KTM 400 SX RACING 2000 User guide

BEDIENUNGSANLEITUNG
OWNER’S HANDBOOK
MANUALE D’USO
MANUEL D’UTILISATION
MANUAL DE INSTRUCCIONES
ART. NR. 3.205.30
9.97
400/620
SX/SC/EGS
’98

ENGLISH
1
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

IGNORING THESE INSTRUCTIONS, CAN ENDANGER YOUR
BODY AND YOUR LIFE.
!
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
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 ren-
dered inoperative by any person.
COMSUMER INFORMATION FOR AUSTRALIA ONLY

ENGLISH
2
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. Your owner’s handbook will furnish you
with important information on how to operate and maintain your new KTM motorcycle.
At the time of printing, the handbook covered the most up-to-date models in this series.
It is, however, possible that we may have made slight modifications in the meantime due
to development in our motorcycle design.
Many motorcyclists have a good working knowledge of motorcycle mechanics; if this is
true in your case, you will be able to use this manual to carry out most of the mainten-
ance 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 inter-
vals. 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.
We wish you a lot of fun when driving !
KTM SPORTMOTORCYCLE AG
5230 MATTIGHOFEN, AUSTRIA
Attachments for the models SX and SC: 1 spare parts manual chassis
1 spare parts manual engine
1 owner handbook for WP Extreme fork
1 owner handbook for WP shock absorber
ALL RIGHTS RESERVED TO MAKE ALTERATIONS TO DESIGN AND MODEL.
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.

ENGLISH
3
Page
SERIAL NUMBER LOCATING.....................................................4
Frame number ........................................................................4
Engine number, Engine type....................................................4
OPERATION INSTRUMENTS .....................................................4
Clutch lever............................................................................4
Hand decompression lever.......................................................4
Choke lever (EGS)...................................................................5
Hand brake lever.....................................................................5
Speedometer, control lamps (SC).............................................5
Odometer (SC - USA)..............................................................5
Speedometer, control lamps (EGS)...........................................5
Ignition lock............................................................................6
Short circuit button (SX)..........................................................6
Combination switch (SC).........................................................6
Combination switch (SC - Aus, SGP) .......................................6
Flasher switch (SC) .................................................................6
Combination switch (EGS) ......................................................7
Emergency OFF switch (EGS)..................................................7
Filler cap.................................................................................7
Fuel........................................................................................8
Fuel tap...................................................................................8
Choke (SC).............................................................................8
Hot start device.......................................................................9
Shift lever ...............................................................................9
Kickstarter ..............................................................................9
Foot brake pedal......................................................................9
Handlebar lock........................................................................9
Compression damping of fork................................................10
Rebound damping of fork......................................................10
Compression damping of shock absorber................................10
Rebound damping of shock absorber......................................10
Baggage rack.........................................................................10
DRIVING INSTRUCTIONS ........................................................11
PERIODIC MAINTENANCE-SCHEDULE...................................14
MAINTENANCE WORK ON CHASSIS AND ENGINE ...............15
Removal of seat (SX, SC) .......................................................15
Removal of seat (EGS)...........................................................15
Tool set.................................................................................16
Breather plugs front fork........................................................16
Check and adjust steering head bearing.................................16
Changing the spring preloading of the shock absorber............17
Lubricate rear suspension linkage ..........................................17
Checking rubber ring on the WP rear shock absorber.............17
Check chain tension..............................................................18
Correct chain tension............................................................18
Chain maintenance...............................................................18
Chain wear...........................................................................19
General informations about KTM disc brakes.........................19
Checking of free travel at the hand brake lever ......................19
Checking of brake fluid level - front brake..............................20
Refilling the front brake fluid reservoir...................................20
Check the front brake pads....................................................20
Replacing front brake pads.....................................................20
Changing the basic position of the brake pedal.......................21
Check the rear brake fluid level.............................................21
Refilling the rear brake fluid reservoir ....................................21
Checking the rear brake pads ................................................22
Replacing the rear brake pads................................................22
Dismounting and mounting the front wheel (SX, SC).............22
Dismounting and mounting the front wheel (EGS).................23
Dismounting and mounting the rear wheel............................23
Checking the cush drive rubbers in the rear wheel hub (EGS) .....24
Tyres, air pressure.................................................................24
Checking spoke tension.........................................................25
Battery (A, CH).....................................................................25
Fuse parking light (A, CH).....................................................25
Fuse fan (EGS) ......................................................................25
Replacing the headlight bulb (EGS)........................................26
Replacing the parking light bulb (EGS)...................................26
Cooling system (SX, SC)........................................................26
Cooling system (EGS)............................................................27
Coolant level check...............................................................28
Cleaning the air filter.............................................................28
Exhaust system.....................................................................28
Carburetor – Adjust idling (DellOrto)....................................29
Adjust hot start device...........................................................29
Check float level ...................................................................29
Checking axial play of float....................................................29
Adjusting the throttle cable (SX, SC)......................................30
Adjusting the throttle cable ( EGS).........................................30
Adjusting the choke cable (SX, SC)........................................30
Adjusting the choke cable (EGS)............................................31
Adjusting the clutch cable .....................................................31
Checking the adjustment of the hand decompression cable....31
Engine oil..............................................................................31
Checking the engine oil level.................................................32
Oil circuit (SX, SC)................................................................32
Changing the engine oil (SX, SC)...........................................33
Replacing and bleeding the microfilter (SX, SC)......................33
Oil circuit (EGS)....................................................................33
Changing the engine oil (EGS)...............................................34
Changing the fine screen filter (EGS).....................................34
Changing oil filter..................................................................35
TROUBLE SHOOTING ..............................................................36
CLEANING ...............................................................................38
CONSERVATION FOR WINTER OPERATION...........................38
STORAGE..................................................................................38
Re-initation after time of storage............................................38
TECHNICAL SPECIFICATIONS - CHASSIS................................39
TECHNICAL SPECIFICATIONS - ENGINE ...............................40
WIRING DIAGRAMME................................................APPENDIX
Index

