KTM 150 SX 2022 (01) PDF DOCUMENT

The meaning of specific symbols is described below:

(All SX models)

This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.

Only operate this vehicle in closed-off areas remote from public road traffic.

(125 XC US)

This vehicle has been designed and built to withstand the normal stresses and strains of racing. This vehicle complies with the currently valid regulations and categories of the top international motorsports organizations.

Only operate this vehicle in closed-off areas remote from public road traffic.

This vehicle is designed for use in offroad endurance competition, and not primarily for use in motocross.

The vehicle must only be used as intended. Dangers can arise for people, property and the environment through use not as intended. Any use of the vehicle beyond the intended and defined use constitutes misuse. Misuse also includes the use of operating and auxiliary fluids which do not meet the required specification for the respective use.

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.

Caution

Identifies a danger that may lead to minor injuries 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.

Note (Environmental)

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

1. The removal or rendering inoperative by any person other than for purposes of servicing, 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, or

2. the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

1. Removal or puncturing of the main silencers, baffles, header pipes or any other components which conduct exhaust gases.

2. Removal or puncturing of parts of the intake system.

3. Lack of proper maintenance.

4. Replacing moving parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

Danger of accidents: A rider who is not fit to ride poses a danger to him or herself and others.

– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

– Do not operate the vehicle if you are physically or mentally impaired.

Danger of poisoning: Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

– Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Danger of burns: Some vehicle components become very hot when the vehicle is operated.

– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally compatible manner. The vehicle should only be used by trained persons. Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop. Adhere to the information and warning labels on the vehicle.

Warning – Risk of injury: Missing or poor protective clothing presents an increased safety risk.

– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.

Unless specified otherwise, the ignition must be turned off during all work (models with ignition lock, models with remote key) or the engine must be at a standstill (models without ignition lock or remote key).

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses.

During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, expansion screws, seals, sealing rings, O-rings, pins, and lock washers).

In the case of certain screws, a screw adhesive (e.g. Loctite®) is required. Observe the manufacturer’s instructions.

If thread locker (e.g., Precote®) has already been applied to a new part, do not apply any additional thread locker.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After completing a repair or service work, check the operating safety of the vehicle.

Note – Environmental hazard: Improper handling of fuel is a danger to the environment.

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Use fuels and auxiliary substances in accordance with the Owner’s Manual and specification.

Vehicle Identification Number (VIN): Stamped on the right side of the steering head.

Type Label: Fixed to the front of the steering head.

Engine Number: Stamped on the left side of the engine under the engine sprocket.

Fork Part Number: Stamped on the inside of the axle clamp.

Shock Absorber Article Number: Stamped on the top of the shock absorber above the adjusting ring towards the engine side.

Clutch lever: Fitted on the handlebar on the left. The clutch is activated hydraulically and adjusts itself automatically.

Hand brake lever: Fitted on the right side of the handlebar. The front brake is engaged using the hand brake lever.

Throttle grip: Fitted on the right side of the handlebar.

Stop button: Fitted on the left side of the handlebar. In its basic position, the ignition circuit is closed and the engine can be started. When pressed, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

Start button (125 XC US): Fitted on the right side of the handlebar. When pressed, the starter motor is actuated.

Shift lever: Mounted on the left of the engine. The gear positions are N-1-2-3-4-5-6, with neutral between first and second gears.

Kick starter lever: Fitted on the right side of the engine. It can be swiveled. Before riding, swing it inwards towards the engine.

Foot brake lever: Located in front of the right footrest. It is used to activate the rear brake.

Opening the Fuel Tank Filler Cap:

All SX models:

– Turn fuel tank filler cap counterclockwise and lift it off.

125 XC US:

– Press the release button, turn the fuel tank filler cap counterclockwise, and lift it off.

Closing the Fuel Tank Filler Cap:

All SX models:

– Mount the fuel tank filler cap and turn it clockwise until the fuel tank is tightly closed.

– Route the fuel tank breather hose without kinks.

125 XC US:

– Mount the filler cap and turn it clockwise until the release button engages.

– Route the fuel tank breather hose without kinks.

The fuel tap is on the left side of the fuel tank.

All SX models:

Possible states:

– Fuel supply closed OFF: Fuel cannot flow from the fuel tank to the carburetor.

– Fuel supply open ON: Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.

125 XC US:

Possible states:

– Fuel supply closed OFF: Fuel cannot flow from the fuel tank to the carburetor.

– Fuel supply open ON: Fuel can flow from the fuel tank to the carburetor. The fuel tank empties down to the reserve level.

– Fuel reserve supply open RES: Fuel can flow from the fuel tank to the carburetor. The fuel tank empties completely.

The choke is fitted on the left side of the carburetor. Activating the choke function frees a drill hole in the carburetor through which the engine can draw extra fuel, resulting in a richer fuel-air mixture needed for a cold start.

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.

If the engine is warm, the choke function must be deactivated.

Plug-in stand (All SX models):

The holder for the plug-in stand is on the left side of the wheel spindle. The plug-in stand is used to park the motorcycle and as a fork locker when transporting. Remove the plug-in stand before riding.

Side stand (125 XC US):

The side stand is located on the left of the vehicle and is used for parking. When you are riding, the side stand must be folded up and secured with the rubber strap.

The service hour counter is fitted in front of the handlebar. It shows the total number of service hours of the engine. The counter begins counting when the engine is started and stops when the engine is switched off. The value indicated cannot be cleared or adjusted.

– Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.

– Before riding for the first time, read the entire Owner’s Manual carefully.

– Get to know the controls.

– Adjust the basic position of the clutch lever.

– Adjust the basic position of the hand brake lever.

– Adjust the basic position of the foot brake lever.

– Adjust the basic position of the shift lever.

– Get used to the handling characteristics of the motorcycle on a suitable surface before undertaking more challenging trips.

– Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.

– Do not make any off-road trips that exceed your ability and experience.

– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

– Do not take luggage along.

– Do not exceed the maximum permissible weight and the maximum permissible axle loads.

