Art.Nr. 3.210.
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.
Introduction We would like to congratulate you on your purchase of a KTM motorcycle. ENGLISH 2 You are now the owner of a state-of-the-art sports motorcycle that guarantees to bring you lots of fun and enjoyment, provided that you clean and maintain it appropriately.
Page Page SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4 Checking of brake fluid level - front brake . . . . . . . . . . .21 Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Refilling the front brake fluid reservoir . . . . . . . . . . . . . .21 Checking the front brake pads . . . . . . . . . . . . . . . . . . .21 Replacing the front brake pads . . . . . . . . . . . . . . . . . . .22 Changing the basic position of the brake pedal . . . . . .
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. ENGLISH 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. 4 OPERATION INSTRUMENTS Clutch lever 1 The clutch lever 1 is located on the left side of the handlebar.
Digital speedometer, indicator lamps (EXC) 1 The green control lamp 1 flashes when the indicator is working in the same rhythm as the flashing indicator. The blue control lamp 2 lights up when the high beam is on. 3 Speedometer – digital (EXC) TRP Some models are equipped with a digital speedometer 3. KMH = Speed, max.
Combination switch (EXC) 1 2 A C The light switch has 2, respetively 3 switch positions. A = Light off (this function is not available in all models) B = Low beam on C = High beam on You may use button 1 to actuate the horn. The red short circuit button 2 serves to switch off the engine. Leave the switch pressed until the engine stops. B ENGLISH Headlamp switch (EXC USA) In this model the headlamp is switched on with the pull switch 3.
Filler cap To open filler cap: Turn the filler cap counter-clockwise. To close filler cap: ut filler cap on and tighten it by turning it clockwise. Install tank breather hose 1 without kinks. Fuel The racing engine needs premium gasoline with an octane number of 95 or higher. ! CAUTION ! LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE. USE WARNING GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS.
Choke If you pull the choke button 1 out as far as possible, a bore in the carburetor will be unblocked through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. 1 To deactivate the choke, push the choke button back into its basic position. ENGLISH 8 Shift lever 2,3,4 (5,6) The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration.
Compression damping of fork 2 2 WP 1418W710 . . . . . . . . . . . . . . . 20 clicks (SX) WP 0518W712 . . . . . . . . . . . . . . . 20 clicks (EXC/MXC) Rebound damping of fork Hydraulic rebound damping determines the reaction when the fork is rebound. By turning the adjusting screw 1 (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding.
Compression damping of shock absorber (MXC, EXC) 2 The compression damping (during compression) can be adjusted for the MXC and EXC shock absorbers (Mono Compression Control). The degree of damping can be adjusted by turning adjusting screw 1 with a screwdriver. Turning in a clockwise direction will increase the damping, turning in a counterclockwise direction will decrease the damping. STANDARD ADJUSTMENT: – Turn the adjusting screw clockwise to the stop.
DRIVING INSTRUCTIONS When you start off, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: 1 CHECK THE OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. 2 FUEL Check that there is sufficient fuel in the tank; when closing the filler cap, check that the tank venting hose is free of kinks.
Starting when the engine is cold 1 2 3 4 5 1 ENGLISH 12 2 Open the fuel tap 1. Swing up the side stand or center stand. Put the gear in neutral. Operate the choke 2. Leave throttle closed and kick the kickstarter briskly ALL THE WAY or actuate the E-starter. WARNING – IF YOU WANT TO START THE ENGINE, MAKE SURE THAT YOU ALWAYS PUT ON STURDY MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES. YOU MIGHT SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY KICK BACK AND PROPEL YOUR FOOT UPWARD WITH GREAT VEHEMENCE.
