Dismounting
• Mastering the Controls
• Learning Activities
11
12
13
16
4
4
5
6
10
CONTENTS
PART 3: Operating Procedures and
Practice
• Learning Area/Riding Area
• Getting Used to the Vehicle in
Motion
• Let’s Start Riding
20
22
25
PART 4: Readiness Checklist
• Visual Perception/Motor/
Development
• Physical Development
• Social/Emotional Development
• Reasoning and Decision-Making
Ability
FINAL NOTE: To Parents
GLOSSARY
ANSWERS
29
32
34
36
38
39
41
3
4
INTRODUCTION
Purpose of the Booklet
P arents, Youngsters and Off-Highway Motorcycles is designed to assist you in determining if your youngster is ready to ride off-highway motorcycles (OHMs). It also provides you and your youngster with important safety information and tips on learning to ride. This booklet is divided into four parts: Part 1: Determining Your
Youngster’s Readiness to Ride an Off-highway
Motorcycle; Part 2: Pre-operating Procedures;
Part 3: Operating Procedures; Part 4: Readiness
Checklist. There is information about protective gear, mounting, control operation and starting the engine. Operating procedures include starting, shifting, stopping and turning.
Important Note To Parents
Once your youngster is ready to learn to ride, YOU must be familiar with the motorcycle. You will be serving as teacher, coach, and safety supervisor for your youngster. You must know the controls, handling characteristics, maintenance requirements, and proper riding techniques. Read and understand the owner’s manual and the labels provided with the vehicle. Review all instructions, requirements, and warnings with your youngster. Find out about state or local off-highway motorcycle requirements.
Other Sources Of Information
In addition to the information provided in Parents, Youngsters and Off-Highway
Motorcycles , there are other sources for obtaining safety information. The owner’s manual provides specific maintenance and operating procedures for your motorcycle. It also includes warnings and cautions, as well as operating tips.
Motorcycle dealers may have other literature and safety information. Another booklet,
Tips and Practice Guide for the Off-Highway
Motorcyclist , gives detailed riding procedures.
The MSF DirtBike School SM offers training on how to ride off-highway motorcycles. The course is available to youth as young as six years of age, as well as to adults. Call toll-free 877. 288.7093 to enroll or for more information. To find out more on the internet, visit dirtbikeschool.com.
INTRODUCTION
5
PART 1
DETERMINING YOUR YOUNGSTER'S READINESS
TO RIDE AN OFF-HIGHWAY MOTORCYCLE
T he first important decision you will have to make concerning your youngster and offhighway motorcycles (OHMs) is whether your youngster is ready to ride. There are several factors that you must consider carefully.
There is no certain way to predict that your child is able to ride an OHM safely. However, the following information is a guide to help you determine your youngster’s readiness to ride.
Only parents can decide if their youngster has the qualities necessary to operate an off-highway motorcycle safely.
Also make sure your youngster can comfortably reach and work all the controls. For example, can they turn the handlebars all the way to the right and left? Can they easily use their feet to work the brake pedal and gearshift lever? Can they operate the throttle and brake levers while they hold onto the handgrips? If not, the youngster is not physically ready to ride this OHM. Refer to the owner’s manual to check for possible adjustments in the position of some of the controls.
Readiness Guidelines
PHYSICAL DEVELOPMENT
Physical size and ability are important considerations. For example, a youngster must be big enough to hold the motorcycle up, get on, and comfortably sit on the seat with both feet touching the ground.
6
PART 1
8
PART 1
Additional signs of physical readiness can be observed in your youngster’s other play activities. In general, a youngster should be well-coordinated, having good balance and agility. This coordination can be demonstrated by the abilities to jump rope, skate, skateboard, ride a bicycle, etc. If a youngster cannot perform well in these types of activities, more physical development is needed.
SOCIAL/EMOTIONAL DEVELOPMENT
How a youngster behaves in a social setting can be a sign of social/emotional development. A youngster needs to know about and understand rules. Certain rules are necessary for the safe operation of any vehicle. Youngsters must be willing to follow rules. A good sign is a youngster who obeys rules set by parents. A youngster who does not follow rules is not ready for an OHM.
One indicator that a youngster is ready to ride an
OHM is when they demonstrate a safety-conscious attitude and are aware of possible injury from reckless OHM operation. If the youngster has a habit of recklessness or is often involved in accidents while using bicycles or skateboards, the youngster is not ready to ride an OHM.
REASONING AND
DECISION-MAKING ABILITY
Youngsters should have some knowledge about what may happen if something is done wrong. They must understand that unsafe actions can result in injury. An example of this is knowing the need to look in both directions before crossing a street when walking to school. The ability to make good decisions relates to a youngster’s ability to reason.
When presented with a problem, the youngster should be able to come up with a sensible answer.
Ask your youngster to tell you what causes accidents and injuries. Your youngster needs to be able to tell
what causes accidents and how to avoid them. In general, a youngster should understand that he or she can get hurt as a result of making poor choices.