ENGLISH
4
Chassis number
The chassis number is stamped on the right side of the steering head tube. Write
this number into the relevant area on page 1.
Engine number, engine type
The engine number and engine type are stamped on the right hand side of the
engine below the chain sprocket. Write this number into the relevant area on
page 1.
Clutch lever
The clutch lever 1is fitted on the left hand side of the handle bar. When engine
is cold, there should allways be a play of 1–3 mm (0,04–0,1 in) at this lever (mea-
sured at outer edge).
!
CAUTION
!
IF THERE IS NO PLAY ON THE CLUTCH LEVER, THE CLUTCH WILL START TO SLIP. THE CLUTCH
WILL THEN OVERHEAT, DESTROYING THE CLUTCH LININGS.
Hand decompression lever
The hand decompression lever 2is only used in two special cases:
a) When the engine stalled.
When you then start the engine, you may feel a hard resistance on the kickstar-
ter, because the automatic decompressor cannot lock into place. If this happens,
pull the hand decompression lever and stand on the kickstarter. You can then
start the engine normally again.
b) When you want to push-start the motorcycle.
While pushing, pull the decompression lever to make it easier to get the engine
going. !
CAUTION
!
THE SETTING OF THE DECOMPRESSION CABLE SHOULD BE REGULARLY CHECKED. A LACK OF
PLAY IN THE DECOMPRESSION LEVER CAN RESULT IN ENGINE DAMAGE.
1-3 mm
1
2
SERIAL NUMBER LOCATIONS
OPERATION INSTRUMENTS

ENGLISH
5
Choke lever (EGS)
If the choke lever 1is pulled backwards, a bore will be opened in the carburetor
through which the engine may draw in additional fuel. This produces a „rich“
fuel/air mixture necessary for cold start. If the choke lever is pushed forward up
to the stop, the bore will be closed again. In this position the choke cable must
have a play of approx. 2mm.
!
CAUTION
!
IF THERE IS NO PLAY IN THE CHOKE CABLE, THE COLD STARTER SYSTEM CANNOT BE COMPLE-
TELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN UNEVEN RUNNING ENGINE,
AN EXTREME WEAR OF PISTON AND CYLINDER.
Hand brake lever
The hand brake lever is mounted on the handle bars on the right and actuates the
front wheel brake.

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 THE BRAKE SYSTEM.
DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOO-
KED OVER BY A KTM DEALER.
Speedometer, control lamps (SC)
The mileage indicator Ain the speedometer 2indicates overall mileage.
The green control lamp flashes when the indicator is working in the same
rhythm as the flashing indicator.
The blue control lamp lights up when the high beam is on.
The red cooling liquid temperature warning lamp lights up at a cooling
liquid temperature of 110°C.
!
CAUTION
!
P AY ATTENTION TO THE DIRECTIONS IN THE CHAPTER „ COOLING SYSTEM “ ON PAGE 26.
Odometer (SC - USA)
The odometer is a mileage indicator and can be set to 0 by means of the adjust-
ment wheel 3.
Speedometer, control lamps (EGS)
The mileage indicator Bin the speedometer 4indicates overall mileage. The day
mileage indicator Ccan be set to 0 by means of the adjustment wheel D. Turn
the adjustment wheel forward until only zeros can be seen in the display.
The green control lamp flashes when the indicator is working in the same
rhythm as the flashing indicator.
The green control lamp lights up when the gear is switched to idle.
The blue control lamp lights up when the high beam is on.
The red cooling liquid temperature warning lamp lights up at a cooling
liquid temperature of 110°C.
!
CAUTION
!
P AY ATTENTION TO THE DIRECTIONS IN THE CHAPTER „ COOLING SYSTEM “ ON PAGE 27.
1
A
2
3
B4
C
D