NOTE: DEDICATED TO NOTHING BUT OFFROAD RACING, 400/520 SX/MXC/EXC RACING MODELS MAKE NO COMPROMISES IN THEIR DESIGN. AS SUCH, THEY DO NOT INCLUDE ANY RADIATOR FAN, AND THE SIZE OF THE RADIATOR IS DIMENSIONED FOR OPTIMUM ERGONOMICS. IN NORMAL RACING, THE COOLING SYSTEM IS SUFFICIENT. IF YOU USE YOUR MOTORBIKE IN OTHER CONDITIONS, PLEASE NOTE THAT – THE E-STARTER ALLOWS YOU TO START MXC/EXC RACING MODELS AGAIN AT ANY TIME.
PERIODIC MAINTENANCE SCHEDULE 2001 ADD- ON PARTS BRAKES CHASSIS WHEELS ENGLISH 14 CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! 400/520 SX/MXC/EXC RACING 1.
AND MAINTENANCE TO BE Check oil level Check brake fluid level Check brake pads for wear Check lights for function Check horn for function Lubricate and adjust cables and nipples Bleed fork legs regulary Remove and clean fork dust bellows regulary Clean and lubricate chain, check tension and adjust if necessary Clean air filter and filter box Check tyres for pressure and wear Check cooling fluid level Check fuel lines for leaks Drain and clean float chamber Check all control elements for smooth operation
MAINTENANCE WORK ON CHASSIS AND ENGINE WARNING MAINTENANCE AND ADJUSTING WORK MARKED WITH AN ASTERISK (*) REQUIRES EXPERT SKILLS AND TECHNICAL KNOW-HOW. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED SKILLED STAFF.
Breather plug front fork After every 5 hours of use for competitive racing, slacken the breather plugs 1 a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to have this job performed in the course of the periodical maintenance service. 1 ! CAUTION ! PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK.
How to change the handlebar position The handlebar position can be readjusted by 22 mm. Thus, you can put the handlebar to the position that is the most convenient for you. The upper triple clamp 1 includes 2 bores arranged at a distance of 15 mm (0,6 in) from one another. The bores at the handlebar support 2 are offset from the center by 3.5 mm (0,13 in). Accordingly, you can mount the handlebar in 4 different positions.
Check chain tension To check the chain tension, park the motorcycle. Press chain upward at the end of the chain sliding component. The distance between chain and swing arm should be approx. 15 mm (0.6 in). In the course of this procedure, the upper chain portion A must be taut (see illustration). If necessary, correct chain tension. A WARNING – – TENSIONING OF THE CHAIN WILL PUT ADDITIONAL LOAD ON THE COMPONENTS OF THE SECONDARY DRIVETRAIN (CHAIN, BEARINGS OF TRANSMISSION AND REAR WHEEL).
Chain wear In order to check the chain wear, regard the following indications: Shift the gear into idling and pull the upper chain strand with approx. 10-15 Kilogramm (33 lb) upwards (see figure). Now one can measure a space of 18 chain reels at the lower chain strand. The chain should be replaced at the latest when a space of 272 mm (10.70 in) is measured. Chains do not always wear off evenly, therefore repeat the measurement at different places on the chain.
Adjusting of free travel at the hand brake lever Free travel at the hand brake lever may be readjusted by using adjustment screw 1. In this way, the position of the point of pressure (i.e., the resistance you feel on the hand brake lever when the brake pads are pressed against the brake disc) can be adjusted for any hand size. min. 3 mm 1 ! CAUTION ! THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0.1 IN).
Replacing front brake pads * 1 Press the brake caliper toward the brake disk, to put the brake piston in its basic position. Remove clips 1 and pull out bolt 2. Remove brake pads from the brake caliper. Clean the brake caliper and the brake caliper support with compressed air. Check the sleeves of the guide bolts for damage, and grease guide bolts if necessary. Mount the right brake pad and fix it with the bolt. Mount the left brake pad and insert the bolt until it stops. Mount the clips.
Checking the rear brake pads min. 1 mm The brake pads can be inspected from the rear. The thickness of the linings may not be less than 1 mm (0.04 in). WARNING AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN 1 MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON’T PUT OFF HAVING YOUR BRAKE PADS CHANGED.