VISUAL PERCEPTIONS
AND MOTOR DEVELOPMENT
This area involves how well a youngster sees and how vision is used with other physical movements. In other words, can a youngster see and react with the proper hand, foot, or body movement?
Several types of visual characteristics are important. The ability to see to the sides while looking straight ahead is called peripheral or side vision. You can determine a youngster’s side vision by having him or her look straight ahead while you move objects to the side. The youngster should be able to see objects ninety degrees to the side while looking straight ahead. Rider awareness and safety improves with good side vision.
PART 1
Being able to judge distance is another visual skill helpful when operating an OHM. Is your youngster able to tell how far one object is from another, or which of two objects is closer?
OHM riding requires a person to judge distance and react properly.
Being good at playing video games, hitting a baseball, etc., is a good sign that a youngster’s eye and hand movements are fairly well coordinated.
In summary, you must consider many things before you decide to put your youngster on an OHM. There is no exact formula to use in making this decision. The Readiness Checklist,
Part 4, can assist you with some points to evaluate. If you are not able to check-off most of the statements, your youngster is probably not ready to ride an OHM.
9
PART 1
Steps For Safe And
Responsible OHM Riding
Once you determine that OHM use is proper for your youngster, it is time to prepare yourself as a good OHM teacher and supervisor.
STEP ONE: Educate Yourself about OHM
Safety and Proper Riding Techniques
You must learn as much as possible about offhighway motorcycles in general, and especially your youngster’s motorcycle. You must be qualified to instruct and supervise your youngster. This means that you will need to understand the features of the motorcycle and proper riding techniques. The best source of information is the owner’s manual supplied with the motorcycle. Read the owner’s manual before you begin to instruct your youngster about OHM safety. Pay particular attention to the warning labels and stickers on the motorcycle.
10
STEP TWO: Teach Your Youngster Safe and
Proper Riding Techniques
Teaching your youngster off-highway motorcycling is a step-by-step process. It begins with safety rules and moves to actual riding techniques. Since youngsters learn at different rates, it will be up to you to set the pace of your youngster’s progress. At some point you may decide that he or she is not ready to ride an OHM.
STEP THREE: Avoid Unsafe Situations
Through Close Supervision
ALWAYS closely supervise your youngster’s riding. This is true even if your youngster has learned and mastered the rules and skills of safe OHM riding. Youngsters can get tired easily and become careless. They do not always see everything that is important around them. Your close supervision and good judgment are important.
PRE-OPERATING PROCEDURES
AND PRACTICE
Protective Gear And Clothing
T he nature of off-highway riding demands that your youngster wear proper protective gear. Motorcycle riders should ALWAYS wear a helmet, eye protection, gloves, long pants, a long-sleeved shirt or jacket, and over-the-ankle boots. Anything less is not adequate protection.
NEVER let anyone ride an off-highway motorcycle without a Department of Transportation (DOT) compliant motorcycle helmet. Be sure the fit is correct. It should be snug but not tight. It must be properly fastened.
Protective gear is necessary in any weather, even when the temperature is warm. In cooler weather you should dress your youngster with additional layers of clothing. Some riders choose to wear a kidney belt and chest or back protector for additional protection. On the right is a drawing of well-equipped riders. Show this drawing to your youngster and point out what is important.
PART 2
11
PART 2
Mounting/Dismounting
Have your youngster wear safety gear whenever getting on a motorcycle. This action will stress the importance of safety gear and help develop safe riding habits.
Mounting is typically from the left side. To mount from the left, point the handlebars straight. While squeezing the front brake lever, swing the right leg over the seat and place the right foot on the ground.
Both feet should be in contact with the ground while sitting on the motorcycle. Dismounting reverses the procedure: the kickstand is placed fully down. With the left foot on the ground, the handlebars straight and the front brake lever squeezed, the right leg is swung over the seat and the foot touches the ground.
Correct riding posture helps your youngster operate the controls. Proper straight line riding posture includes:
• Head and eyes up, looking well ahead.
• Shoulders relaxed, back straight.
12
• Elbows bent, slightly out and away from
the body.
• Hands on the handlebars.
• Knees in toward the tank.
• Feet on the footpegs, toes pointing
straight ahead.
The hand and foot controls are important to riding safely. While riding, both hands should be kept on the handlebars and both feet on the footpegs of the motorcycle. Removing a hand or foot can reduce the ability to control the motorcycle.
An off-highway motorcycle rider will need to shift body weight in certain situations. This is especially true in maneuvers such as turning, negotiating hills, and riding on bumpy terrain.
Your youngster should be able to operate the controls during these maneuvers. Now is a good time to make sure your youngster can reach the controls from different body positions. Have the youngster remount. Turn the handlebars full left
and full right. See that this can be done easily.
Next have the youngster slide up and back on the seat. Mention that body movement is important.