– Check the spoke tension. The spoke tension must be checked after half an hour of operation.

– Run in the engine.

During the running-in phase, do not exceed the specified engine performance. Avoid fully opening the throttle!

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can result in significantly increased wear. It may be necessary to inspect or replace parts before the next scheduled service.

– Prepare air filter box cover for securing.

– Clean the air filter and air filter box.

– Check the air filter approx. every 30 minutes.

– Check the electrical connector for humidity and corrosion and to ensure it is firmly seated. If humidity, corrosion, or damage is found, clean and dry the connector, or change it if necessary.

– Make sure that no radiator covers are installed.

Difficult operating conditions include:

– Rides on dry sand.

– Rides on wet sand.

– Rides on wet and muddy circuits.

– Riding at high temperatures or slow riding.

– Riding at low temperatures and in snow.

– Check the radiator cap. The value on the cap should be 1.8 bar (26 psi). If it doesn’t match, change the radiator cap.

– Mount the air filter dust cover (79006920000).

– Mount the air filter sand cover (79006922000).

– Adjust the carburetor jetting and setting. Your authorized KTM workshop can recommend the right tuning.

– Clean the chain.

– Mount the steel sprocket.

– Grease the chain.

– Clean the radiator fins.

– Straighten any bent radiator fins carefully.

– For regular use in sand, change the piston every 10 operating hours.

– Check the radiator cap. The value on the cap should be 1.8 bar (26 psi). If it doesn’t match, change the radiator cap.

– Mount the air filter rain cover (79006921000).

– Adjust the carburetor jetting and setting. Your authorized KTM workshop can recommend the right tuning.

– Clean the chain.

– Mount the steel sprocket.

– Grease the chain.

– Clean the radiator fins.

– Straighten any bent radiator fins carefully.

– For regular use in sand, change the piston every 10 operating hours.

– Mount the air filter rain cover (79006921000).

– Adjust the carburetor jetting and setting. Your authorized KTM workshop can recommend the right carburetor tuning.

– Mount the steel sprocket.

– Clean the motorcycle.

– Straighten the bent radiator fins carefully.

– Check the radiator cap. The value should be 1.8 bar (26 psi). If not, change the cap.

– Adjust the secondary drive to the road conditions. The engine oil heats up quickly when the clutch is operated frequently due to an excessively high secondary ratio.

– Clean the chain.

– Clean the radiator fins.

– Straighten the bent radiator fins carefully.

– Check the coolant level.

– Mount the air filter rain cover (79006921000).

– Adjust the carburetor jetting and setting. Your authorized KTM workshop can recommend the right carburetor tuning.

Before every trip, check the condition of the vehicle and ensure that it is safe to operate. The vehicle must be in perfect technical condition.

– Check the gear oil level.

– Check the front brake fluid level.

– Check the rear brake fluid level.

– Check the front brake linings.

– Check the brake linings of the rear brake.

– Check that the brake system is functioning properly.

– Check the coolant level.

– Check the chain for dirt.

– Check the chain, rear sprocket, engine sprocket, and chain guide.

– Check the chain tension.

– Check the tire condition.

– Check tire pressure.

– Check the spoke tension. (Incorrect spoke tension will strongly impair riding safety).

– Clean the dust boots of the fork legs.

– Bleed the fork legs.

– Check the air filter.

– Check the settings of all controls and ensure that they can be operated smoothly.

– Check all screws, nuts, and hose clamps regularly for tightness.

– Check the fuel level.

If the motorcycle has been out of use for more than 1 week, empty the carburetor float chamber as the cause for not starting can be old fuel.

(All SX models)

1. Turn tap handle of the fuel tap to the ON position.

2. Remove plug-in stand.

3. Shift the transmission into neutral.

4. If the engine is cold, pull the choke lever out as far as possible.

5. Press the kick starter lever robustly through its full range. Do not open the throttle.

(125 XC US)

1. Turn tap handle of the fuel tap to the ON position.

2. Take the motorcycle off the side stand and secure it with the rubber strap.

3. Shift the transmission into neutral.

4. If the engine is cold, pull the choke lever out as far as possible.

5. Press the start button or press the kick starter lever forcefully all the way. Do not open the throttle.

Starting off:

The plug-in stand must be removed before riding. For 125 XC US, the side stand must be folded up and secured.

Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle carefully.

Shifting, riding:

– First gear is used for starting off and for steep inclines.

– Shift into a higher gear when conditions allow. To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.

– If the choke function has been activated, deactivate it after the engine has warmed up.

– After reaching maximum speed by fully opening the throttle grip, turn the throttle back so it is ¾ open. This will barely reduce the speed, but fuel consumption will be considerably lower.

– Always open the throttle only as much as the engine can handle – abrupt throttle opening increases fuel consumption.

– To shift down, apply the brakes and close the throttle at the same time.

– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.

– Switch off the engine if running at idle speed or stationary for a long time (≥ 2 min).

– Avoid frequent or lengthy slipping of the clutch. This causes the gear oil, engine and cooling system to heat up.

– Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

Warning: Excessively forceful application of the brakes blocks the wheels. Adjust application of the brakes to the respective riding situation and riding surface conditions.

Warning: A spongy pressure point on the front or rear brake reduces braking efficiency. Check the brake system and do not continue riding until the problem is eliminated.

Warning: Moisture and dirt impair the brake system. Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

– On sandy, wet, or slippery surfaces, use the rear brake mostly if possible.

– Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed.

– Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. You will have to apply the brakes far less frequently as a result and the brake system will not overheat.

– Park the vehicle on a firm and level surface.

– Ensure that nobody sits on the vehicle when it is parked on a stand.

– Apply the brakes on the motorcycle.

– Shift the transmission to neutral position.

– Press and hold the stop button while the engine is idling until the engine stops.

(All SX models)

– Turn tap handle of the fuel tap to the OFF position.

– Rest the vehicle on the plug-in stand.

(125 XC US)

– Turn tap handle of the fuel tap to the OFF position.

– Rest the vehicle on the side stand.