ENGLISH
6
Ignition lock
Switch positions of ignition lock 1:
OFF = Ignition off, light off
PARK = Ignition off, parking light on (only versions with battery)
ON 1 = Ignition on, light on (if engine is running)
ON 2 = Ignition on, light on (if engine is running)
The ignition key can be withdrawn in positions OFF and PARK.
Short circuit button (SX)
The short circuit button 2turns off the engine. When pressing this button, the
ignition circuit is short-cicuited.
Combination switch (SC)
The light switch has 3 switch positions.
A= Light off
B= Low beam light
C= High beam light
The red short circuit button 3serves to switch off the engine. Leave the switch
pressed, until the engine stops. With the button 4the horn will sound.
Combination switch (SC - Aus, SGP)
The light switch has 3 switch positions.
B= Low beam light
C= High beam light
The red short circuit button 3serves to switch off the engine. Leave the switch
pressed, until the engine stops. With the button 4the horn will sound.
Flasher switch (SC)
Flasher left
Flasher right
2
1
B
C
34
B
C
34
A

ENGLISH
7
Combination switch (EGS)
The rocker switch LIGHTS 1actuates the high beam or low beam.
= High-beam light
= Low-beam light
The indicator switch 2returns to central position after actuation. Press indicator
switch towards switch housing to switch off the indicator.
The horn is sounded with button 3.
The light signal (high beam) is actuated with button 4.
NOTE: The engine must be running in order to check that the electric compo-
nents are functioning correctly.
Emergency OFF switch (EGS)
The emergency OFF switch 5is mainly a safety and emergency switch and
should normally be ON.
When this symbol is concealed by the switch, the ignition circuit will be
short-circuited.
When this symbol is concealed by the switch, the ignition circuit will be
operative and the engine should start when cranked.
The Button 6is inoperative.
Filler cap
To open filler cap: Pull the tank venting hose 7from the steering head and turn
the filler cap counter-clockwise.
To close filler cap: Screw on the filler cap clockwise. Place the tank venting hose 7
in the steering head, avoiding any kinks.
1
4
2
3
1
5
6
ignition circuit
short-circuited
engine does not start
ignition curcuit
operative
engine can be start
7

ENGLISH
8
Fuel
The LC4 engine needs premium gasoline with an octane number of 95 or higher.
!
CAUTION
!
USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY
GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE.

WARNING

GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED
WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR
BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE CAREFUL
NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE
UP SPILLS PROMPTLY. IF GASOLINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOC-
TOR’S ADVICE IMMEDIATELY.
Fuel expands when its temperature rises. Therefore do not fill the tank to the top
(see fig.).
Fuel tap
OFF In this position the fuel tap is closed. No fuel may flow to the carburetor.
ON When using the motorcycle, the rotating handle must be set to the ON posi-
tion. Now fuel may flow to carburetor. In this position the tank empties
down to the fuel reserve of approx. 1,5 liters.
RES The reserve tank, approximately 1,5 liters, cannot be tapped until the rota-
ting handle is turned to the RES position. Fill the tank as soon as possible
and remember to turn the rotating handle back to the ON position so that
you will have backup fuel next time, too.
!
CAUTION
!
THE FUEL TAP SHOULD BE LOCKED WHENEVER THE MOTORCYCLE IS PARKED. IF THE TAP IS
NOT CLOSED THE CARBURETOR MAY OVERFLOW AND FUEL GET INTO THE ENGINE.
Choke (SX, SC)
In these models the choke operating element is located on the engine. Pull the
knob 1and turn it (approx. 90°) to open a bore in the carburetor through which
the engine can take in additional fuel. The result is a „fat“ fuel-air mixture of the
type needed for cold starts.
To close the bore in the carburetor, turn the knob again (approx. 90°); the knob
moves back into its initial position. In this position, the play of the choke cable
must be approximately 2 mm (0.1 in).
!
CAUTION
!
IF THERE IS NO PLAY IN THE CHOKE CABLE, THE COLD STARTER SYSTEM CANNOT BE COMPLE-
TELY CLOSED. THIS RESULTS IN HIGH FUEL CONSUMPTION, AN UNEVEN RUNNING ENGINE,
AN EXTREME WEAR OF PISTON AND CYLINDER.
N
O
O
F
F
R
E
S
F
U
E
L
N
O
O
F
F
R
E
S
F
U
E
L
N
O
O
F
F
R
E
S
F
U
E
L
35 mm
OFF ON RES
1

ENGLISH
9
Hot-start device
The carburetor is equipped with a hot-start device which makes it easier to start
the engine when hot. Press the hot-start button 1until it engages. This will
slightly lift the throttle valve. Once the engine is running, pull the hot-start button
back into its original position.
NOTE:
Always pull the hot start device back into the initial position as soon as the engine
is running. An activated hot starting device will have a negative impact on the
cold starting properties of the engine.
Shift lever
The shift lever is mounted on the left side of the engine. The position of the gears
is shown in the illustration. Neutral, or the idle speed, is located between first and
second gear.
Kickstarter
The kickstarter is mounted on the left side of the engine. Its upper part can be
swivelled.

WARNING

WHEN STARTING THE ENGINE, PUT ON MOTORCYCLE BOOTS IN ORDER TO AVOID INJURIES.
YOU MAY SLIP OFF THE KICKSTARTER, OR THE ENGINE MAY STRIKE BACK WHEN KICKING NOT
VEHEMENTLY ENOUGH.
Foot brake pedal
The foot brake pedal is disposed in front of the right foot rest. Its basic position
can be adjusted to your seat position (see maintenance work).