Body movement and shifting weight help to control the motorcycle.
(Go through these control exercises with the motorcycle’s engine OFF.)
Mastering The Controls
Show your youngster how to use each control as you describe its action. Refer to the owner’s manual to learn control location and function before instructing your youngster. Test yourself by operating the controls. Have your youngster dress in the proper protective gear and sit on the machine as you point out each control. It is important to have your youngster wear all the protective gear whenever sitting on an offhighway motorcycle.
PART 2
13
PART 2
BRAKES
Most small off-highway motorcycles have a hand lever on the right handlebar which operates the front brake. Most also have a foot pedal on the right side to operate the rear brake. Refer to the owner’s manual for correct brake location and operation.
Explain and demonstrate proper braking procedure. Be sure your youngster can apply the brake(s) properly while seated and without looking down. Smooth operation should be encouraged.
THROTTLE CONTROL
Explain to your youngster that twisting the throttle control back will make the motorcycle go faster. Closing the throttle control slows the motorcycle.
Youngsters need practice using the throttle control smoothly. They tend to use it like an on/off switch. With the engine off, have your youngster
14 move the throttle to various positions. Practice turning the handlebars and using the throttle at the same time.
ENGINE STOP SWITCH
Explain to your youngster how to use the engine stop switch to turn off the engine. With the engine off, show how the stop switch works. Later, your youngster can practice using the stop switch when the engine is actually running.
CLUTCH/SHIFT LEVER
Some small OHMs do not have a clutch lever; some don't have a shift lever either. This section applies only to motorcycles with a shift lever. Those that do have a shift lever may have different shift patterns. Refer to your owner’s manual for proper shifting instructions. It is important to learn how the shift lever works.
Explain that it is possible to shift the motorcycle with the shift lever in order to ride at different speeds.
Have your youngster practice shifting with the engine off. The shift lever, clutch lever (if equiped), and throttle control work together to move the motorcycle. When shifting to first gear from neutral the throttle is closed, the clutch lever is squeezed, and the front brake is applied before moving the shift lever into first gear. When starting out, the front brake is released. The throttle is gradually opened while the clutch is slowly released. If the clutch is released too quickly, or too much throttle is applied, the motorcycle may lunge forward causing loss of control. With the engine off, have your youngster practice upshifts, downshifts, and locating neutral.
PART 2
SPEED LIMITERS
(supervisor control feature)
Some models come equipped with a removable exhaust restrictor, or another feature which reduces maximum speed. Refer to your owner’s manual or talk to your dealer about this.
15
PART 2
Learning Activities
Here are some activities that your youngster can use to help learn about motorcycle parts and controls
CROSSWORD PUZZLE
Here is a crossword puzzle for your youngster to complete.
1.
Across
1. What this booklet is
all about.
2.
2. A piece of safety equipment for your head that you must never forget to wear.
3. Protective gear for the hands.
4. Where you should always
ride your motorcycle. (a synonym)
5. Hand lever you use when
shifting gears.
3.
Down
6. The place on which you keep your feet
when riding.
7. Protective gear for the feet and ankles.
6.
7.
4.
5.
All the words needed are listed below:
CLUTCH
FOOTPEGS
GLOVES
SAFETY
BOOTS
HELMET
OFF-ROAD
Answer Guide on Page 41
16
PART 2
NAME THE MOTORCYCLE PARTS (Typical)
Have your youngster write the number of the motorcycle part or control on the correct line for the diagrams shown. (Answer Guide on Page 42)
1. Clutch lever
2. Hand brake lever
3. Foot brake lever or pedal
4. Throttle
5. Choke or enrichening device
6. Engine stop switch
7. Gas cap/tank vent
8. Starter (kick)
9. Electric starter (if equipped)
17
PART 2
LOCATING THE CONTROLS GAME
Now that you have shown your youngster the controls, it is your youngster’s turn to show you.
The engine remains OFF for this exercise and your youngster will be on the motorcycle. The youngster should be wearing the proper protective gear to develop this safety habit.
1. Have your youngster show you the location of the following:
Brakes (lever and pedal)
Throttle Control
Engine Stop Switch
Shift Lever (if equipped)
Clutch (if equipped)
2. Have your youngster show you how the controls work. Be sure he or she understands the proper operation of each control. Skilled use of these controls should develop with practice. Under actual riding conditions the rider will have to watch ahead while operating the controls. Your youngster should be able to find the controls quickly without looking for them.
3. With your youngster looking ahead (pick out a point to look at), have him or her operate the controls. Repeat often while changing the order.
4. Ask your youngster to operate the controls as if actually riding. Look for smooth and precise operation.
18
PRE-RIDE CHECK
Before you continue:
1. Have you determined your youngster’s readiness to ride an OHM? Do not let your youngster ride if you have any doubt. (Refer to the Readiness
Checklist, Part 4)
2. Have you read the owner’s manual and reviewed it with your youngster?
3. Does your youngster fit the motorcycle properly?
4. Have you inspected the vehicle and maintained it according to the owner’s manual?
PART 2
5. Is your youngster wearing the proper protective gear? Is the mounting procedure correct?
6. Has your youngster learned to locate the motorcycle controls without looking at them? Does he or she know how to operate them smoothly?
