KTM 450 SX-F User manual

OWNER'S MANUAL 2010
450 SX‑F EU
450 SX‑F USA
Art. no. 3211482en

DEAR KTM CUSTOMER 1
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will
give you enormous pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( p. 9) Dealer's stamp
Engine number ( p. 9)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design of our motorcycles can however not be completely excluded.
All details contained in it are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical spec-
ifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to
adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for
delivery options, deviations from illustrations and descriptions, as well as for printing and other errors. The models portrayed partly
contain special equipment that does not belong to the regular scope of delivery.
© 2009 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

TABLE OF CONTENTS 2
TABLE OF CONTENTS
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT INFORMATION ................................................ 5
VIEW OF VEHICLE............................................................... 7
View of the vehicle from the left front (example)................. 7
View of the vehicle from the right rear (example) ................ 8
LOCATION OF SERIAL NUMBERS ........................................ 9
Chassis number............................................................... 9
Type label....................................................................... 9
Engine number................................................................ 9
Fork part number............................................................. 9
Shock absorber part number............................................. 9
CONTROLS....................................................................... 10
Clutch lever .................................................................. 10
Hot start lever ............................................................... 10
Hand brake lever ........................................................... 10
Short circuit button ....................................................... 10
Electric starter button .................................................... 10
Fuel tap........................................................................ 11
Opening filler cap.......................................................... 11
Closing filler cap ........................................................... 11
Choke........................................................................... 11
Shift lever..................................................................... 12
Foot brake pedal ........................................................... 12
Plug-in stand ................................................................ 12
GENERAL TIPS AND HINTS ON PUTTING INTO
OPERATION...................................................................... 13
Advice on first use......................................................... 13
Running-in the engine ................................................... 14
Preparing vehicle for arduous riding conditions................. 14
Preparing for riding on dry sand ...................................... 14
Preparing for riding on wet sand...................................... 15
Preparing for riding on wet and muddy surfaces................ 16
Preparing for rides at high temperature and slow speed..... 17
Preparing for rides at low temperatures or in snow ............ 17
RIDING INSTRUCTIONS .................................................... 18
Checks before putting into operation ............................... 18
Starting ........................................................................ 18
Starting up ................................................................... 19
Shifting, riding.............................................................. 19
Braking ........................................................................ 19
Stopping, parking .......................................................... 19
Refueling...................................................................... 20
SERVICE SCHEDULE......................................................... 21
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 21
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 22
Important checks and maintenance work to be carried
out by the rider. ............................................................ 22
MAINTENANCE WORK ON CHASSIS AND ENGINE.............. 24
Jacking up the motorcycle.............................................. 24
Removing the motorcycle from the work stand.................. 24
Checking the basic suspension setting with the rider's
weight .......................................................................... 24
Compression damping of shock absorber.......................... 24
Adjusting high-speed compression damping of the shock
absorber ....................................................................... 24
Adjusting the low-speed compression damping of the
shock absorber .............................................................. 25
Adjusting the rebound damping of the shock absorber....... 26
Measuring rear wheel sag unloaded ................................. 26
Checking static sag of shock absorber.............................. 27
Checking riding sag of shock absorber ............................. 27
Adjusting the spring preload of the shock absorber x...... 27
Adjusting the riding sag x............................................. 28
Removing the shock absorber x..................................... 28
Installing the shock absorber x..................................... 29
Checking basic setting of fork......................................... 29
Adjusting the compression damping of the fork ................ 29
Adjusting the rebound damping of fork ............................ 30
Bleeding fork legs.......................................................... 30
Cleaning the dust boots of the fork legs ........................... 30
Loosening the fork protector ........................................... 31
Positioning the fork protection ........................................ 31
Checking steering head bearing play................................ 31
Adjusting play of steering head bearing x....................... 32
Removing the fork legs x.............................................. 32
Installing the fork legs x............................................... 32
Removing the fork protector x....................................... 33
Installing the fork protector x....................................... 33
Removing the lower triple clamp x................................ 33
Installing the lower triple clamp x................................. 34
Greasing the steering head bearing x............................. 35
Removing the front fender.............................................. 35
Installing the front fender............................................... 35
Dismount the start number plate..................................... 35
Installing the start number plate ..................................... 35
Handlebar position ........................................................ 36
Adjusting handlebar position x...................................... 36
Checking throttle cable route.......................................... 36
Checking the play in the throttle cable............................. 37
Adjusting the play in the throttle cable x....................... 37
Checking for chain dirt accumulation .............................. 37
Cleaning the chain......................................................... 38
Checking the chain tension ............................................ 38
Checking chain tension when fitting rear wheel ................ 39
Checking the rear sprocket/engine sprocket for wear ......... 39
Checking chain wear...................................................... 39
Adjusting chain tension.................................................. 40
Adjusting chain tension - after checking .......................... 41
Adjusting chain tension - fitting rear wheel ...................... 41
Adjusting the chain guide x.......................................... 42
Checking brake discs ..................................................... 42
Checking free travel on hand brake lever.......................... 42
Adjusting basic position of handbrake lever...................... 43
Checking the brake fluid level of the front brake............... 43
Topping up the front brake fluid x................................. 43
Checking the front brake linings...................................... 44
Removing front brake linings x..................................... 45
Installing the front brake linings x................................. 45
Changing the front brake linings x................................. 46
Checking free play of foot brake lever .............................. 46
Adjusting basic position of foot brake lever x.................. 47
Checking rear brake fluid level........................................ 47
Adding brake fluid to the rear brake circuit x................. 48
Checking rear brake linings ............................................ 48
Removing rear brake linings x....................................... 49
Mounting rear brake linings x....................................... 49
Changing the rear brake linings x.................................. 50
Removing front wheel x................................................ 50
Fitting front wheel x.................................................... 51
Removing the rear wheel x........................................... 52
Fitting rear wheel x...................................................... 52