Note: The parked vehicle can roll away or fall over. Park the vehicle on a firm and level surface.

Note: Hot vehicle components pose a fire hazard and explosion risk. Do not park the vehicle near materials which are highly flammable or explosive. Allow the vehicle to cool down before covering it.

(All SX models)

– Switch off the engine.

– Mount plug-in stand (79029094000) on the fork legs. The plug-in stand is included. Make sure the brake line runs in front of the plug-in stand and does not become wedged.

– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away. Only tighten the tension belts to the point that the plug-in stand is firmly in contact with the fender and the tires.

(125 XC US)

– Switch off the engine.

– Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

Danger – Fire hazard: Fuel is highly flammable. The fuel in the fuel tank expands when warm and can escape if overfilled.

– Do not fuel the vehicle in the vicinity of open flames or lit cigarettes.

– Switch off the engine for refueling.

– Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

– If any fuel is spilled, wipe it off immediately.

Procedure:

1. Switch off the engine.

2. Open the fuel tank filler cap.

3. Fill the fuel tank with fuel up to measurement A (35 mm / 1.38 in from the top).

4. Close the fuel tank filler cap.

○ One-time interval

● Periodic interval

○ One-time interval

● Periodic interval

When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

– For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, link fork and frame, the basic settings of the suspension components must match the rider’s weight.

– As delivered, KTM offroad motorcycles are adjusted for an average rider’s weight (with full protective clothing).

– If the rider’s weight is above or below this range, the basic setting of the suspension components must be adjusted accordingly.

– Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

Adjusting the low-speed compression damping:

The effect can be seen in slow to normal compression of the shock absorber.

1. Turn adjusting screw (1) clockwise with a screwdriver as far as the last perceptible click. Do not loosen fitting (2).

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

Adjusting the high-speed compression damping:

The effect can be seen in fast compression of the shock absorber.

1. Turn adjusting screw (1) all the way clockwise with a socket wrench. Do not loosen fitting (2).

2. Turn counterclockwise by the number of turns corresponding to the shock absorber type. Turn clockwise to increase damping; turn counterclockwise to reduce damping.

1. Turn adjusting screw clockwise up to the last perceptible click.

2. Turn counterclockwise by the number of clicks corresponding to the shock absorber type. Turn clockwise to increase the damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

Measuring the rear wheel dimension unloaded:

1. Raise the motorcycle with a lift stand.

2. Position the sag gage in the rear axle and measure the distance to the marking SAG on the rear fender.

3. Note down the value as dimension A.

4. Remove the motorcycle from the lift stand.

Checking the static sag:

1. Measure dimension A of rear wheel unloaded.

2. Hold the motorcycle upright with the aid of an assistant.

3. Measure the distance again between the rear axle and marking SAG on the rear fender using the sag gage. Note the value as dimension B.

4. Check the static sag (difference between A and B).

If the static sag is incorrect, adjust the spring preload.

Checking the riding sag:

1. Measure dimension A of rear wheel unloaded.

2. With another person holding the motorcycle, the rider, wearing full protective clothing, sits on the seat in a normal position and bounces up and down a few times.

3. Another person again measures the distance between the rear axle and marking SAG on the rear fender. Note the value as dimension C.

4. Check the riding sag (difference between A and C).

If the riding sag differs from the specified measurement, adjust the riding sag.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the shock absorber.

– After removing the shock absorber, clean it thoroughly.

Main work:

– Loosen screw (1).

– Turn adjusting ring (2) until the spring is no longer under tension.

– Measure the total spring length while the spring is not under tension.

– Tension the spring by turning adjusting ring (2) to the specified dimension A.

– Tighten screw (1).

Finishing work:

– Install the shock absorber.

– Remove the motorcycle from the lift stand.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the shock absorber.

– After removing the shock absorber, clean it thoroughly.

Main work:

– Choose and mount a suitable spring based on rider weight. The spring rate is shown on the outside of the spring.

Finishing work:

– Install the shock absorber.

– Remove the motorcycle from the lift stand.

– Check the static sag of the shock absorber.

– Check the riding sag of the shock absorber.

– Adjust the rebound damping of the shock absorber.

For various reasons, no exact riding sag can be determined for the fork.

– Smaller differences in the rider’s weight can be compensated for by the fork air pressure.

– However, if the fork frequently bottoms out (hard end stop on compression), the fork air pressure must be increased, within the specified values, to avoid damage to the fork and frame.

– If the fork feels unusually hard after extended periods of operation, the fork legs need to be bled.

Warning: Modifications to the suspension setting may seriously alter the handling characteristic.

– Only make adjustments within the recommended range.

– Ride slowly to start with after making adjustments to get the feel of the new handling characteristic.

Check or adjust the air pressure at the earliest 5 minutes after switching off the engine. The air suspension is in the left fork leg.

1. Raise the motorcycle with a lift stand.

2. Remove protection cap (1).

3. Push together fork airpump (2) (79412966100) fully.

4. Connect the fork airpump to the left fork leg. The airpump indicator will switch on automatically.

5. Adjust the air pressure as specified. Never adjust the air pressure to a value outside the stated range.

6. Disconnect the fork airpump from the left fork leg.

7. Mount the protection cap by hand.

8. Remove the motorcycle from the lift stand.

The hydraulic compression damping determines the fork suspension behavior. The adjusting screw is located at the upper end of the right fork leg.

1. Turn adjusting screw (1) clockwise all the way.

2. Turn counterclockwise by the number of clicks corresponding to the fork type. Turn clockwise to increase damping; turn counterclockwise to reduce damping during compression.

The hydraulic rebound damping determines the fork suspension behavior. The adjusting screw is located at the lower end of the right fork leg.

1. Turn adjusting screw (1) clockwise all the way.

2. Turn counterclockwise by the number of clicks corresponding to the fork type. Turn clockwise to increase damping; turn counterclockwise to reduce damping when the shock absorber rebounds.

Warning: A repaired handlebar poses a safety risk. If the handlebar is bent or straightened, the material becomes fatigued and may break. Change the handlebar if it is damaged or bent.

