400/520 SX, EXC RACING BEDIENUNGSANLEITUNG OWNERS HANDBOOK MANUALE D'USO MANUEL D'UTILISATION MANUAL DE INSTRUCCIONES 2000 Art.Nr. 3.205.72 11/99 IMPORTANT WE STRONGLY SUGGEST THAT YOU READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE GOING ON YOUR FIRST RIDE. IT CONTAINS A GREAT DEAL OF INFORMATION AND ADVICE WHICH WILL HELP YOU USE AND HANDLE YOUR BIKE PROPERLY. IN YOUR OWN INTEREST, PLEASE PAY PARTICULAR ATTENTION TO NOTICES THAT ARE MARKED AS FOLLOWS: WARNING ! CAUTION ! IGNORING THESE INSTRUCTIONS COULD CAUSE DAMAGE TO PARTS OF YOUR MOTORCYCLE OR THAT THE MOTOR-CYCLE IS NOT ROAD-SAFE ANYMORE. Please insert the series numbers of your motorcycle in the boxes below Frame number Engine number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, 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; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY ANY EQUIPMENT, TECHNICAL SPECIFICATIONS, COLORS, MATERIALS, SERVICES OFFERED AND RENDERED, AND THE LIKE SO AS TO ADAPT THEM TO LOCAL CONDITIONS WITHOUT PREVIOUS ANNOUNCEMENT AND WITHOUT GIVING REASONS, OR TO CANCEL ANY OF THE ABOVE ITEMS WITHOUT SUBSTITUTING THEM WITH OTHERS. ANNOUNCEMENT. IT SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS IN THE EVENT OF SUCH MODIFICATIONS, PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION. WE SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS. ENGLISH 1 IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR BODY AND YOUR LIFE. Introduction We would like to congratulate you on your purchase of a KTM motorcycle. Let us also take this opportunity to thank you for putting your trust in us; we will not let you down. You are now owner of a sporty and modern motorcycle which you are bound to have a great time with provided you care for it properly. Before going for a first ride on your motorbike, you should read this Owner's Handbook carefully, even if this takes some of your precious time, so as to familiarize yourself with how your motorbike is to be operated and which features it offers you. Only by doing so will you learn how you can best tune your motorcycle to your needs and how you can avoid bodily injuries. In addition, this Owner's Handbook contains invaluable information about motorcycle maintenance. At the time of printing, this User's Guide corresponded to the latest state of this model family. It is, however, possible that we may have made slight modifications in the meantime due to development in our motorcycle design. The Owner's Handbook is an essential part of the motorbike and should - when the bike is sold be handed over to the new owner. Many motorcyclists have a good working knowledge of motorcycle mechanics; if this is true in your case, you will be able to use this Owner's Handbook to carry out most of the maintenance steps yourself. If, on the other hand, you are not very familiar with motorcycles, it might be better to have a professional KTM dealer perform those steps marked by * found in the chapter entitled "Maintenance Work on Chassis and Engine" of this manual. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. Be sure to have any maintenance jobs performed by an authorized KTM dealer. Address your special requests to an authorized KTM dealer who, should the need arise, will be supported by the KTM importer. Please do not forget to don your helmet, eye protection, and protective clothing when going for a ride. KTM riders are responsible riders! We wish you a lot of fun when driving ! ENGLISH 2 KTM Austria's certificate of achievement for its Quality System ISO 9001 is the beginning of an on-going total re-engineering quality plan for a brighter tomorrow. KTM SPORTMOTORCYCLE AG 5230 MATTIGHOFEN, AUSTRIA Attachments: 1 spare parts manual chassis 1 spare parts manual engine ALL RIGHTS RESERVED TO MAKE ALTERNATIONS TO DESIGN AND MODEL. © by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved INDEX Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4 OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4 Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . .4 Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Digital speedometer, indicator lamps (EXC) . . . . . . . . . . .5 Digital speedometer (EXC) . . . . . . . . . . . . . . . . . . . . . . .5 Odometer (EXC USA) . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Speedometer, indicator lamps (EXC - Australia) . . . . . . . .5 Short circuit button (SX) . . . . . . . . . . . . . . . . . . . . . . . . .5 Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6 Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . . . . . .6 Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Emergency OFF button (EXC) . . . . . . . . . . . . . . . . . . . . .6 Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . .6 Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Compression damping of fork . . . . . . . . . . . . . . . . . . . . .8 Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .9 Compression damping of shock absorber . . . . . . . . . . . .9 Rebound damping of shock absorber . . . . . . . . . . . . . . .9 