The speedometer shaft must be placed as running along the outside of the fork guard and pas the triple clamp toward the speedometer. Mount the collar nut 4, turn the speedometer drive such that the speedometer shaft leads upward parallel to the fork leg (see photo), tighten the clamping sceews on the right side 6 to prevent the wheel spindle from turning and tighten the collar nut to 40 Nm (30 ft.lb).
Tires, air pressure Tire type, tire condition, and air pressure level affect the way your motorcycle rides, and they must therefore be checked whenever you are getting ready to go anywhere on your motorcycle. – Tire size can be found in the technical specifications and in their homologation certificate – Tire condition has to be checked every time you want to ride your motorcycle. Before leaving, check tires for punctures and nails or other sharp objects that might have become embedded in them.
TOTAL MILEAGE „DST“ 2. push the left button until the right figure is showed in the display 1. use the right button to select the position to be changed AFTER CHANGING BATTERY ENGLISH 1 sec 26 3. by pushing the right button you jump to the next figure 4. repeat nos. 2 + 3 until the previously noted total mileage is indicated 5. push the button on the back with a sharp object approx. 1 second to terminate the setting procedure (the value is thus stored) TIME „CLK“ 1.
WHEEL CIRCUMFERENCE „WS“ 5 sec 2. use the right button to select the position to be changed 1 sec ENGLISH 1. make sure that the indication "TRP" is active and push the button on the back approx. 5 seconds ("WS" appears) 27 3. push the left button until the right figure is showed in the display 4. repeat nos. 2 + 3 until correct wheel circumference is indicated km/h: WS = mm x 3,14 mm x 3,14 5. push the button on the back for approx.
Battery (MXC/EXC) The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. Removing the battery: First disconnect the negative and then the positive pole of the battery. Remove filter box cover and unhitch both rubber bands 1. Remove battery.
Fuse (MXC/EXC) The fuse 1 is disposed in the starter relay of the E-starter 2 underneath the left side paneling. Having removed the left side paneling, the air box cover and the protection cover A, you will be able to see the fuse. A The starter relay also contains a (10 amp) spare fuse 3. Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. The fuse capacity is 10 Ampere.
Cooling system Coolant is circulated by a water pump 1 located in the engine. When the engine is cold the coolant circulates only through the cylinder and the cylinder head. After the engine has reached its operating temperature (about 70°C, 158°F), the thermostat 2 opens and the coolant is also pumped through both aluminum radiators. Air blowing in through the radiators cools the coolant. The slower the speed of the motorcycle, the less the coolant is cooled down.
Cleaning the air filter * 3 1 A dirty air filter impairs the air-flow rate, reduces the engine performance, and increases the fuel consumption. In extreme cases, dirt may even get into the engine and cause damage. Therefore, change the air filter in regular intervals. For this purpose, rotate the two quick-release fasteners 1 counter-clockwise and pull them outward up to the stop, pull the filter box cover forward and remove it.
Checking the adjustment of the hand decompression release cable * 1 3 2 10 mm Start the engine and, at idling speed, slowly pull the hand decompression lever until you can feel the thumping of the rocker arm on the lever. The backlash until said thumping should be approx. 10mm, measured at the lever's outer end. If necessary, correct this backlash. To adjust move back the protective cover 1, loosen the counter nut 2 and correct the adjustment screw 3 accordingly.
Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2. The adjusting wheel is used to adjust the basic setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system.
Draining of float chamber of the carburetor Following every wet cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes malfunction. 1 Perform this task on a cold engine. Close the fuel tap and place a cloth underneath the carburetor, which is able to absorb any escaping fuel. Unscrew the plug 1 and clean it with compressed air. Check the O-ring and reinstall the plug.