The handlebar can be mounted in 2 different positions. The holes on the handlebar supports are placed at a distance of 3.5 mm (0.138 in) from the center.

Preparatory work:

– Remove the handlebar cushion.

Main work:

1. Remove screws (1). Remove the handlebar clamp. Remove the handlebar and lay it to one side. Cover components to protect them and do not kink cables.

2. Remove screws (2). Take off handlebar supports (3).

3. Position rubber bushings (4) and push through nuts (5) from below.

4. Place the handlebar supports in the required position. The handlebar supports are longer and higher on one side. Position them evenly.

5. Mount and tighten screws (2).

6. Position the handlebar, ensuring cables and wiring are positioned correctly.

7. Position the handlebar clamp.

8. Mount screws (1) but do not tighten yet.

9. First bolt the handlebar clamp with screws (1) onto the longer, higher side of the handlebar supports so that both parts touch.

10. Tighten screws (1) evenly.

Finishing work:

– Mount the handlebar cushion.

– Park the vehicle on a firm and level surface.

– Ensure that nobody sits on the vehicle when it is parked on a stand.

– Raise the motorcycle at the frame underneath the engine using a lift stand (78129955100).

– Neither wheel should be in contact with the ground.

– Secure the motorcycle against falling over.

Preparatory work:

– Raise the motorcycle with a lift stand.

Main work:

– Release bleeder screws (1). Any excess pressure escapes from the interior of the fork.

– Tighten the bleeder screws.

Finishing work:

– Remove the motorcycle from the lift stand.

Preparatory work:

– Raise the motorcycle with a lift stand.

– Remove the fork protector.

Main work:

– Push dust boots (1) of both fork legs downward.

– Clean and oil the dust boots and inner fork tubes of both fork legs using universal oil spray.

– Press the dust boots back into their normal position.

– Remove excess oil.

Finishing work:

– Install the fork protector.

– Remove the motorcycle from the lift stand.

Removing the fork legs:

1. Raise the motorcycle with a lift stand.

2. Remove the front wheel.

3. Remove screws (1) and take off the clamp.

4. Remove screws (2) and take off the brake caliper. Allow it to hang loosely.

5. Loosen screws (3). Remove the left fork leg.

6. Loosen screws (4). Remove the right fork leg.

Installing the fork legs:

1. Position the fork legs. The air bleeder screw (1) of the right fork leg is positioned to the front. The valve (A) of the left fork leg faces the front. The second milled groove from the top must be flush with the upper edge of the upper triple clamp.

2. Tighten screws (2).

3. Tighten screws (3).

4. Position the brake caliper. Mount and tighten screws (4).

5. Position the brake line and the clamp. Mount and tighten screws (5).

6. Install the front wheel.

Removing the fork protector:

– Remove screws (1). Remove the clamp.

– Remove screws (2). Take off the left fork protector.

– Remove screws (3). Take off the right fork protector.

Installing the fork protector:

– Position the fork protection on the left fork leg. Mount and tighten screws (1).

– Position the brake line and clamp. Mount and tighten screws (2).

– Position the fork protector on the right fork leg. Mount and tighten screws (3).

Warning: Incorrect steering head bearing play impairs the handling characteristic and damages components. Correct immediately.

Checking steering head bearing play:

1. Raise the motorcycle with a lift stand.

2. Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel. Play should not be detectable.

3. If there is detectable play, adjust the steering head bearing play.

4. Move the handlebar to and fro over the entire steering range. It must be possible to move it easily. There should be no detectable detent positions.

5. If detent positions are detected, adjust the steering head bearing play and check the bearing, changing it if necessary.

Adjusting steering head bearing play:

1. Raise the motorcycle with a lift stand and remove the handlebar cushion.

2. Loosen screws (1) on the top triple clamp.

3. Remove screw (2) from the top steering stem.

4. Loosen and retighten screw (3) on the top steering head.

5. Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

6. Tighten screws (1) on the top triple clamp.

7. Mount and tighten screw (2) on the top steering stem.

8. Check steering head bearing play again.

9. Mount the handlebar cushion and remove the motorcycle from the lift stand.

Removing the shock absorber:

1. Raise the motorcycle with a lift stand.

2. Remove the cable ties.

3. Remove screws (1) with the washers.

4. Remove screw (2) and take off the left frame protector.

5. Push the right frame protector to the front and take off at the bottom.

6. Remove screw (3) and fitting (4). Raise the wheel slightly to make removal easier.

7. Press angle lever (5) toward the rear.

8. Press linkage lever (6) downward.

9. Remove screws (7) and pull the foot brake cylinder off the push rod.

10. Remove the connecting link of the chain and take off the chain.

11. Remove nut (8) and pull out the fork pivot. Push the link fork back and secure it.

12. Hold the shock absorber and remove screw (9).

13. Remove the shock absorber carefully at the bottom.

Installing the shock absorber:

1. Carefully position the shock absorber into the vehicle from the bottom.

2. Mount and tighten screw (1) for the top of the shock absorber.

3. Position the link fork and mount the fork pivot. Pay attention to flat area A.

4. Mount and tighten nut (2) for the fork pivot.

5. Mount and connect the chain. The closed side of the chain joint lock must face in the direction of travel.

6. Position the foot brake cylinder. Ensure push rod (3) engages and the dust boot is correctly positioned.

7. Mount and tighten screws (4).

8. Position the angle lever and linkage lever. Mount and tighten fitting (5). Pay attention to flat area B.

9. Mount and tighten screw (6) for the bottom of the shock absorber. Raise the wheel slightly to help.

10. Position left frame protector. Insert right frame protector from below and push to the rear.

11. Mount and tighten screws (7) with the washers.

12. Mount and tighten screw (8).

13. Mount the new cable ties.

14. Remove the motorcycle from the lift stand.

Removing the seat:

– Remove screw (1).

– Raise the rear of the seat, pull the seat back, and lift it off.