7. Does your youngster understand that he or she must always ride off-road?
8. Have you stressed to your youngster to keep his or her feet on the footpegs while riding?
If you have completely covered all these areas, you are ready to go on to Part 3.
19
20
PART 3
OPERATING PROCEDURES
AND PRACTICE
C arefully observe your youngster’s first use of the motorcycle. Observe his or her readiness to ride. Only permit your youngster to continue to ride if they have the size, strength, and attitude needed to ride safely.
Show your youngster the engine, exhaust pipe, and muffler. Tell him or her not to touch these parts because they are hot while the engine is running. Explain that they will remain hot after the engine is stopped. Also explain that hands and feet must be kept away from moving parts of the motorcycle.
Your youngster’s safety depends in part on the mechanical condition of the motorcycle. Be sure to inspect it thoroughly before each use.
Starting and refueling of the vehicle should be done by responsible adults only. Follow a regular maintenance program. See the owner’s manual for inspection details.
Even after young riders have learned the basic riding skills, direct supervision by an experienced adult is necessary AT ALL TIMES. Make sure that all off-highway motorcycle users under your supervision get proper riding instructions.
Stress that an OHM is not a toy. Follow safety precautions strictly to provide a “safety first” approach to off-highway motorcycle riding.
Teaching your youngster how to ride an OHM safely will increase the enjoyment of off-highway motorcycle riding.
Learning Area/Riding Area
The best place for learning is a level area 100' x 200' that is free from obstacles such as rocks, stumps, or holes. The learning area may have a loose or hard dirt surface. A grassy surface is also acceptable. It should not have two different surfaces.
Under no circumstances should the surface be concrete or asphalt.
Be sure there is room enough to maneuver, and that no other riders are close.
PART 3
21
PART 3
Getting Used To The
Vehicle In Motion
GETTING THE FEEL OF THE BRAKES
Be sure your youngster is wearing all of the proper protective gear. With the engine still OFF, have your youngster mount the motorcycle. If you physically can, push the motorcycle slowly. Have your youngster brake to feel how much pressure is needed for a smooth stop. If your youngster’s motorcycle has more than one brake, both should be applied with even pressure. Practice this several times until you are sure this skill is developed. Remind your youngster to keep his or her head up and look forward.
GETTING THE FEEL OF THE THROTTLE
With the engine OFF, have your youngster practice smooth throttle control. Your youngster will learn how much throttle it takes to start moving in
22 a later exercise. Explain that opening the throttle will increase speed and that closing the throttle will decrease speed. Releasing the throttle and applying the brakes will slow the motorcycle. Ask your youngster to tell you how throttle control and braking affect the motorcycles speed.
GETTING THE FEEL OF THE CLUTCH
(if equipped)
With the engine OFF, have your youngster practice smooth clutch control. Have your youngster shift the motorcycle into first gear.
While you push the motorcycle have the youngster slowly release the clutch lever. The point which the motorcycle stops moving indicates the clutch engagement point or “friction zone.”
The “friction zone” is the point at which engine power begins to be transmitted to the rear wheel.
Explain that this is the point the motorcycle will start moving when the engine is running.
Smooth operation will prevent stalling and
allow smooth shifting. Remind the youngster that the throttle should be closed when shifting gears. Practice this exercise several times until the skill is developed.
GETTING THE FEEL OF TURNING
With the vehicle stopped and the engine
OFF, have your youngster practice the proper turning technique:
1. For a right turn, look to the right and lean the motorcycle to the right.
2. For a left turn, look to the left and lean the motorcycle to the left.
Repeat this exercise with the kickstand up as you push the motorcycle. Make sure he or she can turn the vehicle in both directions using this technique while you maintain balance of the motorcycle.
PART 3
23
PART 3
BEING PREPARED FOR RIDING PRACTICE
Be sure to observe all the safety precautions covered in the Introduction and Parts 1 and 2.
Double check that the riding area is free from hazards. Your youngster should wear all the proper protective gear, and the speed limiter (if equipped) should be installed and working correctly.
STARTING THE MOTORCYCLE
Always start the motorcycle for your youngster. To remember the proper starting technique use “FINE-C.”
Double check for neutral. Start the engine.
Have your youngster carefully mount. Let your youngster operate the engine stop switch and shut off the motor. Re-start the engine and repeat. Allow the engine to warm up until it runs smoothly with the choke off.
F
I
N
E
C
FUEL
VALVE
IGNITION Ignition on.
NEUTRAL
ENGINE
CHOKE
Put to "on" position.
Motorcycle in neutral
(the motorcycle rolls with the clutch lever released).
