Motorcycle Type:
High-performance motocross competition motorcycle.
Target Audience:
Motocross racers, off-road enthusiasts, mechanics specializing in performance dirt bikes.
Key Competitors 2011:
Honda CRF450R, Yamaha YZ450F, Suzuki RM-Z450, Kawasaki KX450F.
Vehicle Focus:
Competition-ready, lightweight, powerful, advanced chassis and suspension.
Manual Value Proposition:
Enables owners and technicians to perform accurate diagnostics, maintenance, and repairs, optimizing performance and longevity.
Engine Mechanical:
Complete engine disassembly, inspection, assembly, torque specifications, valve clearance adjustment, timing, lubrication system.
Fuel System:
Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), troubleshooting, cleaning, and calibration.
Ignition System:
Ignition coil, CDI unit, spark plug specifications, timing adjustments, troubleshooting.
Cooling System:
Radiator, coolant, fan operation, hoses, troubleshooting for overheating.
Transmission:
Clutch assembly, gear shifting mechanism, gear ratios, oil specifications, troubleshooting clutch slip or engagement issues.
Drivetrain:
Final drive chain and sprockets, lubrication, adjustment, replacement procedures.
Suspension Front:
Front fork (WP USD), oil levels, fork seal replacement, damping adjustments, spring rates, stanchion and slider inspection.
Suspension Rear:
Rear shock absorber (WP PDS), linkage system, spring preload adjustment, damping adjustments, seal head replacement, bearing inspection.
Brakes Front:
Brake caliper, master cylinder, brake pads, brake discs, brake fluid type and bleeding procedures, troubleshooting.
Brakes Rear:
Rear brake caliper, master cylinder, brake pads, brake disc, brake fluid type and bleeding procedures, troubleshooting.
Electrical System:
Wiring diagrams, battery specifications, starter motor, lighting system, fuse types and locations, troubleshooting electrical faults.
Chassis Frame:
Frame inspection, headstock bearings, swingarm bearings, alignment checks.
Bodywork:
Fairing removal and installation, seat, fuel tank, fender procedures.
Maintenance Routine:
Scheduled maintenance intervals for oil changes, filter replacements, chain lubrication, general inspection.
Troubleshooting:
Systematic fault diagnosis for starting issues, performance problems, electrical faults, fluid leaks.
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Component Replacement:
Procedures for replacing wear items such as brake pads, filters, spark plugs, cables, and bearings.
Rebuilds:
Complete engine and transmission rebuild procedures, including cylinder head, piston, crankshaft, and gearbox.
Specifications Data:
All critical torque values, clearances, fluid capacities, and tolerances for every component.
Depth Level:
Factory-level technical detail suitable for professional mechanics and experienced DIY enthusiasts.
Diagrams Illustrations:
High-quality diagrams, pictures, and illustrations to guide users through complex procedures.
Searchability:
Active index and searchable text for quick access to specific information.
Engine Type:
Four-stroke, single-cylinder
Bore X Stroke:
97.0 mm x 60.8 mm (Refer to manual for exact values)
Valvetrain:
SOHC (Single Overhead Camshaft), 4 valves
Cooling System:
Liquid-cooled
Horsepower Est:
Approx. 54 hp @ 8500 rpm (Refer to manual for precise factory rating)
Torque Est:
Approx. 47 Nm @ 6500 rpm (Refer to manual for precise factory rating)
Fuel Delivery:
Keihin MX FI electronic fuel injection with 42mm throttle body
Fuel Type:
Unleaded gasoline, minimum 95 RON (Refer to manual for specific octane requirement)
Ignition Type:
Digital CDI
Lubrication System:
Wet sump (integrated gearbox lubrication)
Engine Oil Capacity:
1.1 Liters (Refer to manual for exact capacity and dipstick procedure)
Starter:
Electric starter
Length:
Approx. 2160 mm (Refer to manual)
Width:
Approx. 820 mm (Refer to manual)
Height:
Approx. 1265 mm (Refer to manual)
Seat Height:
Approx. 995 mm (Refer to manual)
Dry Weight:
Approx. 103.5 kg (Refer to manual)
Curb Weight Est:
Approx. 110-115 kg (with all fluids, refer to manual for precise specification)
Fuel Tank Capacity:
7.5 Liters (Refer to manual)
Payload Capacity:
N/A (Competition motorcycle)
Front Wheel Size:
21 inches (Refer to manual)
Rear Wheel Size:
19 inches (Refer to manual)
Front Tire Size:
80/100-21 (Refer to manual for specific brand/model recommendations)
Rear Tire Size:
110/90-19 (Refer to manual for specific brand/model recommendations)
Oil Change Interval:
Every 10-15 hours of operation or as specified in the manual. Motocross engines experience severe duty cycles.
Air Filter Cleaning:
Before every ride, or more frequently in dusty conditions. Critical for engine longevity.
Valve Clearance Check:
Every 20-30 hours of operation (Refer to manual for exact interval and procedure).
Chain Maintenance:
Lubricate and adjust chain tension every 5-10 hours of riding.
Engine Oil Spec:
Refer to manual. Typically high-quality synthetic motorcycle oil, e.g., Motorex Power Synt 4T 10W-50 or similar API SG/SH/SJ/SL/SM rated oil.
Coolant Spec:
Ethylene glycol-based coolant with corrosion inhibitors. KTM recommends Motorex Coolant M3.0 (Blue). Mix 50/50 with distilled water.
Brake Fluid Spec:
DOT 4 (Refer to manual for specific recommendation and fluid type for clutch actuation).
Common Wear Items:
Clutch plates, brake pads, sprockets, chain, wheel bearings, steering head bearings, fork seals, piston rings (due to high operating RPMs and stress).
Potential Failures If Neglected:
Engine seizure due to lack of lubrication, transmission damage from improper oil, suspension performance degradation, electrical system faults.