Mounting the seat:

– Mount the front of the seat on the collar bushing of the fuel tank, lower the seat at the rear, and push the seat forward.

– Make sure that the seat is locked in correctly.

– Mount and tighten screw (1).

Removing the air filter box cover:

If secured:

– Remove the seat.

– Remove screw (1).

– Pull off the air filter box cover in area A sideways and take off toward the front.

If not secured:

– Pull off the air filter box cover in area A sideways and take off toward the front.

Installing the air filter box cover:

If secured:

– Insert the air filter box cover in area A and clip it into area B.

– Mount and tighten screw (1).

– Mount the seat.

If not secured:

– Insert the air filter box cover in area A and clip it into area B.

Removing the air filter:

– Remove the air filter box cover.

– Detach retaining tab (1). Remove air filter with air filter support.

– Take off air filter from air filter support.

Cleaning the air filter and air filter box:

– Remove the air filter.

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly. Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high-grade air filter oil.

– Clean the air filter box.

– Clean the intake flange and check it for damage and tightness.

Installing the air filter:

– Mount the clean air filter on the air filter support.

– Grease the air filter in area A with long-life grease.

– Insert the air filter and position the top retaining pin (1) in bushing B. The air filter must be correctly positioned.

– Secure the bottom retaining pin with holding tab (2).

– Install the air filter box cover.

Warning: The exhaust system gets very hot. Allow it to cool down before performing any work.

Preparatory work:

– Remove the main silencer.

Main work:

1. Remove screws (1). Pull out inner tube (2).

2. Remove the glass fiber yarn filling (3) from the inner tube.

3. Clean the parts that need to be reinstalled and check for damage.

4. Fit the new glass fiber yarn filling (3) into the inner tube.

5. Slide outer tube (4) over the inner tube with the new glass fiber yarn filling.

6. Mount and tighten all screws (1).

Finishing work:

– Install the main silencer.

Removing the fuel tank:

1. Remove the seat.

2. Turn the fuel tap to the OFF position.

3. Pull off the fuel hose. Remaining fuel may flow out.

4. Remove screws (1).

5. Remove screw (2) with the rubber bushing.

6. Pull the fuel tank breather hose off the fuel tank lid.

7. Pull both spoilers laterally off the radiator and take off the fuel tank upwards.

Installing the fuel tank:

1. Check the throttle cable routing.

2. Position the fuel tank and fit the two spoilers laterally to the radiator. Ensure no cables are trapped.

3. Attach the fuel tank breather hose.

4. Mount and tighten screw (1) with the rubber bushing.

5. Mount and tighten screws (2).

6. Connect the fuel hose.

7. Mount the seat.

Cleaning the chain:

1. Raise the motorcycle with a lift stand.

2. Rinse off loose dirt with a soft jet of water.

3. Remove old grease residue with chain cleaner.

4. After drying, apply off-road chain spray.

5. Remove the motorcycle from the lift stand.

Checking the chain, sprockets, and guide:

1. Raise the motorcycle with a lift stand and shift to neutral.

2. Check chain, rear sprocket, and engine sprocket for wear. If worn, change the complete drivetrain kit (chain, sprockets).

3. Pull on the top section of the chain with a weight of 10-15 kg (22-33 lb).

4. Measure the distance of 18 chain rollers in the lower chain section. Repeat at different positions.

If the distance is greater, change the drivetrain kit.

5. Check the chain sliding guard and chain sliding piece for wear. If the lower edge of the chain pins is in line with or below the guard/piece, change it.

6. Check the chain guide for wear. The minimum thickness is 6 mm (0.24 in). If less, change it.

7. Ensure all components are firmly seated and tighten if loose.

Warning: Incorrect chain tension damages components and can cause accidents.

Checking chain tension:

1. Raise the motorcycle with a lift stand.

2. Pull the chain upward at the end of the chain sliding piece. The lower chain section must be taut.

3. Measure the chain tension. Repeat at different chain positions.

If the tension is incorrect, adjust it.

Adjusting chain tension:

1. Raise the motorcycle with a lift stand and check the tension.

2. Loosen nut (1) on the rear wheel spindle.

3. Loosen nuts (2) on the chain adjusters.

4. Adjust the chain tension by turning adjusting screws (3) left and right. The markings on the left and right chain adjusters must be in the same position relative to reference marks A for correct wheel alignment.

5. Tighten nuts (2).

6. Make sure chain adjusters (4) are fitted correctly on adjusting screws (3).

7. Tighten nut (1) on the rear wheel spindle.

8. Remove the motorcycle from the lift stand.

Checking the frame:

– Check the frame for damage, cracks, and deformation.

– If the frame shows signs of damage, cracks, or deformation, change the frame. Repairs on the frame are not permitted.

Checking the link fork:

– Check the link fork for damage, cracks, and deformation.

– If the link fork shows signs of damage, cracks, or deformation, change the link fork. Repairs on the link fork are not permitted.

– Adjust the basic position of the clutch lever to your hand size by turning adjusting screw (1).

– Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.

– Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

– The range of adjustment is limited. Turn the adjusting screw by hand only, and do not apply any force.

– Do not make any adjustments while riding.

Warning: Brake fluid causes skin irritation. Keep out of reach of children and wear protective gear. Do not use DOT 5 brake fluid.

Checking/correcting the fluid level:

1. Move the clutch fluid reservoir on the handlebar to a horizontal position.

2. Remove screws (1) and cover (2) with membrane (3).

3. Check the fluid level.

4. If the fluid level is low, correct it with Brake fluid DOT 4 / DOT 5.1.

5. Position the cover with the membrane. Mount and tighten the screws.

Changing the hydraulic clutch fluid:

1. Move the clutch fluid reservoir to a horizontal position. Remove screws (1), cover (2), and membrane (3).

2. Fill bleeding syringe (4) (50329050000) with the appropriate hydraulic fluid (Brake fluid DOT 4 / DOT 5.1).

3. On the clutch slave cylinder, remove bleeder screw (5) and mount the bleeding syringe (4).

4. Inject the liquid into the system until it emerges from the drill hole (6) of the master cylinder without bubbles. Extract fluid from the reservoir to prevent overflow.