Stop switch in run/on start position.
On (for cold engine only).
24
Start the motorcycle for your youngster
PART 3
Let's Start Riding
Walk next to the motorcycle when your youngster first starts riding. You can also let the beginner ride back and forth between you and another adult.
Help your youngster with the turns as he or she practices throttle control and braking.
STARTING OUT AND STOPPING
Before your youngster moves the motorcycle under power, take a few moments to practice smooth clutch control. After shifting to first gear, have your youngster rock the motorcycle a few inches back and forth by moving the clutch in and out of the “friction zone.” The clutch is not fully released while doing this. It is important that clutch operation is smooth before riding in the practice area.
The next practice session is straight-line starts and stops. Keep the riding under control.
25
PART 3
However, riding too slowly will make balance more difficult. Both brakes should be used together for smooth stops. The left foot should be placed on the ground first, keeping the right foot on the rear brake.
Be sure your youngster develops a good feel for the use of the throttle and controls. After the youngster has mastered starting and stopping at slower speeds, increase speeds by shifting.
TURNING
Remind your youngster of the two steps for turning:
1. For a right turn, look to the right and lean the motorcycle to the right.
2. For a left turn, look to the left and lean the motorcycle to the left.
Have your youngster practice turning in both directions at slow speeds. Allow enough room to make a wide turn. After your youngster is skilled in making wide turns, try tighter turns.
Keep speed slow.
Your youngster should master these skills at low speeds before going faster. Next, practice some figure eights. This will help your youngster make left and right turns. Make sure your youngster keeps both feet on the footpegs and looks ahead in the turns.
Once these skills are mastered, refer to the Tips
& Practice Guide for the Off-Highway Motorcyclist, for additional skills used in off-highway riding.
26
PART 3
27
28
PART 4
READINESS CHECKLIST
T his Readiness Checklist is provided to help you determine your youngster’s readiness to learn to safely operate and control an OHM. There is a significant amount of judgment needed in determining a youngster’s readiness to ride an
OHM. The ultimate decision is the responsibility of the parent, guardian, or supervising adult. It is important that parents make informed decisions about whether or not their youngster becomes involved in off-highway motorcycle activity.
There are four developmental areas considered in the Readiness Checklist. These include: visual perception/motor development, physical development, social/emotional development, and reasoning and decision-making ability. Several questions are listed to help you determine if your youngster possesses the skills and capabilities to safely learn to operate an OHM.
The best way to utilize the Readiness Checklist is to read the particular ability, consider the answers to the questions for that ability, and check those abilities that you determine are present in your youngster.
There are no suggestions as to how many abilities or the degree of ability that your youngster should possess. This Readiness Checklist may help you consider the appropriateness of OHM operation for your child. The ultimate decision for your youngster’s involvement with off-highway motorcycles belongs to you, the parent.
PART 4
VISUAL PERCEPTION/MOTOR DEVELOPMENT
Ability
1. Youngster can see with sufficient clarity.
✓ Points to Evaluate
Can youngster see letters and numbers at least as well as you?
Can youngster distinguish colors?
Has youngster demonstrated adequate vision in other activities (riding bicycles, running, sports, or other recreational activities)?
2. Youngster possesses ability to perceive depth or distance.
3. Youngster has adequate side vision/ peripheral vision.
4. Youngster can judge the speed of objects.
When looking at two objects in the distance, can youngster tell which is farther or closer?
Can youngster see objects 90 degrees to each side while looking straight ahead?
Does the youngster judge the speed of objects (fast, medium, slow) that agree with your judgments? (For example, a car on the highway, a train moving past a crossing, a dog running, people walking.)
29
PART 4
Ability
5. Youngster can state the distances of objects in terms of feet, yard, miles.
6. Youngster can follow movement of objects.
7. Youngster can visualize distances as displayed by a picture or photograph.
8. Youngster can follow a moving object while accomplishing hand manipulation.
9. Youngster can describe cause-andeffect experiences.
✓ Points to Evaluate
Can youngster tell how many feet or yards it is from the house to the road?
Can youngster tell how wide a hallway is, or the width of a room?
Can youngster follow the path of such things as: a hit or thrown baseball, a moving car, objects in a video game?
Can youngster estimate distance between objects in a family photograph?
Can youngster estimate distance between objects when looking at a landscape picture?
Can youngster dribble a basketball without looking at it?
Can youngster manipulate video game controls while following objects on a screen?
Can youngster describe a minor injury he or she received and correctly describe the causes?
Can youngster describe settings or situations that can produce injury if precautions are not taken?
30
Ability
10. Youngster can concentrate on more than one element at a time in solving a puzzle or problem.
11. Youngster can maintain relative spans of attention when given a variety of stimuli.
✓
PART 4
Points to Evaluate
Can youngster describe what may cause injury when doing such things as running, swimming, bicycling, riding in a car?
