21 TECHNICAL DATA 138 Design Lreylinder 2-stroke engine, water-cooled, with reed intake and exhaust control Displacement 64.85 cms (3.9574 cu in) ‘Stroke 40.8 mm (1.606 in) Bore 45 mm (1.77 in) Control Exhaust control PCEV (Pneumatic Controlled Exhaust Valve) Crankshaft bearing 2 grooved ball bearings Conrod bearing Needle bearing Piston pin bearing Needle bearing Pistons ‘Aluminum cast Piston rings 1 rectangular ring Engine lubrication | ‘Mixture oil lubrication Primary transmission 23:75 straight cut spur gear Clutch Mullidisc clutch in oll bath/hydraulicaly activated Gearbox 6-gear, claw shifted Transmission ratio Ist gear 13:37 2nd gear 16:34 3rd gear 18:31 4th gear 21:30 5th gear 23:28 “th gear 2:26 Terition ‘Non-contact controled fully electronic ignition system with digi- tal ignition adjustment ‘Spark plug NGKLR BB ‘Spark plug electrode gap (0.60 mm (0.0236 in) Cooling Water-cooled Starting aid Kickstarter X-distance (distance from adjusting gauge to piston) 0... 0.10 mm (0... 0.0039 in) Piston - diameter ‘Size 1 44.985... 44.965 mm (1.76988... 1.77027 in) ‘Size 2 44,965... 44.975 mm (1.77027... 1.77067 in) Gylinder - bore diameter ‘Size A 45.025... 45.037 mm (1.77263... 1.77311 in) Size 8 45.037... 45.050 mm (1.77311... 1.77362 in) Pistonveylinder - mounting clearance New condition (0.060... 0.085 mm (0.00236... 0.00335 in) Wear limit (0.10 mm (0.0039 in) Piston ring end gap '§ 0.60 mm (s 0.0236 in} Clutch facing disc - thickness = 18mm 20071 in) Clutch spring - length 21.5... 21.9 mm (0.846... 0.862 in) Contact surface, clutch facing discs in outer clutch hub $0.5 mm (s 0.02 in} Connecting rod - axial clearance of lower conrod bearing (0.40... 0.75 mm (0.0157... 0.0295 in) (Grankshaft - run-out on bearing pin $0.03 mm (5 0.0012 in} ‘Shift shaft - play in sliding plate/shift quadrant (0.40... 0.80 mm (0.0157... 0.0315 in)21 TECHNICAL DATA (21.3 engine tightening torques 138 Nut, exhaust control diaphragm MS hm Gt = ‘Screw, clutch line holder M5 Nm G7 lif) = ‘Screw, diaphragm cover of exhaust | MB Nm BIT = control ‘Screw, ignition system/stator 5 Sm G7 bi) Loctite? 222" Screw, main shaft bearing retainer | MS Nm 3.7 bff) Loctite 643" ‘Screw, reed valve housing of exhaust | MB SNm G7 IR) = control ‘Screw, retaining bracket forretun | MB Nm (4.4 TA) Loctte® 243 spring of shift shaft ‘Screw, shift drum locating MB Nm (44 OTR) Loctte® 243™ ‘Screw, water pump wie! 5 Nm 3.7 lf) Loctite® 243% Drain plug, water pump cover NG Nm (6.4 lb) = Screw, alternator cover NG Nm 6.9 THR) = Screw, clutch intermediate cover | M6 10 Nm (7-4 IF) = Screw, clutch slave cylinder MG TO Nm (7-4 IoF) Loctite 243° ‘Screw, clutch springs 6 TONm (7.4 IF) = ‘Screw, engine case Ne 10 Nm (7-4 IFA) = ‘Screw, engine sprocket cover M6 TO Nm (7-4 1oF A) = Screw, exhaust flange 6 TO Nm (7-4 IF) Loctite® 243 ‘Screw, gear oll level check NG 6 Nm (4.4 Tot ft = ‘Screw, intake Tlangelreed valve housing | M6 10 Nm (7-4 IF FO = ‘Screw, Kickstarter stop piece NG TONm (7-4 IoF A) Loctite® 243 Screw, outer clutch cover Ne 10. Nm (7.4 Ib A = ‘Screw, reed valve housing of exhaust | M6 TO Nm (7.4 1oF = control ‘Screw, shift drum bearing retainer __| MG SN G7 DIR) Teoctie® 648 ‘Screw, shift drum lating NG 10 Nm (7-4 IBF) Loctite® 243° ‘Screw, shift lever Ne 14 Nm (10.3 ft AD Loctte® 243™ ‘Screw, water pump cover NG Nm 6.9 IR) = Vacuum connection/vent connection | M6 51Nm (3.7 Iot ft Loctte® 648 Screw, cylinder head M7 18 Nm (13.3 1A = Nuts, cylinder base NB 20Nm (14.8 IFA = ‘Screw, kickstarter a 25. Nm (18.4 Io f Loctte® 243 ‘Stud, cylinder base (eft section of the | MB Tightening sequence: Loctte® 243 engine case) screw in unti it projects by 27 mm (1.063 in) ‘Stud, eylinder base (right section of | MB Tightening sequence: Loctte® 243 the engine case) screw in unti it projects by 29 mm (1.142 in) Screw, inner clutch hub Mio 6ONm (44.3 IF A) Loctite 243° ‘Spark plug MI0x1 10... 