5. Remove the bleeding syringe. Mount and tighten the bleeder screw.

6. Correct the fluid level of the hydraulic clutch to 4 mm (0.16 in) below the rim.

7. Position the cover with the membrane. Mount and tighten the screws. Clean up any spilled fluid immediately with water.

Checking the free travel:

Warning: If there is no free travel, pressure builds up and the brake system can fail. Set the free travel according to the specification.

– Push the hand brake lever forward and check free travel A.

– If the free travel does not match the specification, adjust the basic position of the hand brake lever.

Adjusting the basic position:

– Check the free travel of the hand brake lever.

– Adjust the basic position to your hand size by turning adjusting screw (1). Turn clockwise to increase distance from handlebar, counterclockwise to decrease. Do not make adjustments while riding.

Warning: An insufficient or old brake fluid level will cause the brake system to fail. Check the system and change fluid according to the service schedule.

Checking the front brake fluid level:

1. Check the front brake linings.

2. Move the brake reservoir on the handlebar to a horizontal position.

3. Check the brake fluid level in the level viewer (1). If the fluid level has dropped below the marking A, add front brake fluid.

Adding front brake fluid:

1. Move the brake reservoir to a horizontal position.

2. Remove screws (1), then take off cover (2) with membrane (3).

3. Add brake fluid (DOT 4 / DOT 5.1) to level A.

4. Position the cover with the membrane. Mount and tighten the screws. Clean up spilled fluid with water.

Warning: Worn-out or non-approved brake linings reduce braking effect. Replace immediately with approved linings.

Checking the front brake linings:

– Check the brake linings for minimum thickness A.

– If the minimum thickness is less than specified, change the front brake linings.

– Check for damage and cracking. If found, change the linings.

Changing the front brake linings:

1. Move the brake fluid reservoir to a horizontal position. Remove the cover and membrane.

2. Manually press the brake caliper toward the brake disc to push back the brake pistons. Extract some fluid if necessary to prevent overflow.

3. Remove cotter pins (4), pull out pin (5), and remove the brake linings.

4. Clean the brake caliper and bracket.

5. Check that spring plate (6) and brake pad sliding plate (7) are seated correctly.

6. Insert the new brake linings, insert pin, and mount cotter pins. Always change linings in pairs.

7. Operate the hand brake lever repeatedly until the linings are in contact with the disc and a pressure point is felt.

8. Correct the brake fluid level to 5 mm (0.2 in) below the reservoir rim.

9. Position the cover with the membrane, mount and tighten the screws. Clean up any spilled fluid.

Warning: If there is no free travel, pressure builds up in the rear brake system, which can cause it to fail from overheating.

Checking the free travel:

1. Disconnect spring (1).

2. Move the foot brake lever back and forth to check free travel A.

3. If free travel is incorrect, adjust the basic position. Reconnect spring (1).

Adjusting the basic position:

1. Detach spring (1).

2. Loosen nut (2) and, with push rod (3), turn it back until you have maximum free travel.

3. To adjust the basic position for individual requirements, loosen nut (4) and turn screw (5) accordingly.

4. Turn push rod (3) until you have the specified free travel (3-5 mm).

5. Hold screw (5) and tighten nut (4).

6. Hold push rod (3) and tighten nut (2).

7. Attach spring (1).

Warning: An insufficient or old brake fluid level will cause the brake system to fail.

Checking the rear brake fluid level:

1. Check the rear brake linings.

2. Stand the vehicle upright.

3. Check the brake fluid level in level viewer (1). If the fluid level has dropped below marking A, add rear brake fluid.

Adding rear brake fluid:

1. Stand the vehicle upright.

2. Remove screw cap (1) with membrane (2) and the O-ring.

3. Add brake fluid (DOT 4 / DOT 5.1) to level A.

4. Mount the screw cap with the membrane and the O-ring. Clean up any overflowed fluid immediately with water.

Warning: Worn-out or non-approved linings reduce braking effect. Incorrect servicing can cause brake system failure.

Checking the rear brake linings:

– Check the brake linings for minimum thickness A.

– If less than specified, or if damaged/cracked, change the rear brake linings.

Changing the rear brake linings:

1. Position the vehicle vertically.

2. Remove screw cap (1) with membrane (2) and the O-ring.

3. Manually press the brake caliper toward the disc to push back the piston. Extract fluid if necessary.

4. Remove cotter pins (3), pull out pin (4), and remove the linings.

5. Clean the caliper and bracket.

6. Check that spring plate (5) and brake pad sliding plate (6) are seated correctly. The arrow on the spring plate points in the direction of rotation of the disc.

7. Insert new linings, pin (4), and cotter pins (3). Always change in pairs. Ensure decoupling plate (7) is on the piston-side lining.

8. Operate the foot brake lever repeatedly until a pressure point is felt.

9. Correct the brake fluid level to marking A.

10. Mount screw cap (1) with membrane (2) and the O-ring. Clean up any spills.

Removing the front wheel:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper toward the disc to push back the pistons.

3. Loosen screw (1) by several rotations.

4. Loosen screws (2).

5. Press on screw (1) to push the wheel spindle out of the axle clamp. Remove screw (1).

6. Hold the front wheel and remove the wheel spindle. Take the wheel out of the fork.

7. Remove spacers (3).

Installing the front wheel:

1. Check the wheel bearing for damage/wear. If needed, change it.

2. Clean and grease shaft seal rings (1) and contact surfaces (A) of the spacers with long-life grease.

3. Insert the spacers. Clean and grease the wheel spindle.

4. Position the front wheel, insert the spindle, and ensure brake linings are correct.

5. Mount and tighten screw (2).

6. Operate the hand brake lever several times until linings are seated.

7. Remove motorcycle from lift stand. Operate front brake and compress the fork a few times firmly to straighten fork legs.