TABLE OF CONTENTS 3
Checking the tire condition............................................. 53
Checking tire air pressure............................................... 54
Checking spoke tension.................................................. 54
Removing the battery x................................................ 54
Installing the battery x................................................. 55
Recharging the battery x.............................................. 55
Removing a fuse............................................................ 56
Installing the fuse ......................................................... 56
Ignition curve plug connection........................................ 57
Changing the ignition curve ............................................ 57
Removing the seat......................................................... 57
Mounting the seat ......................................................... 57
Removing the fuel tank x............................................. 57
Installing the fuel tank x.............................................. 58
Cooling system .............................................................. 59
Checking the anti-freeze and coolant level ....................... 59
Checking the coolant level.............................................. 60
Draining the coolant x.................................................. 60
Refilling coolant x....................................................... 61
Removing main silencer ................................................. 61
Installing the main silencer ............................................ 61
Glass fiber yarn filling of main silencer ............................ 62
Removing glass fiber yarn filling from the main
silencer x................................................................... 62
Installing the glass fiber yarn filling of the main
silencer x................................................................... 62
Changing glass fiber yarn filling of main silencer x......... 63
Removing the air filter box lid......................................... 63
Installing the air filter box lid.......................................... 63
Removing the air filter x............................................... 63
Installing the air filter x............................................... 64
Cleaning air filter x...................................................... 64
Adjusting basic position of clutch lever............................ 64
Checking fluid level of hydraulic clutch ........................... 65
Changing the hydraulic clutch fluid x............................ 65
Carburetor - idle ............................................................ 66
Carburetor - adjusting idle x......................................... 66
Emptying the carburetor float chamber x....................... 67
Checking engine oil level................................................ 67
Changing engine oil and oil filter, cleaning oil screen x... 68
Draining the engine oil x.............................................. 68
Cleaning the oil screen x.............................................. 68
Removing the oil filter x............................................... 69
Installing the oil filter x............................................... 69
Filling up with engine oil x........................................... 70
Topping up engine oil .................................................... 70
TROUBLESHOOTING......................................................... 71
CLEANING........................................................................ 73
Cleaning motorcycle ...................................................... 73
STORAGE ......................................................................... 74
Storage......................................................................... 74
Putting into operation after storage ................................. 74
TECHNICAL DATA - ENGINE.............................................. 75
Capacity - engine oil ...................................................... 75
Capacity - coolant.......................................................... 75
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 76
TECHNICAL DATA - CARBURETOR..................................... 78
TECHNICAL DATA - CHASSIS ............................................ 79
Capacity - fuel............................................................... 79
TECHNICAL DATA - FORK.................................................. 80
450 SX‑F EU ................................................................ 80
450 SX‑F USA .............................................................. 80
TECHNICAL DATA - SHOCK ABSORBER ............................. 81
450 SX‑F EU ................................................................ 81
450 SX‑F USA .............................................................. 81
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 83
WIRING DIAGRAM ............................................................ 84
Wiring diagram.............................................................. 84
SUBSTANCES................................................................... 86
AUXILIARY SUBSTANCES.................................................. 88
STANDARDS..................................................................... 90
INDEX .............................................................................. 91