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .10 PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE . .13 MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .14 Changing the original position of the clutch lever . . . . .14 Checking and adjusting the steering head bearing . . . . .14 Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .15 Cleaning the dust sleeves of the telescopic fork . . . . . . .15 How to change the handlebar position . . . . . . . . . . . . .15 Changing the spring preload of shock absorber . . . . . . .16 Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .17 Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 General informations about KTM disc brakes . . . . . . . .18 Adjusting of free travel at the hand brake lever . . . . . . .18 Checking of brake fluid level - front brake . . . . . . . . . . .19 Refilling the front brake fluid reservoir . . . . . . . . . . . . . .19 WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . . . . .Appendix HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .40 TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . .38 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Re-initiation after time of storage . . . . . . . . . . . . . . . . .37 CONSERVATION FOR WINTER OPERARION . . . . . . . . .37 Page Checking the front brake pads . . . . . . . . . . . . . . . . . . .19 Replacing the front brake pads . . . . . . . . . . . . . . . . . . .19 Changing the basic position of the brake pedal . . . . . .20 Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .20 Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .20 Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .21 Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .21 Dismounting and mounting the front wheel . . . . . . . . .21 Dismounting and mounting the rear wheel . . . . . . . . .22 Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .23 Replacing the battery of the digital speedometer . . . . .23 Adjusting digital speedometer . . . . . . . . . . . . . . . . . . .24 Check/set distance of magnetic sensor . . . . . . . . . . . . .25 Battery (EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Fuse (EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Replacing head light lamp (H4) . . . . . . . . . . . . . . . . . .27 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .28 Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . .28 Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .29 Replacing the glass fiber yarn packing of the silencer . .29 Cleaning the spark arrestor (EXC USA) . . . . . . . . . . . . .29 Draining of float chamber of the carburetor . . . . . . . . .27 Checking adjustment of the hand decompression release cable .30 Adjust the throttle cables . . . . . . . . . . . . . . . . . . . . . . .30 Checking the oil level of the hydraulic clutch . . . . . . . .30 Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .30 Carburetor adjust idling . . . . . . . . . . . . . . . . . . . . . . . .31 Adjusting the mixture control screw . . . . . . . . . . . . . . .31 Checking the float level . . . . . . . . . . . . . . . . . . . . . . . .31 Draining of float chamber of the carburetor . . . . . . . . .32 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Checking engin oil level . . . . . . . . . . . . . . . . . . . . . . . .32 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .33 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .35 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 ENGLISH 3 SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the field on page no 1. Engine number, engine type The engine number and the engine type are stamped into the left side of the engine below the engine sprocket. Please note this number down on page 1. ENGLISH 4 1 A 2 3 B OPERATION INSTRUMENTS Clutch lever The clutch lever 1 is located on the left side of the handlebar. The adjusting screw A is used to change the original position of the clutch lever (see maintenance work on chassis and engine). Hand decompression lever The hand decompression lever 2 is needed only if a fall on your motorcycle causes overflowing in the carburetor. To "pump the engine free", pull the hand decompression lever during the starting procedure. The outer end of the lever must at all times provide for a backlash of approx. 10mm (0,4 in). Only thereafter may it cause valve motion (to be recognized by the stronger resistance which the hand decompression level encounters). ! ­ ­ NEVER CAUTION ! USE THE HAND DECOMPRESSION LEVER TO TURN OFF THE ENGINE. RATHER, USE THE SHORT-CIRCUIT BUTTON OR THE EMERGENCY-OFF BUTTON. THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED. A LACK OF PLAY IN THE DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE. Hand brake lever The hand brake lever 3 is mounted on the handle bars on the right and actuates the front wheel brake. The adjusting screw B can be used to change the basic position of the hand brake lever (see "Maintenance"). WARNING IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS "SPONGY" (TOO MUCH GIVE), THIS IS AN INDICATION THAT SOMETHING IS WRONG WITH ...