8. Tighten screws (3).

Removing the rear wheel:

1. Raise the motorcycle with a lift stand.

2. Manually press the brake caliper toward the disc to push back the piston.

3. Remove nut (1).

4. Take off chain adjuster (2). Pull out wheel spindle (3) far enough to allow the wheel to be pushed forward.

5. Push the rear wheel forward and remove the chain from the sprocket.

6. Hold the rear wheel, remove the spindle, and take the wheel out of the link fork.

7. Remove spacers (4).

Installing the rear wheel:

1. Check the wheel bearing for damage/wear. If needed, change it.

2. Clean and grease shaft seal rings (1) and contact surfaces (A) of the spacers with long-life grease.

3. Insert the spacers. Clean and grease the wheel spindle.

4. Position the rear wheel and insert the spindle (2). Ensure brake linings are correct.

5. Mount the chain.

6. Position chain adjuster (3). Mount nut (4), but do not tighten yet.

7. Ensure chain adjusters (3) are fitted correctly on adjusting screws (5).

8. Check the chain tension.

9. Tighten nut (4).

10. Operate the foot brake lever repeatedly until the linings are seated.

11. Remove the motorcycle from the lift stand.

Checking the tire condition:

– Only mount tires approved and/or recommended by KTM. Worn tires have a negative effect on handling.

– Check front and rear tires for cuts, run-in objects, and other damage. If found, change the tires.

Checking the tire age:

– The tire date of manufacture is in the last four digits of the DOT number (week/year). KTM recommends changing tires after 5 years, regardless of wear.

Checking tire pressure:

– Low pressure leads to abnormal wear and overheating. Correct pressure ensures optimal comfort and service life.

– Remove the protection cap and check pressure when tires are cold.

– If pressure is incorrect, correct it. Mount the protection cap.

Warning: Incorrectly tensioned spokes impair handling and can lead to damage. Check tension regularly, especially on a new vehicle.

– Strike each spoke briefly using a screwdriver blade. You should hear a high note. If you hear different tone frequencies from spokes of equal length and diameter, it indicates different tensions.

– If spoke tension differs, correct the tension.

– Check the spoke torque.

Use Torque wrench kit (58429094000).

Warning: 12 V batteries contain harmful substances. Keep out of reach of children, away from sparks/flames, and charge in well-ventilated rooms.

Removing the battery:

1. Remove the seat.

2. Disconnect negative cable (1).

3. Pull back positive terminal cover (2) and disconnect the positive cable.

4. Remove screw (3).

5. Pull holding bracket (4) forward and remove the battery upwards.

Installing the battery:

1. Position the battery (HJTZ5S-FP-C) in the compartment with terminals facing forward, and secure with holding bracket (1).

2. Mount and tighten screw (2).

3. Connect positive cable (3). Contact disks A must be under screws (5) and cable sockets (6) with claws toward the terminal.

4. Slide positive terminal cover (7) over the terminal.

5. Connect negative cable (4).

6. Mount the seat.

Preparatory work:

– Remove the seat.

– Remove the 12-V battery.

Main work:

– Check the battery voltage.

– If voltage is < 9 V, do not charge the battery. Replace it.

– If voltage is ≥ 9 V, charge the battery.

– Connect a suitable battery charger (e.g., (EU) 79629974000 or (US) 79629974500) and switch it on. This type of charger is for lithium iron phosphate batteries.

– After charging, switch off the charger and disconnect it.

Finishing work:

– Install the 12 V battery.

– Mount the seat.

Warning: Incorrect fuses overload the electrical system. Only use fuses with the required ampere value.

The main fuse is located in the starter relay housing under the seat.

Preparatory work:

– Remove the seat.

Main work:

1. Pull starter relay (1) from the holder.

2. Take off protection caps (2).

3. Remove faulty main fuse (3). A faulty fuse has a burned-out wire (A). A spare fuse (4) is located in the starter relay.

4. Insert a new main fuse (58011109110, 10A).

5. Check that the electrical system is functioning properly.

6. Mount the protection caps.

7. Mount the starter relay onto the holder and route the cable.

Finishing work:

– Mount the seat.

Do not use radiator covers in difficult operating conditions. The cover is installed based on ambient temperature to keep coolant between 65-70°C (149-158°F).

Installing the radiator cover:

1. Remove screws (1) and (2). Take off radiator shield (3).

2. Position the matching radiator cover. The larger holding lug is at the top left.

3. Position radiator shield (3).

4. Mount and tighten screws (2) and (1).

Removing the radiator cover:

1. Remove screws (1) and (2). Take off radiator shield (3).

2. Remove the radiator cover.

3. Position radiator shield (3) and tighten screws (2) and (1).

Warning: Coolant gets very hot and is under pressure. It is also toxic. Handle with care and allow the system to cool before working on it.

Checking antifreeze and coolant level:

1. With the engine cold, stand the motorcycle upright and remove the radiator cap.

2. Check the coolant antifreeze protection level. It should be between -25 to -45 °C (-13 to -49 °F).

3. Check the coolant level. It should be 10 mm (0.39 in) above the radiator fins.

4. If the level is incorrect, add coolant. Mount the radiator cap.

Draining the coolant:

1. With the engine cold, position an appropriate container under the water pump cover.

2. Remove screw (1). Take off radiator cap (2).

3. Completely drain the coolant.

4. Mount and tighten screw (1) with a new seal ring.

Refilling with coolant:

1. Make sure drain screw (1) is tightened. Position the motorcycle upright.

2. Completely fill the radiator with coolant.

3. Loosen bleeder screw (2) on the cylinder head until coolant escapes without bubbles. Then mount and tighten it.

4. Completely fill the radiator with coolant again.

5. Mount radiator cap (3).

6. Allow the engine to warm up and cool down. Check the coolant level again.

Checking the play:

1. Check the throttle grip for smooth operation.

2. Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth to determine the play in throttle cable A.

3. Start the engine at idle. Move the handlebar to and fro over the entire steering range. The idle speed must not change. If it does, adjust the play.