Engine oil Only use fully synthetic branded oils (Shell Advance Ultra 4) meeting or surpassing the quality requirements of API classes SG or SH (see specifications on the container). API: SG, SH TEMPERATUR – 32°F 10W 40 10W 50 + CAUTION ! ! INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. 15W 40 15W 50 Changing the engine oil * NOTE: WHEN CHANGING THE ENGINE OIL, IT IS NECESSARY TO CLEAN THE SHORT AND LONG OIL SCREENS AND TO REPLACE BOTH OIL FILTERS.
1 CHANGING THE OIL FILTERS Remove the screw 1 and swing the brake fluid container sideward. Place a receptacle underneath the engine to collect the drained oil. Remove the 4 screws 2 and dismount the two oil filter covers. 2 2 2 2 ENGLISH Using circlip pliers, you may now pull the oil-filter inserts 3 out of the housing. Clean the oil filter cover, the sealing surfaces of the O-rings and the engine casing. Check the O-rings of the oil filter covers for damage and, if necessary, replace them.
TROUBLE SHOOTING If you let the specified maintenance work on your motorcycle be carried out, disturbances can hardly be expected. Should an error occur nevertheless, we advise you to use the trouble shooting chart in order to find the cause of error. We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer. Engine doesn’t (E-starter). crank Engine cranks but doesn’t start (E-starter). Engine will not start (Kickstarter).
Carburettor fuel level too high because float needle valve is dirty or worn out Dismount carburettor and check if worn out Loose carburettor jets Tighten jets Electronical ignition timing faulty Have ignition system checked Fuel supply partically interrupted or carburettor dirty Clean and check fuel system as well as carburettor Float leaks Replace the float Air filter very dirty Clean or replace air filter Exhaust system is not tight, deformed, or the silencer contains not enough glass fiber ya
CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal brand-name washing detergent and a sponge. The hard dirt can be removed before washing with the help of a soft water jet. CAUTION ! ! CLEAN YOUR MOTORCYCLE WITH A HIGH-PRESSURED CLEANER OR A HIGH-PRESSURED WATER JET. THE WATER COULD OTHERWISE RUN INTO THE ELECTRICAL COMPONENTS, CONNECTORS, SHEATHED CABLES, BEARINGS, CARBURETOR ETC.
TECHNICAL DATA – ENGINE 400/520 SX, MXC, EXC RACING 2002 ENGLISH 40 Type Design Displacement Bore/Stroke Ratio Fuel Valve Timing Camshaft Valve diameter Intake Valve diameter Exhaust Valve clearence cold Intake Valve clearence cold Exhaust Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Quantity of engine oil Primary ratio Clutch Transmission claw shifted Gear ratio 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear 6th Gear Ignition system Generator
Hexagon collar screw engine case, clutch cover, ignition cover Oil drain plug Allan head plug oil screen short Hexagon plug oil screen long Plug pressure valve Jet screw and hollow screw oil line Screws oil pump cover Hexagon collar screw cylinderhead top section Hex.
ASSEMBLY CLEARANCE, WEAR LIMIT 400 Crankshaft axial clearance run out of crank stud Conrod bearing Cylinder Piston 400 (cast) ENGLISH 42 max. 0,08 mm/0,003 in radial clearance max. 0,05 mm/0,002 in max.
TECHNICAL DATA – CHASSIS 400/520 SX, MXC, EXC RACING 2002 Batterie Steering head angle Wheel base Seat hight, unloaded Ground clearance, unloaded Dead-weight * 400/520 EXC RACING 400/520 MXC, EXC USA Central tube chrom-moly-steel frame WP USD 4860 MXMA WP Up Side Down 4357 MXMA 295/320 mm WP Progressive Damping System shock absorber, aluminium swingarm Disk brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Disk brake with carbon-steel brake disc Ø 220 mm (8.
HEAD WORD INDEX ENGLISH 44 Page Page Adjust the throttle cables ....................................................32 Dismounting and mounting the rear wheel .........................24 Adjusting digital speedometer.............................................26 Draining of float chamber of the carburetor........................34 Adjusting of free travel at the hand brake lever...................21 Driving instructions .............................................................
KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet: www.ktm.