Can youngster pick out or describe several items within a picture?
Can youngster assemble a puzzle without unusual problems or delays?
Can youngster describe what to do if a house fire should occur?
Can youngster complete school homework assignments without being easily distracted?
Can youngster assemble more difficult puzzles; for example, a nature scene or picture?
31
PART 4
PHYSICAL DEVELOPMENT
Ability
1. Youngster can sit comfortably on the motorcycle and reach the controls easily.
✓
2. Youngster has sufficient strength and familiarity to operate the controls with ease.
Points to Evaluate
Can youngster place his or her feet firmly on the footpegs?
Do the youngster’s fingers reach comfortably around the handlebars and control levers? How about with the handlebars turned? How about in different seating positions?
Can youngster stand (with knees slightly bent) and have a few inches of space from the seat?
Can youngster easily reach the foot controls?
Can youngster dress with proper protective gear including putting on helmet and fastening the chin strap?
While sitting on the vehicle, can youngster:
Squeeze the hand controls?
Operate the shift lever (if equipped)?
Operate the choke and fuel valve with ease?
Press the brake lever with sufficient pressure
Operate the controls without looking at them?
32
Ability
3. Youngster is sufficiently coordinated.
4. Youngster has sufficient endurance to maintain strength over a period of time.
✓
PART 4
Points to Evaluate
Can youngster walk a “balance beam” (2" x 4" x 8') flat on floor?
Can youngster ride a bicycle, rollerskate or skateboard safely?
Can youngster walk on tiptoes for 10 feet?
Can youngster jump rope?
Can youngster catch a ball with hands rather than with arms?
Can youngster play outdoor games without fatigue?
Can youngster participate in indoor games and sports without tiring before other youngsters?
33
PART 4
SOCIAL/EMOTIONAL DEVELOPMENT
Ability
1. Youngster can understand and follow rules.
✓
2. Youngster generally will obey parents and supervisors.
3. Youngster controls behavior according to expectations?
Points to Evaluate
Does youngster follow rules established at home?
Do teachers say that the youngster follows rules?
Does youngster listen and respond to adult supervision?
Does youngster comprehend the importance and seriousness of having rules and regulations?
Does youngster avoid challenging authority or rebelling when rules are imposed?
Does youngster show evidence of self-control...doesn’t get easily frustrated or upset?
Does youngster understand consequences associated with certain actions (like not wearing a safety belt in the car)?
Does youngster think about results before performing some action (like crossing the street, hitting or throwing a ball)?
34
Ability
4. Youngster understands other youngsters may be permitted to do what he/she may not be allowed to.
5. Youngster can give reasons and/or solutions to problems seen in the environment.
6. Youngster can make decisions based on reality and not fantasy.
✓
PART 4
Points to Evaluate
Does youngster recognize unsafe actions of other youngsters?
Does youngster appreciate being safer than others?
Does youngster accept rules that are more stringent than what other youngsters have to follow?
Can youngster explain how land (or grass) gets worn?
Can youngster explain how even small damage to land can take years to recover?
Can youngster distinguish between untouched land and used land?
Can youngster complete a task in a step-by-step fashion
(assemble a toy, clean a room)?
Does youngster comprehend real injury as opposed to
“cartoon” injury?
Does youngster respond with logical solutions when asked to solve a problem?
35
PART 4
REASONING AND DECISION-MAKING ABILITY
Ability
1. Youngster comprehends that interaction with others and things can result in injury.
✓ Points to Evaluate
Can youngster describe how and why a person received physical injury or pain?
Does youngster notice impending accidents or potential injury-producing events, such as in sports activities or bicycle riding?
Can youngster explain why it takes distance to stop?
Can youngster explain how moving at even low speed can result in injury if stopped suddenly or by hitting something?
2. Youngster has a basic understanding of what being careful means.
Does youngster know why rules are established?
Does youngster notice or recognize others being careful in action-oriented activities?
Does youngster notice professional athletes use protective gear as part of their sport?
36
Ability
3. Youngster understands that rules are made to reduce injury and provide long-term enjoyment.
4. Youngster has basic understanding of the physical limitations of stopping and turning.
✓
PART 4
Points to Evaluate
Can youngster explain the reason for rules at home or school?
Does youngster understand the value of prevention?
Of wearing protective gear?
Can youngster recognize that not following rules can eliminate future fun and enjoyment?
Can youngster explain what may happen if moving too fast while going around a curve on a bicycle? On a skateboard?
On an off-highway motorcycle?
37
38
FINAL NOTE
TO PARENTS
W e hope this booklet has helped you and your youngster take a “safety first” approach to off-highway motorcycle riding. All offhighway motorcycle riders must use good judgment and be responsible. It is up to YOU to set a good example about motorcycle safety. You must help your youngster ride sensibly and safely at all times. should ride on flat areas, gentle hills, and gradual slopes. Be sure that your youngster rides slowly over unfamiliar terrain to locate and avoid bumps, holes, and other possible hazards. You should check the area first.