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 THE BRAKE SYSTEM.
DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOO-
KED OVER BY A KTM DEALER.
Handlebar lock
The handlebar can be locked by means of the lock located on the control head.
Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right
and withdraw.!
CAUTION
!
NEVER LEAVE THE KEY INSERTED IN THE LOCK. IF YOU TURN THE STEERING TO THE LEFT THE
KEY COULD GET DAMAGED.
1
2,3,4,5
1
N

ENGLISH
10
Compression damping of fork
The compression damping mechanism is built into the left fork tube. It only regu-
lates the degree of damping during compression.
By using the knob 1(COM), the degree of damping of the compression can be
adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise
to reduce damping during compression.
BASIC SETTING:
– turn rotary knob clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of fork
– WP09.18.S7.40 8 clicks
WP09.18.S7.44 12 clicks
WP06.18.Q7.12 (K4T96L3) 10 clicks
Rebound damping of fork
The rebound damping mechanism is built into the right fork tube. It only regulates
the degree of damping during rebounding.
By using the knob 2(REB), the degree of damping of the rebound can be adju-
sted. Turn the knob clockwise to increase damping, turn it counterclockwise to
reduce damping during rebounding.
BASIC SETTING:
– turn rotary knob clockwise as far as it will go
– turn it back by as many clicks as are specified for the relevant type of fork
– WP09.18.S7.40 12 clicks
WP09.18.S7.44 12 clicks
WP06.18.Q7.12 (K4T96L3) 14 clicks
Compression damping of shock absorber
With the knob 3the degree of damping of the compression can be adjusted to 7
positions. Turn the knob counterclockwise to increase damping, turn it clockwise
to reduce damping during rebounding.
WP01.18.S7.98 3
WP01.18.Q7.82 3
WP01.18.Q7.81 (K4T96S) 3
Rebound damping of shock absorber
With the setting wheel 4the degree of damping of the rebound can be adjusted
to 11 positions. Turn the knob to the left side to increase damping, turn it to the
right side to reduce damping during rebounding.
WP01.18.S7.98 5
WP01.18.Q7.82 4
WP01.18.Q7.81 (K4T96S) 4

WARNING

–N
EVER CHANGE DAMPING BETWEEN THE TEST DRIVES MORE THAN 2 CLICKS.
– T HE DAMPING UNITY OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN .
NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK
YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
Baggage rack (EGS)
The baggage rack may be loaded with up to 10 kg. The two lateral hoops serve as
handles for the passenger
3
4
2
1
1
2

ENGLISH
11
Instructions for initial operation
– Verify that your KTM dealer performed the PREPARATION OF
VEHICLE jobs (see Customer Service Manual).
– Read these operating instructions carefully before your first ride.
– Familiarize yourself with the operating elements.
– Adjust the hand brake lever and foot brake lever to the most com-
fortable positions for you.
– Get used to handling the motorcycle on an empty parking lot or
open space, before starting on a longer drive. Also try to drive as
slowly as possible and in standing position, to improve your fee-
ling for the vehicle.
– Do not drive along off-road tracks which go beyond your abitily
and experience.
– Hold the handle bars with both hands and leave your feet on the
foot rests while driving.
– Remove your foot from the foot brake lever when you are not
braking. If the foot brake lever is not released the brake pads rub
continuously and the braking system is overheated.
– A passenger is allowed only if your motorcycle is fitted and regi-
stered for such purposes. The passenger must hold tight to the
strap or hold on to the driver during the drive, with his feet on
the passenger foot rests.
– Do not make any alterations to the motorcycle and always use
ORIGINAL KTM SPARE PARTS. Spare parts from other manufac-
turers can impair the safety of the motorcycle.
– Motorcycles are sensitive to alterations in the distribution of
weight. If you are taking luggage with you, this should be secured
as close as possible to the middle of the vehicle; distribute the
weight evenly between the front and rear wheel. Never exceed
the maximum permissible laden weight and the axle weights.
The maximum permissible laden weight is made up of the follo-
wing components:
– Motorcycle ready for operation and tank full
– Luggage
– Driver and passenger with protective clothing and hemlet.
– Pay attention to running-in procedure.
Running in the LC-4 models
Even very precisely machined sections of engine components have
rougher surfaces than components which have been sliding across
one another for quite some time. Therefore, every engine needs to
be broken in. For this reason, during its first 1000 kilometers (620
miles) the engine must not be revved up to its performance limits.
The engine speed of 4800 r.p.m. must not be exceeded during the
first 1000 kilometers (620 miles). During this break-in time, you
should ride your motorcycle in different conditions (roads, easy off-
road terrain). The following table shows you the maximum velocity
values in the different gears at 4800 r.p.m. as based on the rear
wheel transmission ratio of your motorcycle.
km/h (mph)
NOTE:
During the stage of running the engine in, that is the first 1000 KM
(620 miles), the engine oil used should be of a mineral oil (non syn-
thetic) formula. This also applies if the engine has been repaired.
Check the following before each start
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.
3 CHAIN
A loose chain can fall from the chain wheels; an extremely worn
chain can tear, and insufficient lubrication can result in unneces-
sary wear to the chain and chain wheels.
4 TIRES
Check for damaged tires. Tires showing cuts or dents must be
replaced. The tread depth must comply with the legal regulations.
Also check the air pressure. Insufficient tread and incorrect air
pressure deteriorate the driving performance.
5 BRAKES
Check correct functioning of the braking system. Check for suffi-
cient brake fluid in the reservoir. The reservoirs have been desi-
gned in such a way that brake fluid does not need to be refilled
even when the brake pads are worn. If the level of brake fluid
falls below the minimum value, this indicates a leak in the bra-
king system or completely worn out brake pads. Arrange for the
braking system to be checked by a KTM specialist, as complete
failure of the braking system can be avoided.
Also check the state of the brake hose and the thickness of the
brake linings.
Check free travel at hand brake lever and foot brake lever.
6 CABLES
Check correct setting and easy running of all control cables.
7 COOLING FLUID
Check the level of cooling fluid when the engine is cold.
8 ELECTRICAL SYSTEM
Check correct functioning of headlamps, tail-lights, brake lights,
indicators, control lamps and horn while the engine is running.
9 LUGGAGE
If you are taking luggage with you, check that this is securely
fastened.