MEANS OF REPRESENTATION 4
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your motorcycle will be serviced
optimally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT INFORMATION 5
Use definition
KTM sport motorcycles are designed and built to withstand the normal stresses and strains of competitive use. The motorcycles com-
ply with currently valid regulations and categories of the top international motorsport organizations.
Info
The motorcycle must be used only in closed off areas remote from public road traffic.
Maintenance
A prerequisite for trouble free operation and avoiding premature wear is that the engine and suspension are maintained and adjusted
as described in this manual. Poor adjustment and tuning of the engine and suspension can lead to damage and breakage of compo-
nents.
Using a motorcycle in difficult conditions such as on sand or very wet and muddy ground can lead to excessive wear of components
such as the power train or brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
service schedule is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. Observing these rules will vastly
increase the service life of your motorcycle.
Warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
service record; otherwise, all warranty claims will be void. No warranty claim can be honored for damage resulting from manipulation
and/or other changes to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, only use spare parts and accessory products that have been approved and/or recommended by KTM and have
them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Some spare parts and accessories are specified in brackets in the respective descriptions. Your KTM dealer will be happy to advise
you.
You will find the current KTM PowerParts for your vehicle on the KTM website.
International KTM Website: http://www.ktm.com
Work rules
Special tools are necessary for some of the work. These are not included with the vehicle and can be ordered under the number in
parentheses. Ex: valve spring compressor (59029019000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be
replaced by new parts.
If thread lock (e.g. Loctite®) is used for screw connections, be sure to comply with the manufacturer's specific instructions on its
usage.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
Transport
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from
being run. Always let the vehicle cool first.
–Switch off the engine.
–Turn handle of the fuel tap to the OFF position. (Figure 500178-10 p. 11)
–Use straps or other suitable devices to secure the motorcycle against accidents or falling over.

IMPORTANT INFORMATION 6
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it is a potential problem for the
environment and can lead to conflicts with other persons. But if you use your motorcycle responsibly, you can ensure that such prob-
lems and conflicts do not have to occur. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, dis-
play environmental consciousness, and respect the rights of others.
Notes/warnings
Pay close attention to the notes/warnings.
Info
Various information and warning labels are affixed to the vehicle. Do not remove information/warning labels. If they are miss-
ing, you or others may not recognize potential hazards and may therefore be injured.
Grades of risks
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures
are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
Owner's manual
–It is important that you read this owner's manual carefully and completely before making your first trip. It contains useful infor-
mation and many tips on how to operate and handle your motorcycle. Only then will you find out how to best customize the motor-
cycle for your own use and how you can protect yourself from injury. The owner's manual also contains important information on
servicing the motorcycle.
–The owner's manual is an important component of the motorcycle and should be handed over to the new owner if the vehicle is
sold.