The Motorcycle Safety Foundation also recommends a video program, The MSF DirtBike
School: Learn to Ride Safely . It demonstrates and discusses responsible riding practices.
After your youngster has mastered the riding skills in this booklet and has matured to a higher level of skills, he or she may be ready to practice more advanced riding. The Motorcycle
Safety Foundation’s Tips & Practice Guide for the
Off-Highway Motorcyclist booklet provides information about riding on hills, riding across slopes, and other more advanced skills.
Youngsters should have a good understanding of riding skills before using unfamiliar areas. They
It is also recommended that you and your youngster read the information in the owner’s manual. To find out more about rider education and off-highway motorcycle safety programs offered, or to order the video or publications, contact the Motorcycle Safety Foundation at
2 Jenner, Suite 150, Irvine CA 92618,
949.727.3227 or visit dirtbikeschool.com
BRAKES - The parts of a motorcycle which allow the operator to slow down or stop the machine.
BRAKE LEVER - The hand brake located on the handlebar.
BRAKE PEDAL - The foot brake which is operated by the right foot.
CABLES - Heavy insulated wires. There are two kinds: mechanical and electrical. Brake cables are mechanical. The headlamp cable is electrical.
CARBURETOR - Device which provides the engine the proper mixture of fuel and air.
CHOKE - A device which enriches the mixture of gasoline and air supplied to the engine for cold engine starting.
CLUTCH LEVER - The hand lever used to disengage the clutch when changing gears.
DRIVE CHAIN - The chain which connects the engine to the rear axle to give a motorcycle motion.
ENGINE STOP SWITCH - Switch used to stop the engine without removing the hands from the handlebars.
OHM TERMS
GLOSSARY
EXHAUST - Leftover gases from the combustion process that come out of the tailpipe when the motorcycle engine is running. Exhaust contains deadly carbon monoxide gases.
EYE PROTECTION - Goggles or a shatter resistant shield worn over the eyes while riding to protect against dust, flying insects, or other debris. Such eye protection, when tinted, may be effective against bright sun or snow-glare conditions.
FINE-C - A pre-start routine. A way to remember the pre-start routine:
F - Fuel valve on
I - Ignition on
N - Neutral
E - Engine stop switch in run position
C - Choke
FOOTPEGS - Pivoting pegs on which a motorcycle operator should keep his/her feet while riding.
FUEL VALVE - A valve, usually hand operated, with an on, off and “reserve” position. Controls gasoline flow to the carburetor.
39
GLOSSARY
HANDLEBAR - The metal bar attached to the front end of the motorcycle that turns the front wheel for steering. Many of the controls for the motorcycle are located on the handlebar.
HELMET - The most important protective clothing to be worn when operating a motorcycle. It covers the head and helps protect against skull fracture or brain injury in an accident.
OFF-HIGHWAY or OFF-ROAD VEHICLE -
Any vehicle, including off-highway motorcycles and
ATVs, which is restricted by law from operating on public roads.
OHM - Off-Highway Motorcycle
PSI - Refers to air pressure in the tires and stands for
“Pounds per Square Inch.”
READING THE TERRAIN - Looking well ahead while riding, anticipating hazards.
SHIFT LEVER - On those motorcycles equipped with a shift lever, it allows the operator to change gears. The shift lever is operated by the left foot.
TAILPIPE - That part of the exhaust system which expels waste gases.
THROTTLE - The control operated by the right hand which controls the engine speed.
TRACTION - Tread friction between the ground and the tires.
TRANSMISSION - Mechanism used to transmit power from the engine to the wheels.
40
CROSSWORD PUZZLE
ANSWERS
2.
H
3.
G
E
L
L M
O
1.
S
V
A
E
E
E
G
T
P
S
6.
F
O
4.
O
E
F
T Y
5.
F —
C L
R
U
7.
B
O
O
T
S
A
C
D
H
41
ANSWERS
NAME THE MOTORCYCLE PARTS (Typical)
1. Clutch lever
2. Hand brake lever
3. Foot brake lever or pedal
4. Throttle
5. Choke or enrichening device
6. Engine stop switch
7. Gas cap/tank vent
8. Starter (kick)
9. Electric starter (if equipped)
42
NOTES
43
44
NOTES
For the rider training location nearest you, call: (877) 288-7093
dirtbikeschool.com
© 2015 Motorcycle Safety Foundation, Inc.