WARNING

–WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER
KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A JACKET,
REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP.
THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT
OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER
WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING.
–D
O NOT DRIVE AFTER HAVING CONSUMED ALCOHOL.
–ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAM-
PLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE
MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRI-
BUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES.
–T
HE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH
TIRES THAT HAVE THE SAME PROFILE TYPE.

WARNING

IMPORTANT INSTRUCTIONS FOR MODELS SX AND SC:
–THE ABOVE MODELS WERE DESIGNED AND BUILT FOR ONE PERSON ONLY -
NO ADDITIONAL PASSENGER ALLOWED!
–N
EITHER DO THE SX-MODEL MEET THE APPLICABLE STATUTORY REGULATI-
ONS AND SAFETY STANDARDS. USING THEM ON PUBLIC ROADS, HIGH-
WAYS, FREEWAYS ETC. IS AGAINST THE LAW.
–W
HEN RIDING YOUR MOTORCYCLE, PLEASE BEAR IN MIND THAT OTHER
PEOPLE MAY FEEL MOLESTED BY EXCESSIVE NOISE.
DRIVING INSTRUCTIONS
16:40 t 15:40 t 16:45 t 15:45 t 15:50 t 14:50 t
1st 40 (25) 40 (25) 35 (22) 35 (22) 30 (19) 30 (19)
2nd 55 (34) 55 (34) 50 (31) 50 (31) 40 (25) 40 (25)
3rd 75 (46) 70 (43) 65 (40) 65 (40) 60 (37) 55 (34)
4th 90 (56) 85 (53) 80 (50) 80 (50) 70 (43) 65 (40)
5th 115 (71) 110 (71) 100 (62) 100 (62) 85 (53) 80 (50)
gear
i

ENGLISH
12
Starting when the engine is cold
1 Open the fuel tap 1
2 Switch on the ignition 2and the emergency OFF switch 3.
3 Swing up the side stand or center stand.
4 Put the gear in neutral
5 Operate the choke 4
6 Leave throttle closed and push the kickstarter hard ALL THE WAY.
7 If the engine starts, push the choke lever back a little bit, as soon as the engine
runs unevenly.

WARNING

–TO AVOID INJURY WHEN STARTING THE ENGINE, ALWAYS WEAR BOOTS!
–DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED AREA. EXHAUST FUMES
ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUSNESS AND DEATH. ALWAYS PRO-
VIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING.
!
CAUTION
!
DON’T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON’T REV ENGINE WHEN COLD.
BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN
CAUSE ENGINE DAMAGE.
Starting when the engine is warm
1 Open the fuel tap 1
2 Switch on the ignition 2and the emergency OFF switch 3.
3 Swing up the side stand or center stand.
4 Put the gear in neutral
5
Leave the throttle closed and push the kickstarter hard ALL THE WAY
Starting when the engine is hot
1 Open the fuel tap 1
2 Switch on the ignition 2and the emergency OFF switch 3.
3 Swing up the side stand or center stand.
4 Put the gear in neutral
5 Push in the hot-start button 5on the carburettor as far as it will go
6
Leave the throttle closed and push the kickstarter hard ALL THE WAY
7 Once the engine is running, pull hot-start button back into its original position.
What to do when the engine is „flooded”
Pull in the hand decompression lever, open the throttle fully, kick the kick starter
through the stroke 5 to 10 times and start the motor as described above.
Starting off
Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever
and open throttle at the same time.

