KTM 400 LS-E/MIL User manual

KTM-Sportmotorcycle AG
A–5230 Mattighofen
www.ktm.at
KTM Group Partner
12/2003 FOTO: MITTERBAUER
400 LS-E/mil
ART.NR: 3.211.23-E
OWNER´SMANUAL2004

IMPORTANT
PLEASE READ THE ENTIRE MANUAL BEFORE YOU TAKE YOUR
FIRST RIDE. IT CONTAINS USEFUL TIPS AND INFORMATION THAT
WILL MAKE IT EASIER FOR YOU TO OPERATE AND HANDLE THE
MOTORCYCLE.
IN YOUR OWN INTEREST, BE SURE TO READ THE INFORMATION
MARKED AS FOLLOWS:

WARNING

FAILING TO OBSERVE THESE INSTRUCTIONS CAN BE DANGEROUS TO
LIFE AND LIMB!
! CAUTION !
FAILING TO OBSERVE THESE INSTRUCTIONS MAY DAMAGE THE
MOTORCYCLE OR IMPAIR ITS TRAFFIC SAFETY.
Please fill in the vehicle's serial numbers below.
Chassis number
Engine number
Dealer's stamp
KTM SPORTMOTORCYCLE AG RESERVES THE RIGHT TO MODIFY OR CANCEL EQUIPMENT, TECHNICAL
INFORMATION, COLORS, MATERIAL, SERVICE OFFERS, SERVICES, ETC. WITHOUT NOTICE AND WITHOUT STATING
REASONS OR TO STOP PRODUCING A CERTAIN MODEL WITHOUT PRIOR NOTICE. NO LIABILITY ACCEPTED FOR
PRINTING ERRORS.
1

Dear KTM owner,
Congratulations on your decision to purchase a KTM motorcycle.
You are now the proud owner of a modern, sporty motorcycle that will certainly give you
great pleasure if you give it the service and care it deserves. Be sure to read this owner's
manual carefully before starting up for the first time to become familiar with its opera-
tion and features, even if this will take a little time. The manual will show you how to
tune the motorcycle to meet your needs and how to protect yourself from injuries. In
addition the handbook contains useful information on servicing the motorcycle. The
manual was up to date for this series when it went into print. Minor deviations resulting
from enhancements to the motorcycle design cannot be entirely precluded.
The Operating Manual is an integral part of the motorcycle and should be handed over
to the owner upon purchasing.
Perhaps you are a motorcycle pilot with excellent technical skills and will be able to ser-
vice the motorcycle as described in this manual yourself. If not, please note that you
should have the work marked with an asterisk * in the chapter "Maintenance of the
chassis and engine" performed by an authorized KTM workshop, also in the interest of
your own safety.
For your safety, only use spare parts and accessories approved by KTM. KTM shall not
assume any liability for other products or consequential damage resulting from the use
of such products.
Please observe the prescribed breaking-in periods, inspection intervals and service inter-
vals. Strict observance will significantly prolong the service life of your motorcycle. Have
all service work performed by an authorized KTM workshop to avoid losing your right to
claim under the warranty.
Enjoy driving your motorcycle!
The ISO 9001 certification is part of KTM Sportmotorcycle AG's quality system and
an ongoing modification of the quality assurance program for a better future.
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
SUBJECT TO CHANGES IN CONSTRUCTION AND DESIGN.
©by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved
2