VIEW OF VEHICLE 7
3.1View of the vehicle from the left front (example)
800113-10
1 Hand brake lever
2 Filler cap
3 Clutch lever
4 Air filter box lid
5 Fuel tap
6 Choke button
7 Chain guide
8 Shift lever

VIEW OF VEHICLE 8
3.2View of the vehicle from the right rear (example)
800114-10
1 Shock absorber rebound adjustment
2 Level viewer for brake fluid, rear
3 Level viewer for engine oil
4 Fork rebound adjustment
5 Foot brake pedal
6 Shock absorber compression adjustment
7 Fork compression adjustment
8 Short circuit button
9 Electric starter button

LOCATION OF SERIAL NUMBERS 9
4.1Chassis number
400193-10
The chassis number is stamped on the steering head on the right.
4.2Type label
400284-10
The type label is fixed to the front of the steering head.
4.3Engine number
400194-10
The engine number is stamped on the left side of the engine under the engine
sprocket.
4.4Fork part number
500082-10
The fork part number is stamped on the inner side of the fork stub.
4.5Shock absorber part number
500083-10
The shock absorber part number is stamped on the top of the shock absorber above
the adjusting ring on the engine side.

CONTROLS 10
5.1Clutch lever
800024-10
The clutch lever is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
5.2Hot start lever
800024-11
The hot start lever is fitted on the left side of the handlebar.
If you pull the hot start lever to the handlebar during the start procedure, a bore is
opened in the carburetor through which the engine can draw in extra air. This gives a
leaner fuel-air mixture, which is needed for a hot start.
Possible states
• Hot start function activated –Hot start lever is pulled out to the stop.
• Hot start function deactivated –Hot start lever is pushed back to the stop.
5.3Hand brake lever
400196-10
Hand brake lever is located on the right side of the handlebar.
The hand brake lever is used to activate the front brake.
5.4Short circuit button
400197-10
Short circuit button is fitted on the left side of the handlebar.
Possible states
• Short circuit button in basic position –In this position, the ignition circuit is
closed, and the engine can be started.
• Short circuit button pressed –In this position, the ignition circuit is interrupted,
a running engine stops, and a non-running engine will not start.
5.5Electric starter button
400198-10
Electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed –In this position, the electric starter is actuated.

CONTROLS 11
5.6Fuel tap
500178-10
The fuel tap is on the left side of the fuel tank.
Using tap handle on the fuel tap, you can open or close the supply of fuel to the
carburetor.
Possible states
• Fuel supply closed OFF –No fuel can flow from the tank to the carburetor.
• Fuel supply open ON –Fuel can flow from the tank to the carburetor. The fuel tank
empties completely.
5.7Opening filler cap
400199-10
–Press release button , turn filler cap counterclockwise and lift it upwards and
remove.
5.8Closing filler cap
400199-11
–Replace the filler cap and turn clockwise until the release button locks in place.
Info
Route the fuel tank breather hose without kinking.
5.9Choke
400202-10
Choke is fitted on the left side of the carburetor.
Activating the choke function frees an opening through which the engine can draw
extra fuel. This gives a richer fuel-air mixture, which is needed for a cold start.
Info
If the engine is warm, the choke function must be deactivated.
Possible states
• Choke function activated –The choke lever is pulled out to the stop.
• Choke function deactivated –The choke lever is pushed in to the stop.