WARNING

B EFORE YOU START OFF
, CHECK THAT THE MAIN OR SIDE STAND HAS BEEN SWUNG UP FULLY .
I F THE STAND DRAGS ON THE GROUND , THE MOTORCYCLE CAN GO OUT OF CONTROL .
Shifting/Riding
You are now in first gear, refered to as the drive or uphill gear. Depending on the
conditions (traffic, hill size, etc.), you can shift to a higher gear. Close throttle, at
the same time pull clutch lever in and shift to the next higher gear. Let clutch
lever go again and give gas. If you turned on the choke, make sure you turn it off
again as soon as engine is warm.
When you reach full speed through opening the throttle all the way, turn throttle
back to 3/4; the speed hardly decreases although the engine will use less gas.
Only give as much gas as the engine can handle. Through quick and high reving
of throttle, the gas usage increases.
1
2
3
45

ENGLISH
13
By shifting down, use the brakes if necessary and close throttle at the
same time. Pull clutch lever and shift down to the next gear. Let
clutch lever go slowely and open throttle or shift down again.

WARNING

–O
BSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING TO
LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZARDS CAN BE RECO-
GNIZED AS EARLY AS POSSIBLE.
–A
DJUST YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR
DRIVING SKILLS.
–D
RIVE CAREFULLY UN UNKNOWN ROADS OR ON UNFAMILIAR TRIALS.
–W
HEN DRIVING OFF-ROAD, ALWAYS HAVE A FRIEND ON A SECOND
MOTORCYCLE TO KEEP YOU COMPANY, SO THAT YOU CAN HELP EACH
OTHER SHOULD DIFFICULTIES ARISE.
–R
EPLACE HELMET VISOR OR GOGGLE LENS WHEN SCRATCHED OR DAMA-
GED. IF BRIGHT LIGHT SHINES THROUGH A SCRATCHED VISOR OR LENS,
THE OPERATOR WILL BE BLINDED.
–A
FTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS
THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN.
!
CAUTION
!
–H
IGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT
ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN
A MODERATE RPM RANGE FOR A FEW MILES GIVING IT A CHANCE TO
WARM UP. AFTER THAT NO FURTHER PRECAUTIONS IN THIS RESPECT NEED
BE TAKEN. THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS
SOON AS THE RADIATORS BECOME WARM.
–N
EVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A
LOWER GEAR. THE ENGINE WILL OVER-REV, DAMAGING THE VALVES. IN
ADDITION, THE REAR WHEEL LOCKS SO THAT THE MOTORCYCLE CAN
EASILY GET OUT OF CONTROL.
–L
ONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD
TO MOTOR DAMAGE.
–I
F THE RED COOLING LIQUID TEMPERATURE WARNING LAMP LIGHTS UP
WHILE YOU ARE DRIVING, PLEASE PROCEED AS SPECIFIED IN THE NOTES
CONTAINED ON PAGES 26 (SX, SC) AND 27 (EGS)!
–IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT THE
ENGINE FASTENING BOLTS ARE TIGHT.
–I
N THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU NOTICE
ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMMEDIATELY, TURN THE
ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER.
Braking
Close throttle and apply the hand and foot brakes at the same time.
When driving on sandy, wet or slippery ground use mainly the rear
wheel brake. Always brake with feeling, blocking wheels can cause
you to skid or fall. Also change down to lower gears depending on
your speed.
When driving down hill, use the braking effect of the engine.
Change down one or two gears but do not overspeed the engine. In
this way, you will not need to brake so much and the brakes will not
overheat.

WARNING

WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND
BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRA-
KING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL.
Stopping and parking
Apply the brakes fully and put the engine into neutral. To stop the
engine, switch off the ignition or pull the short circuit button when
the engine is idling, until the engine stops. Turn the fuel tap to the
OFF position, park on an area where the ground is firm, and lock the
motorcycle.

WARNING

–N
EVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE
IS RUNNING.
–M
OTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN-
NING. THE ENGINE, EXHAUST PIPE, MUFFLER, BRAKE ROTORS, AND SHOCK
ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS
AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE
PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED.
–ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE
SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.
!
CAUTION
!
–C
LOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE
CARBURETTOR CAN FLOOD AND FUEL WILL ENTER THE ENGINE.
–N
EVER LET THE PARKING LIGHT ON FOR LONGER THAN 90 MINUTES IF
THE ENGINE IS SWITCHED OFF! IF THE OPERATING TIME EXTENDS THIS
LIMIT, THE BATTERY WILL BECOME TOTALLY DISCHARGED AND THUS DEST-
ROYED (ONLY MODELS WITH BATTERY).
–A
LWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE
SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS.
–N
EVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE
HAZARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS.
NOTE REGARDING THE MAIN STAND:
We advise the following procedure to place the motorcycle on the
main stand as effortlessly as possible:
a) press main stand to ground using foot
b) swing out kickstarter and pull at an angle toward the rear of
motorcycle (see illustration)
NOTE REGARDING THE SIDE STAND:
Use your foot to kick side stand forward up to the stop and lean the
motorcycle sideways. Make sure that the ground is solid and that
your motorcycle is standing securely. Just in case, you can shift into
first gear.!
CAUTION
!
T HE SIDE STAND IS DESIGNED TO BEAR ONLY THE LOAD OF THE MOTORCYCLE .
THE SIDE STAND AND/OR THE FRAME CAN BE DAMAGED AND THE MOTORCY-
CLE CAN FALL OVER IF YOU MOUNT THE MOTORCYCLE, THUS PUTTING AN
ADDITIONAL LOAD ON THE SIDE STAND.

