KTM 400 User Manual

ENGLISH
3
Page
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . .4
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine number, engine type . . . . . . . . . . . . . . . . . . . . . .4
OPERATION INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . .4
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Hand decompression lever . . . . . . . . . . . . . . . . . . . . . . .4
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Digital speedometer, indicator lamps (EXC) . . . . . . . . . . .5
Digital speedometer (EXC) . . . . . . . . . . . . . . . . . . . . . . .5
Odometer (EXC USA) . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Speedometer, indicator lamps (EXC - Australia) . . . . . . . .5
Short circuit button (SX/MXC) . . . . . . . . . . . . . . . . . . . .5
Combination switch (EXC) . . . . . . . . . . . . . . . . . . . . . . . .6
Headlamp switch (EXC USA) . . . . . . . . . . . . . . . . . . . . . .6
Flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Emergency OFF button (EXC) . . . . . . . . . . . . . . . . . . . . .6
Emergency OFF switch (EXC Australia) . . . . . . . . . . . . . .6
Filler cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Fuel tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Kickstarter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foot brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Compression damping of fork . . . . . . . . . . . . . . . . . . . . .9
Rebound damping of fork . . . . . . . . . . . . . . . . . . . . . . . .9
Damping action during compression of shock absorber (SX) 9
Compression damping of shock absorber (MXC, EXC) .10
Rebound damping of shock absorber (SX, MXC, EXC) .10
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
DRIVING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .11
PERIODIC LUBRICATION- AND MAINTENANCE-SCHEDULE . .14
MAINTENANCE WORK ON CHASSIS AND ENGINE . . . . .16
Changing the original position of the clutch lever . . . . .16
Checking and adjusting the steering head bearing . . . . .16
Breather plug front fork . . . . . . . . . . . . . . . . . . . . . . . . .17
Cleaning the dust sleeves of the telescopic fork . . . . . . .17
Adjusting the spring preload on the fork (SX) . . . . . . . .17
How to change the handlebar position . . . . . . . . . . . . .18
Changing the spring preload of shock absorber . . . . . . .18
Pivot bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Check chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Correct chain tension . . . . . . . . . . . . . . . . . . . . . . . . . .19
Chain maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
General informations about KTM disc brakes . . . . . . . .20
Adjusting of free travel at the hand brake lever . . . . . . .21
Page
Checking of brake fluid level - front brake . . . . . . . . . . .21
Refilling the front brake fluid reservoir . . . . . . . . . . . . . .21
Checking the front brake pads . . . . . . . . . . . . . . . . . . .21
Replacing the front brake pads . . . . . . . . . . . . . . . . . . .22
Changing the basic position of the brake pedal . . . . . .22
Checking rear brake fluid level . . . . . . . . . . . . . . . . . . .22
Refilling the rear brake fluid reservoir . . . . . . . . . . . . . .22
Checking the rear brake pads . . . . . . . . . . . . . . . . . . . .23
Replacing the rear brake pads . . . . . . . . . . . . . . . . . . .23
Dismounting and mounting the front wheel . . . . . . . . .23
Dismounting and mounting the rear wheel . . . . . . . . .24
Tires, air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Checking spoke tension . . . . . . . . . . . . . . . . . . . . . . . .25
Replacing the battery of the digital speedometer . . . . .25
Adjusting digital speedometer . . . . . . . . . . . . . . . . . . .26
Check/set distance of magnetic sensor . . . . . . . . . . . . .27
Battery (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Charging battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Fuse (MXC/EXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Replacing head light/parking light lamp . . . . . . . . . . .29
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Checking the coolant level . . . . . . . . . . . . . . . . . . . . . .30
Bleeding the cooling system . . . . . . . . . . . . . . . . . . . . .30
Cleaning the air filter . . . . . . . . . . . . . . . . . . . . . . . . . .31
Replacing the glass fiber yarn packing of the silencer . .31
Cleaning the spark arrestor (MXC/EXC USA) . . . . . . . .31
Checking adjustment of the hand decompression release cable .32
Adjust the throttle cables . . . . . . . . . . . . . . . . . . . . . . .32
Checking the oil level of the hydraulic clutch . . . . . . . .32
Bleeding of the hydraulic clutch . . . . . . . . . . . . . . . . . .32
Carburetor adjust idling . . . . . . . . . . . . . . . . . . . . . . . .33
Adjusting the mixture control screw . . . . . . . . . . . . . . .33
Checking the float level . . . . . . . . . . . . . . . . . . . . . . . .33
Draining of float chamber of the carburetor . . . . . . . . .34
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Checking engin oil level . . . . . . . . . . . . . . . . . . . . . . . .34
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . .35
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . .37
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
CONSERVATION FOR WINTER OPERARION . . . . . . . . .39
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Re-initiation after time of storage . . . . . . . . . . . . . . . . .39
TECHNICAL SPECIFICATIONS - ENGINE . . . . . . . . . . . . .40
TECHNICAL SPECIFICATIONS - CHASSIS . . . . . . . . . . . . .43
HEAD WORD INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
WIRING DIAGRAMME . . . . . . . . . . . . . . . . . . . . . .Appendix
INDEX

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