KTM 400 User Manual

ENGLISH
18
How to change the handlebar position
The handlebar position can be readjusted by 22 mm. Thus, you can put the
handlebar to the position that is the most convenient for you. The upper tri-
ple clamp
1 includes 2 bores arranged at a distance of 15 mm (0,6 in) from
one another. The bores at the handlebar support
2 are offset from the cen-
ter by 3.5 mm (0,13 in). Accordingly, you can mount the handlebar in
4 different positions.
For this purpose, remove screws
3 of the handlebar clamps and screws 4
of the handlebar support. Position handlebar support, and tighten screws 4
to 40 Nm (30 ft.lb). Mount handlebar and handlebar clamps, and tighten
screws
3 to 20 Nm (15 ft.lb). The gap between handlebar support and
handlebar clamps is to be of equal size in the front and in the rear.
Changing the spring preloading of the shock absorber
The spring preload can be changed by turning the adjusting ring 5. For this
purpose, you should dismount the shock absorber and clean it thoroughly.
NOTE:
– Before changing the spring preload note down the basic setting, e.g.
how many threads are visible above the adjusting ring.
– One rotation of the adjusting ring 5 changes the spring pretension by
approximately 1,75 mm (0,07 in).
Loosen the clamping screw
6 and use the hook wrench contained in the
vehicle tool set to turn the adjusting ring as desired. Turning it counter-
clockwise will reduce the preload, turning it clockwise will increase the
preload.
After readjusting the clamping screw
6, tighten it to 8 Nm (6 ft.lb)
ADJUSTMENT VALUES - SPRING PRELOAD
A
minimum preload . . . . . . . . . . . . . . . . . 4 mm (0,15 in)
STANDARD PRELOAD . . . . . . . . . . . . . 6 mm (0,24 in)
maximum preload . . . . . . . . . . . . . . . . . 10 mm (0,4 in)
Pivot bearing
The pivot bearing 7 for PDS suspension struts at the swinging fork is
Teflon-coated and must not be lubricated with either grease or other lubri-
cants. Grease and other lubricants cause the Teflon coat to dissolve,
whereby the bearing’s lifecycle will be reduced dramatically.
When cleaning your bike with a high-pressure cleaner, do not aim the high-
pressure spray directly at the pivot bearing.
A
1
2
3
4
15 mm
3,5 mm
5
6
7

KTM 400 Specifications

General

Transmission	6-speed
Engine	Single-cylinder, 4-stroke
Starter	Electric
Cooling System	Liquid-cooled
Front Suspension	WP USD
Rear Suspension	WP
Front Brake	Single disc
Rear Brake	Single disc

Summary

Important Safety and Operational Guidelines

Operation Instruments

Clutch, Decompression, and Brake Levers

Front Fork Suspension Adjustment

Compression and Rebound Damping Adjustment (Fork)

How to adjust the fork's compression and rebound damping.

Rear Shock Absorber and Steering Adjustment

Shock Absorber Damping Adjustment

Adjusting compression and rebound damping on shock absorbers.

Pre-Ride Checks and Initial Operation

Essential Pre-Ride Checks

A checklist of critical inspections before riding.

Initial Operation and Running-In Procedures

Guidance for first rides and engine break-in.

Engine Starting and Riding Techniques

Engine Starting Procedures (Cold, Warm, Flooded)

Steps for starting the engine in various states.

Starting Off and Shifting Gears

How to begin riding and change gears smoothly.

Braking and Stopping Procedures

Braking Techniques and Safety

Proper use of brakes and associated safety warnings.

Stopping and Parking Guidelines

Safe procedures for stopping the motorcycle and parking it.

Periodic Maintenance Schedule

Recommended Extra Order Maintenance

Key maintenance tasks recommended for professional service.

Rider Maintenance and Specialized Workshop Checks

Regular Rider Maintenance Checks

Essential checks riders should perform regularly.

Chassis and Engine Maintenance Procedures

Clutch Lever and Steering Head Bearing Adjustment

Front Fork Maintenance and Spring Preload

Handlebar Position and Shock Absorber Preload

Chain Tension, Maintenance, and Wear

Disc Brake System Information and Maintenance

Details on brake calipers, pads, discs, fluid, and safety.

Hand Brake Lever and Front Brake Fluid Checks

Rear Brake Pad and Fluid Checks

Front Wheel Removal and Installation

Rear Wheel Removal and Installation

Tire Pressure and Spoke Tension Checks

Cooling System Checks and Bleeding

Checking coolant level and bleeding the cooling system.

Air Filter Cleaning and Oiling

Carburetor Idle and Mixture Adjustment

Engine Oil Specifications and Changing

Selecting and changing engine oil and filters.

Troubleshooting Common Issues

Technical Data - Engine and Carburetor

Engine Specifications and Carburetor Settings

Detailed engine technical data and basic carburetor settings.

Technical Data - Chassis, Torques, and Clearances

Chassis Specifications and Tightening Torques

Chassis data, fork/shock adjustments, and torque specifications.

Assembly Clearances and Wear Limits

Specifications for assembly clearances and wear limits.