ENGLISH
14
Check engine oil level 
Change engine oil (SX, SC)  
Change engine oil (EGS) 
Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil 
Change oil filter unit 
Change microfilter (SX, SC) 
Change fine screen filter (screwed filter) at the frame tube 
Check oil lines for leakage and proper instalment 
Check valve clearance 
Clean spark plug and adjust electrode gap 
Change spark plug after 10 000 kilometers (6 200 miles)
Check valve clearance 
Drain and clean carburator float bowl 
Adjust idling 
Check breather hoses of engine gase and gas tank for correct position without buckles 
Clean air filter and air filter box 
Check sprockets, chain guides and chain for wear 
Maintaining chain tension eccentrics (Duke) 
Clean and lube chain  
Check chain tension 
Check cooling liquid level 
Check quality of antifreeze 
Check cooling system for leaks 
Check exhaust system for leakage 
Change exhaust muffler packing (aluminium-muffler) 
Check exhaust brackets 
Disassemble and clean spark arrestor discs (USA models)
Check brake fluid level front and rear 
Change brake fluid 
Check brake pad thickness 
Check brake discs 
Check condition and correct instalment of brake hoses 
Check freeplay and easy operation of hand brake lever and foot brake lever 
Check adjustment and function of fork 
Check fork for leaks 
Loosen breather screws at fork legs (overpressure) 
Change fork oil 
Perform a full maintenance job for the telescopic fork 
Clean dust scrabber on forks 
Check steering head bearing clearance / adjust 
Clean and grease steering head bearings and its seals 
Check adjustment and funktion of shock absorber 
Check O-ring of the shock absorber for wear 
Servicing the shock absorber 
Grease lubricating nipple of the Pro Lever suspension system 
Disassemble the Pro Lever suspension system and perform a full maintenance job on it 
Servicing swingarm pivots 
Check tightness of spokes and rim join 
Check wheel bearings for clearance 
Check chock absorber rubbers on the rear wheel hub 
Check tire condition and air pressure 
Check cables for damage and easy working 
Lube and adjust cables  
Check the electrical system 
Check battery holder and connections (Duke) 
Check adjustment of head light 
Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray 
Check all screws, nuts and hose clamps for proper tightness 
Grease or lube all pivot points and sliding components  
PERIODIC MAINTENANCE SCHEDULE
before each start after washing 1st service, after 1000 km (600 miles) or 10 hours after 2500 km (1500 miles) or 25 hours after 5000 km (3000 miles) or once a year at least once a year
KTM
rider KTM dealer
IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR
COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO
BE CARRIED OUT AFTER EACH RIDE OR RACE
9.97

ENGLISH
15

WARNING

ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A *REQUIRE SPECIALIST
KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER
!
CAUTION
!
–
W HEN CLEANING THE MOTORCYCLE , DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE , OTHERWISE WATER WILL PENETRATE THE BEARINGS , CARBURETTOR ,
ELECTRIC CONNECTORS ETC.
–W
HEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES AND THAT THE
FUEL TAP IS IN THE OFF POSITION - IF THE MOTORCYCLE SHOULD FALL OVER, BE AWARE OF ANY LEAKING FUEL FROM THE CARBURETOR OR FUEL TANK
–DO NOT USE TOOTHED WASHERS OR SPRING RINGS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE.
INSTEAD, USE SELF-LOCKING NUTS.
–LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED.
–R
EMOVE OILS, FATTY MATTERS, FILTERS, FUELS, WASHING DETERGENTS ETC. ORDERLY.
–U
NDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIZE. 1 LITER USED OIL CONTAMINATES
1.000.000 LITERS WATER.
Removal of seat (SX, SC)
By using the quick-release fastener 1, the seat can be removed without using
tools. Turn the quick-release fastener about 180° counter clockwise and lift up
the rear of the seat. Pull the seat backwards and unhook it from the front fastener
screw 2. When installing the seat, be sure to insert the rear portion of the seat
into the metal clasp 3.
Removal of seat (EGS)
Remove the attachment screws 4from the underside of the fender. Lift the rear
of the seat, pull backwards, and unhook it from the fastener screw 2. To install
the seat, hook the seat into the attachment screw, set the rear portion down on
the frame, and slide it forward. If necessary, press down on the front area of the
seat so that the seat catches on the metal clasp 3. Insert and tighten the attach-
ment screws.
1
2
3
4
MAINTENANCE WORK ON CHASSIS AND ENGINE
1