2 Jenner, Suite 150 • Irvine, CA 92618
(949) 727-3227 • msf-usa.org
PN MSPU3444NC00
PARENTS,
YOUNGSTERS
& OFF-HIGHWAY
MOTORCYCLES
INDEX
A
Accessories
. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air filter
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Air filter box
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Air suspension XACT 5235
. . . . . . . . . . . . . . . . . 29
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Auxiliary substances
. . . . . . . . . . . . . . . . . . . . . 10
B
Basic chassis setting
with rider's weight, checking . . . . . . . . . . . . 29
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Brake fluid
of front brake, adding . . . . . . . . . . . . . . . . . 68
rear brake, adding . . . . . . . . . . . . . . . . . . . 74
Brake fluid level
of the front brake, checking . . . . . . . . . . . . . 67
rear brake, checking . . . . . . . . . . . . . . . . . . 73
Brake linings
of rear brake, changing . . . . . . . . . . . . . . . . 76
rear brake, checking . . . . . . . . . . . . . . . . . . 75
C
Capacity
Carburetor
float chamber, emptying . . . . . . . . . . . . . . . 92
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 58
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 58
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Choke
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . 97-98
Clutch
fluid level, checking . . . . . . . . . . . . . . . . . . 62
fluid level, correcting . . . . . . . . . . . . . . . . . 63
fluid, changing . . . . . . . . . . . . . . . . . . . . . . 64
Clutch lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
basic position, adjusting . . . . . . . . . . . . . . . 62
Coolant
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 88
draining . . . . . . . . . . . . . . . . . . . . . . . . . . 86
refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . 85-86
Cooling system
. . . . . . . . . . . . . . . . . . . . . . . . . 85
Customer service
. . . . . . . . . . . . . . . . . . . . . . . 10
E
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine number
. . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Environment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F
Figures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Filling up
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Foot brake lever
. . . . . . . . . . . . . . . . . . . . . . . . 18
basic position, adjusting . . . . . . . . . . . . . . . 73
Fork
air pressure, adjusting . . . . . . . . . . . . . . . . . 36
Fork article number
. . . . . . . . . . . . . . . . . . . . . . 13
Fork legs
basic setting, checking . . . . . . . . . . . . . . . . 35
bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 39
dust boots, cleaning . . . . . . . . . . . . . . . . . . 40
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 42
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Fork protector
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 41
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Frame
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Front fender
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 79
117
INDEX
INDEX
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fuel tank
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 55
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuel tank filler cap
Fuel tap
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel, oils, etc.
. . . . . . . . . . . . . . . . . . . . . . . . . 10
G
Gear oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
changing . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Gear oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 94
H
Hand brake lever
. . . . . . . . . . . . . . . . . . . . . . . 15
Handlebar position
. . . . . . . . . . . . . . . . . . . . . . 37
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 38
High-speed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 31
I
Implied warranty
. . . . . . . . . . . . . . . . . . . . . . . . 10
Intended use
. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
K
Kick starter lever
. . . . . . . . . . . . . . . . . . . . . . . 18
L
Link fork
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Lower triple clamp
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 44
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Lowspeed compression damping
shock absorber, adjusting . . . . . . . . . . . . . . 30
M
Main silencer
glass fiber yarn filling, changing . . . . . . . . . . 53
Manufacturer warranty
. . . . . . . . . . . . . . . . . . . . 10
Misuse
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 97
O
Owner's Manual
. . . . . . . . . . . . . . . . . . . . . . . . . 8
P
Play in throttle cable
Plug-in stand
. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Preparing for use
advice on preparing for first use . . . . . . . . . . 19
after storage . . . . . . . . . . . . . . . . . . . . . . 100
checks and maintenance measures when
preparing for use . . . . . . . . . . . . . . . . . . . . 22
Protective clothing
. . . . . . . . . . . . . . . . . . . . . . . 8
R
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 81
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Rebound damping
fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 37
shock absorber, adjusting . . . . . . . . . . . . . . 31
Riding sag
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rubber grip
S
Safe operation
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . 50
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Service hour counter
. . . . . . . . . . . . . . . . . . . . . 18
Service schedule
. . . . . . . . . . . . . . . . . . . . . 27-28
Shift lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shock absorber
riding sag, checking . . . . . . . . . . . . . . . . . . 33
spring preload, adjusting . . . . . . . . . . . . . . . 34
static sag, checking . . . . . . . . . . . . . . . . . . 33
Shock absorber article number
. . . . . . . . . . . . . . 14
Spare parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Start number plate
installing . . . . . . . . . . . . . . . . . . . . . . . . . . 47
118
removing . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Steering head bearing
lubricating . . . . . . . . . . . . . . . . . . . . . . . . . 47
Steering head bearing play
Stop button
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . 106
carburetor . . . . . . . . . . . . . . . . . . . . . . . . 105
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 107
chassis tightening torques . . . . . . . . . . . . . 108
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Throttle cable routing
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Throttle grip
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Tire pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Transporting
. . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting
. . . . . . . . . . . . . . . . . . . . 101-102
Type label
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
U
Use definition
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
V
Vehicle identification number
. . . . . . . . . . . . . . . 13
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . 11
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 12
W
Work rules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INDEX
119
*3214407en*
3214407en
03/2021
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria
KTM.com
Photo: Mitterbauer/KISKA/KTM
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