Adjusting the play:

1. Remove the seat. Turn the fuel tap to OFF. If routing is correct, the fuel tank does not need to be removed.

2. Move the handlebar to straight-ahead.

3. Push back sleeve (1). Ensure the throttle cable sleeve is pushed all the way into barrel adjuster (2).

4. Loosen nut (3).

5. Turn barrel adjuster (2) to achieve the specified play (2-3mm).

6. Tighten nut (3) and slide on sleeve (1).

7. Check for smooth operation and re-check play. Install fuel tank and seat if removed.

The idle setting of the carburetor significantly influences starting behavior, idle stability, and acceleration.

The idle speed is adjusted with adjusting screw (1). The idle mixture is adjusted using the idle air adjusting screw (2).

Adjusting the idle speed:

1. Screw in idle air adjusting screw (1) all the way and turn it to the specified basic setting shown in the technical data for your model.

2. Run the engine until warm (≥ 5 min).

3. Adjust the idle speed with adjusting screw (2). Choke must be deactivated.

4. Turn idle air adjusting screw (1) slowly clockwise until the idle speed begins to fall.

5. Note the position and turn the idle air adjusting screw slowly counterclockwise until the idle speed again begins to fall.

6. Adjust to the point between these two positions with the highest idle speed.

If there is a big engine speed rise, reduce the idle speed and repeat. If this procedure does not work, the idling jet may be wrongly dimensioned.

The plug-in connector for the ignition timing map is located on the frame under the fuel tank.

Possible states (All models):

– Soft: The plug-in connector is disconnected to achieve better rideability.

– Performance: The plug-in connector is joined to achieve higher performance.

Changing the map:

– To switch from Performance to Soft, disconnect the plug-in connector.

– To switch from Soft to Performance, join the plug-in connector.

Checking the basic position:

– When driving, the shift lever must not touch the rider’s boot when in the basic position.

– Sit on the vehicle in the riding position and determine the distance A between the upper edge of your boot and the shift lever.

– If the distance is not correct, adjust the basic position.

Adjusting the basic position:

1. Remove screw (1) with the washers and take off shift lever (2).

2. Clean gear teeth (A) of the shift lever and shift shaft.

3. Mount the shift lever on the shift shaft in the required position and engage gearing. The range of adjustment is limited.

4. Mount and tighten screw (1) with washers.

Carry this work out with a cold engine. Water in the float chamber can cause malfunctions.

Preparatory work:

– Turn the tap handle of the fuel tap to the OFF position. Fuel should no longer flow to the carburetor.

Main work:

1. Place a cloth under the carburetor to capture the draining fuel.

2. Remove screw plug (1).

3. Fully drain the fuel.

4. Mount and tighten the screw plug.

Checking the gear oil level:

Check when the engine is cold.

1. Stand the motorcycle upright on a horizontal surface.

2. Remove gear oil level monitoring screw (1).

3. A small quantity of gear oil must run out of the drilled hole. If not, add gear oil.

4. Mount and tighten the gear oil level monitoring screw.

Changing the gear oil:

Drain the gear oil while the engine is at operating temperature. Warning: Engine and gear oil get very hot.

1. Park the motorcycle on a level surface and position a container under the engine.

2. Remove gear oil drain plug (1) with magnet and drain plug (2).

3. Let the gear oil drain fully. Clean the drain plugs and sealing surface.

4. Mount and tighten drain plug (1) with magnet and a new seal ring.

5. Mount and tighten drain plug (2) with a new seal ring.

6. Remove filler plug (3) with the O-ring and fill up with 0.80 L (0.85 qt.) of Engine oil (15W/50).

7. Mount and tighten the filler plug with the O-ring.

8. Start the engine and check for leaks. Then check the gear oil level.

Adding the gear oil:

Top up only when the engine is cold.

1. Park the motorcycle on a level surface.

2. Remove gear oil level monitoring screw (1) and filler plug (2).

3. Add gear oil (15W/50) until it emerges from the drill hole of the monitoring screw.

4. Mount and tighten the monitoring screw and the filler plug.

Note: High pressure from a pressure cleaner can damage components. Maintain a minimum distance of 60 cm (23.6 in) and do not direct the jet at electrical components, connectors, cables, or bearings.

1. Close off the exhaust system to keep water from entering.

2. Remove coarse dirt with a gentle water jet.

3. Spray heavily soiled parts with a normal commercial motorcycle cleaner and clean using a brush. Never apply cleaner to a dry vehicle; always rinse first.

4. After rinsing with a gentle spray of water, allow it to dry thoroughly.

5. Empty the carburetor float chamber.

6. Remove the closure of the exhaust system.

7. After cleaning, ride the vehicle a short distance until the engine warms up to evaporate water from inaccessible locations.

8. After the motorcycle has cooled down, lubricate all moving parts and pivot points.

9. Clean the chain.

10. Treat bare metal (except brake discs and exhaust) with a corrosion inhibitor.

11. Treat all plastic and powder-coated parts with a mild cleaning and care product.

If you plan to garage the motorcycle for a longer period, perform the following steps:

– When refueling for the last time, add fuel additive.

– Refuel.

– Clean the motorcycle.

– Change the gear oil.

– Check the antifreeze and coolant level.

– Empty the carburetor float chamber.

– Check tire pressure.

– Store the vehicle in a dry location not subject to large temperature fluctuations.

– KTM recommends jacking up the motorcycle with a lift stand.

– Cover the vehicle with a tarp or similar cover that is permeable to air. Do not use non-porous materials.

– Avoid running the engine for only a short time to prevent condensation and rust.

– Remove the motorcycle from the lift stand.

– Perform checks and maintenance measures when preparing for use.

– Take a test ride.

Carburetor: MIKUNI TMX 38. The following table provides tuning settings based on altitude (ASL) and temperature (TEMP). Abbreviations: ASO (Idle air adjusting screw open), IJ (Idling jet), NDL (Needle), POS (Needle position from top), MJ (Main jet).

Do not use these settings on sandy terrain.

If the engine is not running smoothly, use a smaller main jet.