ENGLISH
16
Tool set (SC)
The tool set 1is located at the bottom of the seat.
Tool set (EGS)
The tool set 2is located in the tool box under the right side cover.
Breather plug front fork
After every 5 hours of use for competitive racing, slacken the breather plugs 3a
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.
!
CAUTION
!
EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF YOUR
FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE
SEALS REPLACED.
Check and adjust steering head bearing*
Check steering head bearing for play periodically. To check this put motorcycle on
a stand so that the front wheel is off the ground. Now try to move the fork for-
ward and backward. To adjust, loosen the five pinch bolts 4of the top triple
clamp and turn steering stem bolt clockwise 5until there is no more play. Don’t
tighten the steering stem bolt all the way, otherwise the bearings will be dama-
ged. With a plastic hammer, lightly rap on the triple clamp to release tension. Re-
tight the five pinch bolts.
WP Extreme fork:.................................15 Nm
WP USD (UpSideDown) fork:...............15 Nm

WARNING

I F THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY , THE MOTORCYCLE WILL
SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL
.
!
CAUTION
!
I
F YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERIODS , FIRST THE BEA -
RINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED .
At least once a year, the steering head bearings should be smeared with water-
proof grease.
2
33
4
4
5
1

ENGLISH
17
Changing the spring preloading of the shock absorber
KTM sets the shock absorber for a driver only, weighing approximately 75 kg
(165 lb). If you want to take a passenger with you, of if you weigh considerably
more or less than 75 kg (165 lb), you should change the spring preloading A
accordingly. This is easily done.
NOTE:
– Before changing the spring preload note down the basic setting, e.g. how many
threads are visible above the adjusting ring.
– One rotation of the adjusting ring 2changes the spring pretension by approxi-
mately 1,75 mm (0,07 in).
Loosen the locking ring 1with the hook spanner from the tool set. Change the
spring preload with the adjusting ring 2and re-tighten the locking ring.
BASIC SETTING – SPRING PRELOAD
SX: 17 mm (0.7 in) / SC, EGS: 23 mm (0,9 in)
Lubricate rear suspension linkage
The bearings in the link lever must be greased in regular intervals. For this pur-
pose, a lubricating nipple 3is mounted on the link lever.
!
CAUTION
!
AFTER EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALY IMPORTANT TO GREASE
THE LUBRICATING NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS.
Checking rubber ring on the WP rear shock absorber
A rubber ring mounted on the rear shock absorber serves as a vibration damper.
This ring gets pressed together with time and loses its shock absorbing quality.
Measure the distance between the two discs at various points around their cir-
cumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubber
ring replaced by an KTM dealer when compaction due to wear has exceeded this
lower limit. !
CAUTION
!
NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK
ABSORBER.

WARNING

THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COMPRESSED NITROGEN.
NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK
YOURSELF. SEVERE INJURIES COULD BE THE RESULT.
3
min. 2,5 mm
1
2
A

ENGLISH
18
Checking chain tension
– For checking, put the motorcycle on its main stand or jack it up on its frame so
that the rear wheel is relieved of any load.
– Push the chain upwards appr. 30 mm (1,2 in) from the end of the chain sliding
component until the upper part of the chain is tensioned (see illustr.)
– Now, the distance Abetween chain and swingarm should be 0 mm respec-
tively 5 mm (0,2 in) (depending on final drive ratio). The upper part of the
chain Bmust be tight (see illustr.).
– Correct chain tension, if necessary!

WARNING

–I F CHAIN TENSION IS TOO GREAT , PARTS WITHIN THE SECONDARY TRANSMISSION ( CHAIN ,
SPROCKETS , DRIVE ASSEMBLY AND REAR WHEEL BEARINGS ) WILL BE SUBJECTED TO UNNECES -
SARY STRESS , RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE .
–TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN JUM-
PING OFF THE SPROCKETS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK THE REAR
WHEEL OR DAMAGE THE ENGINE.
–I
N EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTORCYCLE.
Correct chain tension
– Loosen collar nut 1, loosen lock nuts 2, and turn right and left adjusting screws 3
equally far. Tighten lock nuts 2.
– Before tightening the collar nut, verify that the chain adjusters 4are sitting
close to the adjusting screws and that the rear wheel has been aligned with the
front wheel.
– Tighten fcollar nut 1with 80 Nm (59 ft.lb).
Chain maintenance
For long chain life, good maintenance is very important. Chains without O-rings
should be cleaned in fireproof solvent regularly and afterwards treated with hot
grease or chain spray (Shell Advance Bio Chain).
O-ring chains on the other hand are very simple to clean. The best way is to use
lots of water, but never use brushes or cleaning liquids. After letting the chain dry,
you can use a special O-ring chain spray (Shell Advance Bio Chain).

WARNING

NO LUBRICATION IS ALLOWED TO REACH THE REAR TYRE OR THE BRAKE DISKS, EITHERWISE
THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDU-
CED AND THE MOTORCYCLE COULD EASILY LOSE CONTROL.
!
CAUTION
!
WHEN MOUNTING THE CHAIN MASTERLINK CLIP, THE CLOSED SIDE OF THE MASTERLINK CLIP
MUST POINT IN RUNNING DIRECTION.
Also check sprockets and chain guides for wear, and replace if necessary.
✓
A
B
15:40
15:45 A = 0mm
16:40
16:45
14:50 A = 5mm
15:50
30mm
1
2
3
4
4