CONTROLS 12
5.10Shift lever
400204-12
Shift lever is mounted on the left side of the engine.
400204-11
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
5.11Foot brake pedal
800005-10
Foot brake pedal is located in front of the right footrest.
The foot brake pedal is used to activate the rear brake.
5.12Plug-in stand
400203-10
Note
Danger of damage The parked vehicle can roll away or fall over.
–Always place the vehicle on a firm and even surface.
To park the motorcycle, insert plug-in stand into the left side of the wheel spindle.
Info
Remove the plug-in stand before starting on a trip.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 13
6.1Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–Do not use the vehicle if you are inexperienced or if you have consumed alcohol or drugs.
Warning
Risk of injury Missing or poor protective clothing present an increased safety risk.
–Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always
wear protective clothing, which must be undamaged and meet legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
–The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Critical handling characteristic due to inappropriate riding style.
–Adapt your riding speed to the road conditoins and your riding ability.
Warning
Danger of accidents Accident risk caused by presence of a passenger.
–Your vehicle is not designed to carry passengers. Do not ride with a passenger.
Warning
Danger of accidents Failure of brake system.
–If the foot brake lever is not released, the brake linings drag permanently. The rear brake can fail due to overheating. Take
your foot off the foot brake lever if you do not want to brake.
Warning
Danger of accidents Unstable riding behavior.
–Do not exceed the maximum permissible weight and axle loads.
Warning
Risk of misappropriation Usage by unauthorized persons.
–Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons.
Info
When using your motorcycle, remember that others may feel disturbed by excessive noise.
–Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the service record at vehicle handover.
–Before your first trip, read the entire operating instructions carefully.
–Get to know the controls.
–Adjust the basic position of clutch lever. ( p. 64)
–adjust the basic position of handbrake lever. ( p. 43)
–Adjust the basic position of the foot brake lever. x( p. 47)
–Get used to handling the motorcycle on a suitable piece of land before making a longer trip.
Info
Your motorcycle is not authorized for riding on public roads.
Offroad, you should be accompanied by another person on another machine so that you can help each other.
–Try also to ride as slowly as possible and in a standing position to get a better feeling for the vehicle.
–Do not make any offroad trips that over-stress your ability and experience.
–Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–Do not transport luggage.
–Do not exceed the overall maximum permitted weight and the axle loads.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 14
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load 145 kg (320 lb.)
Maximum permissible rear axle load 190 kg (419 lb.)
–Check the spoke tension. ( p. 54)
Info
The spoke tension must be checked after half an hour of operation.
–Run the engine in.
6.2Running-in the engine
–During the running-in phase, do not exceed the specified engine speed and engine performance.
Guideline
Maximum engine speed
During the first 3 service hours 7,000 rpm
Maximum engine performance
During the first 3 service hours ≤50 %
During the next 12 service hours ≤75 %
–Avoid fully opening the throttle!
6.3Preparing vehicle for arduous riding conditions
–Using a motorcycle in arduous conditions can lead to excessive wear of components such as the power train or brakes. For this
reason, it may be necessary to service or replace worn parts before the limit specified in the service schedule is reached.
Arduous riding conditions are:
–Riding on dry sand. ( p. 14)
–Riding on wet sand. ( p. 15)
–Riding on wet and muddy surfaces. ( p. 16)
–Rides at high temperature and slow speed. ( p. 17)
–Rides at low temperatures or in snow. ( p. 17)
6.4Preparing for riding on dry sand
600872-10
–Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box on the edges against dirt.
–Clean the air filter. x( p. 64)
Info
Check the air filter approx. every 30 minutes.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 15
600869-01
–Fit a dust protection device on the air filter.
Dust protection device for air filter (59006019000)
Info
See the KTM PowerParts fitting instructions.
600871-01
–Fit a sand screen device on the air filter.
Sand protection device for air filter (59006022000)
Info
See the KTM PowerParts fitting instructions.
–Adjust the carburetor jetting and settings.
Info
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
600868-01
–Clean the chain.
Chain cleaner ( p. 88)
–Fit the steel sprocket.
Tip
Do not grease the chain.
–Clean radiator fins.
–Straighten bent radiator fins carefully.
6.5Preparing for riding on wet sand
600872-10
–Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box on the edges against dirt.
–Clean the air filter. x( p. 64)
Info
Check the air filter approx. every 30 minutes.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 16
600870-01
–Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
–Adjust the carburetor jetting and settings.
Info
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
600868-01
–Clean the chain.
Chain cleaner ( p. 88)
–Fit the steel sprocket.
Tip
Do not grease the chain.
–Clean radiator fins.
–Straighten bent radiator fins carefully.
6.6Preparing for riding on wet and muddy surfaces
–Seal the air filter box. x
Tip
Seal the air filter box along the edges to prevent the ingress of dirt.
–Clean the air filter. x( p. 64)
Info
Check the air filter approx. every 30 minutes.
600870-01
–Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
–Adjust the carburetor jetting and settings.
Info
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.
600868-01
–Fit the steel sprocket.
–Clean the motorcycle. ( p. 73)
–Straighten bent radiator fins carefully.

