2000r.pdf

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:

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR

BODY AND YOUR LIFE.

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 mainten-

ance, 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 S PORTMOTORCYCLE 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 SUBSTI -

TUTING THEM WITH OTHERS . I T SHALL BE ACCEPTABLE TO STOP MANUFACTURING A CERTAIN MODEL WITHOUT PREVIOUS

ANNOUNCEMENT . I N THE EVENT OF SUCH MODIFICATIONS , PLEASE ASK YOUR LOCAL KTM DEALER FOR INFORMATION .

W E SHALL NOT BE HELD LIABLE FOR ANY PRINTING ERRORS .

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 informa-

tion 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 modificati-

ons 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 !

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

INDEX

Page

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4

Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4

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

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

TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .35

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

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

CONSERVATION FOR WINTER OPERARION . . . . . . . . .37

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Re-initiation after time of storage . . . . . . . . . . . . . . . . .37

TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . .38

TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .40

HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . . . . .Appendix

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