LOCATION OF SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . .4
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4
CONTROL ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . . .4
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Choke lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speedometer, indicator lamps . . . . . . . . . . . . . . . . . . . . .5
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Starter pushbutton, emergency off switch, light switch . .5
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Switch for the grip heater . . . . . . . . . . . . . . . . . . . . . . . .6
Switch for the camouflage light . . . . . . . . . . . . . . . . . . . .6
Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Compression damping of the fork . . . . . . . . . . . . . . . . . .8
Rebound damping of the fork . . . . . . . . . . . . . . . . . . . . .8
Compression damping of the shock absorber . . . . . . . . . .8
Spring preload of the shock absorber . . . . . . . . . . . . . . . .8
Rebound damping of the shock absorber . . . . . . . . . . . . .8
Rear mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Headlight range adjustment . . . . . . . . . . . . . . . . . . . . . . .9
Headlight mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Taillight mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Tank bag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Trunk system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Grab handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Center stand / side stand . . . . . . . . . . . . . . . . . . . . . . . .10
TIPS AND WARNINGS WHEN STARTING THE MOTORCYCLE . .11
Information on initial start-up . . . . . . . . . . . . . . . . . . . .11
Breaking-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Accessories and payload . . . . . . . . . . . . . . . . . . . . . . . .11
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .12
Tests to be performed before each start . . . . . . . . . . . . .12
Starting with a cold engine . . . . . . . . . . . . . . . . . . . . . .13
Starting with a warm or hot engine . . . . . . . . . . . . . . . .13
Starting with a flooded engine . . . . . . . . . . . . . . . . . . . .13
Starting the engine with the kickstarter . . . . . . . . . . . . .13
Driving off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Shifting gears, cruising . . . . . . . . . . . . . . . . . . . . . . . . . .14
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Stopping and parking . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fuel, refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Activating the ignition curve for low-octane fuel . . . . . .15
LUBRICATION AND MAINTENANCE CHART . . . . . . . . . .16
MAINTENANCE WORK - CHASSIS AND ENGINE . . . . . . .18
Removing the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Checking and adjusting the steering head support * . . .19
Bleeder screws for the telescopic fork . . . . . . . . . . . . . .19
Cleaning the dust boots on the telescopic fork . . . . . . . .19
Changing the spring preload of the shock absorber . . . .20
Checking the rubber ring the WP shock absorber . . . . .20
Lubricating the shock absorber linking . . . . . . . . . . . . . .20
Checking the chain tension . . . . . . . . . . . . . . . . . . . . . .21
Correcting the chain tension . . . . . . . . . . . . . . . . . . . . .21
Chain care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
General information on KTM disk brakes . . . . . . . . . . . .23
Changing the basic setting of the hand brake lever . . . .23
Checking the front brake fluid level . . . . . . . . . . . . . . . .24
Refilling the front brake fluid * . . . . . . . . . . . . . . . . . . .24
Checking the front brake pads . . . . . . . . . . . . . . . . . . . .24
Changing the basic setting the foot brake lever * . . . . .24
Checking the rear brake fluid level . . . . . . . . . . . . . . . . .25
Refilling the rear brake fluid * . . . . . . . . . . . . . . . . . . . .25
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .25
Dismounting and mounting the front wheel . . . . . . . . .26
Dismounting and mounting the rear wheel . . . . . . . . . .27
Checking the rubber damping seal on the rear hub * . . .27
Tires, tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Checking the spoke tension . . . . . . . . . . . . . . . . . . . . . .28
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Main fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Fuses for individual power consumers . . . . . . . . . . . . . .30
Replacing the headlight lamp . . . . . . . . . . . . . . . . . . . . .31
Replacing the parking lamp . . . . . . . . . . . . . . . . . . . . . .31
Replacing the rear brake/taillight . . . . . . . . . . . . . . . . . .31
Adjusting the headlight range . . . . . . . . . . . . . . . . . . . .32
Changing the basic setting of the clutch lever . . . . . . . .33
Checking the oil level in the hydraulic clutch . . . . . . . . .33
Checking the setting of the hand decompression cable *33
Choke cable - checking and adjusting the play * . . . . . .33
Adjusting the throttle cable * . . . . . . . . . . . . . . . . . . . . .34
Adjusting the idle speed * . . . . . . . . . . . . . . . . . . . . . . .34
Draining the float chamber in the carburetor * . . . . . . .34
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Checking the cooling liquid level . . . . . . . . . . . . . . . . . .35
Cleaning the air filter * . . . . . . . . . . . . . . . . . . . . . . . . .36
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Checking the engine oil level . . . . . . . . . . . . . . . . . . . . .36
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Changing the engine oil, oil filter and fine screen filter,
ventilating the oil system * . . . . . . . . . . . . . . . . . . . . . .37
Changing the oil filter * . . . . . . . . . . . . . . . . . . . . . . . . .38
TOOL SET DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
PRESERVATION FOR WINTER OPERATION . . . . . . . . . . .43
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Starting up after immobilization . . . . . . . . . . . . . . . . . . .43
TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .44
TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . . .45
TIGHTENING TORQUES - CHASSIS . . . . . . . . . . . . . . . . . .46
COMPARISON OF AUTOMOTIVE FLUIDS . . . . . . . . . . . .46
CIRCUIT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
INDEX
Page Page
3

2
3
B
1-3 mm
1
A
LOCATION OF SERIAL NUMBERS
CONTROL ELEMENTS
Chassis number
The chassis number is embossed on the right side of the steering head pipe.
Write the number down on page 1.
Engine number, engine type
The engine number and engine type are imprinted on the right side of the
engine below the engine sprocket. Write the number down on page 1.
Clutch lever
The clutch lever 1is located on the left side of the handlebar. The basic
setting of the clutch lever can be adjusted with adjusting screw A(see
Maintenance Work).
Hand brake lever
The hand brake lever 3is located on the right side of the handlebar and
actuates the front brake. The basic setting of the hand brake lever can be
changed with adjusting screw B(see Maintenance Work).
Hand decompression lever
The hand decompression lever 2is only used in 2 exceptional cases:
a) When the engine is flooded.
Sometimes the starter engine won't switch on again because the auto-
matic decompression system is not functioning. In this case, pull the
hand decompression lever and start again. Afterwards you will be able
to start normally.
b) When you are trying to "jump start" the motorcycle
While pushing the motorcycle, pull the hand decompression lever to
help the engine start up.
4