GENERAL TIPS AND HINTS ON PUTTING INTO OPERATION 17
6.7Preparing for rides at high temperature and slow speed
600872-10
–Check the radiator cap.
Value on radiator cap 1.8 bar (26 psi)
» If the displayed value does not correspond to specifications:
Warning
Danger of scalding During motorcycle operation, the coolant gets
very hot and is under pressure.
–Do not remove the radiator cap, radiator hoses or other cooling
system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse
immediately with lukewarm water.
–Change the radiator cap.
–Seal the air filter box. x
Tip
Seal the air filter box on the edges against dirt.
–Clean the air filter. x( p. 64)
Info
Check the air filter approx. every 30 minutes.
600868-01
–Adjust the secondary drive to the road conditions.
Info
The engine oil quickly gets hot if the clutch has to be operated very often
due to an excessively high secondary drive.
–Clean the chain.
Chain cleaner ( p. 88)
–Clean radiator fins.
–Straighten bent radiator fins carefully.
–Check the coolant level. ( p. 60)
6.8Preparing for rides at low temperatures or in snow
–Seal the air filter box. x
Tip
Seal the air filter box on the edges against dirt.
–Clean the air filter. x( p. 64)
Info
Check the air filter approx. every 30 minutes.
600870-01
–Fit a waterproofing device on the air filter.
Waterproofing device for air filter (59006021000)
Info
See the KTM PowerParts fitting instructions.
–Adjust the carburetor jetting and settings.
Info
Your authorized KTM workshop has the recommended carburetor tuning set-
tings.

RIDING INSTRUCTIONS 18
7.1Checks before putting into operation
Info
Make sure that the motorcycle is in a perfect technical condition before use.
Info
In the interests of riding safety, make a habit of making a general check before you ride.
–Check the engine oil level. ( p. 67)
–Check the fuel reserves.
–Check the chain tension. ( p. 38)
–Check for chain dirt accumulation. ( p. 37)
–Check the tire condition. ( p. 53)
–Check the tire air pressure. ( p. 54)
–Check the brake fluid level of the front brake. ( p. 43)
–Check the rear brake fluid level. ( p. 47)
–Check the front brake linings. ( p. 44)
–Check the rear brake linings. ( p. 48)
–Check the brake system function.
–Check the coolant level. ( p. 60)
–Check the settings of all controls and ensure that they can be operated smoothly.
7.2Starting
Danger
Danger of poisoning Exhaust gases are poisonous and inhaling them may result in unconsciousness and/or death.
–When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–Always warm up the engine at low engine speeds.
Info
If the motorcycle is unwilling to start, the cause can be old fuel in the float chamber. The flammable elements of the fuel
evaporate after a long time of standing.
If the float chamber is filled with fresh fuel, the engine starts immediately.
Press the starter for a maximum of 5 seconds. Wait for a least 5 seconds until trying again.
400733-01
Engine has been out of use for more than 1 week
–Empty the carburetor float chamber. x( p. 67)
–Turn handle of the fuel tap to the ON position. (Figure 500178-10 p. 11)
Fuel can flow from the fuel tank to the carburetor.
–Remove the motorcycle from the stand.
–Shift transmission to neutral.
The engine is cold
–Pull choke lever out as far as possible.
The engine is hot
–Pull the hot start lever out to the stop.
–Press the electric starter button .
Info
Do not open the throttle.
The engine is hot and running
–Push back the hot start lever to the stop with the engine running.