12 Nm (7.4. = 89 loft) Nut rotor Mizai 50 Nm (36.9 1oF A = Oil drain plug with magnet Mizx5 20 Nm (14.8 [oF A) = Nut, primary geae MI4ax1.25 40.Nm (29.5 lof) Loctte® 24321 TECHNICAL DATA 140 Carburetor type MIKUNETM 24 Needle position 2nd position from top lale air adjusting screw ‘Open 3.5 turns Main jet 210 Jet needle SIPLAR laling jet 20 Needle jet 0-0 (454) Throttle slide 25 21.4.1 Carburetor tuning, IMIKUNI TM 24 MT ASL Temp | -20°C..-7°C | -6°C... °C | 6°C...15%C | 16°C... 24°C | 25°C... 36°C | 37°C... 49°C. { | 2... 20°F | 19°F... 41°F | 42°F... 60°F | 61°F... 78°F | 79°F... 98°F | 99°F... 120°F 3.000 m ASO 35 35 35 35 35 10,000 ft W 20 20 15 15 10 t NOL SIPLA3 SIPLA3 SIPL43 SIPL43 SIPLA3 Pos 2 1 1 1 1 2.301 m Ms 210 210 205 200 195 7,501 ft 2.300 m ASO 35 35 35 35 35 35 7,500 ft u 20 20 20 15 15 10 t NOL SIPLAS SIPLAS SIPLAS SIPLA3 SIPLAS SIPLAS Pos 2 2 1 1 1 1 1.501 m Ms 210 210 210 205 200 195, 5,001 ft 1.500 m ASO 35 35 35 35 35 35 5,000 ft WW 20 20 20 20 15 18 t NDL SIPLA3 SIPLA3 SIPL43 SIPLa3 SIPLA3 SIPL43 Pos 3 2 2 a 1 1 751m Ms 215 210 210 210 205 200 2,501 ft 750 m ASO. 25 35 35 35 35 36 2,500 ft u 25 20 20 20 20 15 t NOL SIPLAS SIPLAS SIPLAS SIPLA3 SIPLAS SIPLAS POs 3 a 2 2 1 1 301 m Ms 220 25 210 210 210 205 1,001 ft 300 m ASO. 2 25 35 35 35 35 1,000 ft u 25 25 20 20 20 20 t NDL SIPLA3 SIPLA3 SIPLA SIPLA3 SIPLA3 SIPLa3 Pos. 4 sg 3 2 2 1 Om Ms 225 220 218 210 210 210 on 100810-01, WPT ASL. ‘Above sea level TEMP, Temperature ASO ladle air adjusting screw open (rotations) u laling jet NOL Jet needle21 TECHNICAL DATA wat POs: Needle position from above Md Main jet ‘The carburetor tuning depends on the defined ambient and operating conditions. 21.5.1 Gearoil Gear ol (0.50 1 (0.53 at) Engine oil (15W/50) (* p. 150) 21.5.2 Coolant Coolant (0.55 | (0.58 gt) Coolant ( p. 150) 21.5.3 Fuel Fuel tank capaci B51 aly ‘Super unleaded (5 octane) mixed with 2-strake engine oll (2:60) ( p. 151) Frame Central tube frame of chrome molybdenum steel tubing, powder- coated Fork WP Performance Systems USD 35 ‘Shock absorber WP Suspension 3614 BAVP ‘Suspension travel Front 215 mm (8.46 in) Rear 270 mm (10.63 in) Fork offset 22 mm (0.87 in) Brake system Front Disc brake with four-pot brake caliper Rear Disc brake with two-pot brake caliper Brake disc diameters Front 198 mm (7-8 in) Rear 160 mm (6.3 in) Brake isos - wear limits Front 2.5 mm (0.098 in) Rear 2.5 mm (0.098 in) Tire air pressure off road Front 1.0 bar (15 psi) Rear 1.0 bar (15 psi) ‘Secondary drive ratio 1448 Chain V2 x 1/4" O-ing Rear sprockets available 46, 48, 60 Steering head angle 64.5 Wheelbase 1,137 mm (44.76 in) ‘Seat height unloaded "750 mm (29.53 in) Ground clearance unloaded 280 mm (11.02 in) Weight without fuel, approx. 55.5 kg (122.4 1b.) Maximum rider weight 50 kg (110 1b.)21 TECHNICAL DATA Fork part number O7.18.7L.08 Fork WP Performance Systems USD 35 Compression damping ‘Standard 2 turns Rebound damping ‘Standard 2 turns Spring rate Weight of rider: < 35 kg (= 77 1b.) 2.6 Nimm (14.8 Iblin) Weight of rider: 35... 45 kg (77... 99 Ib) 2.8 Nimm (16 Tbvin) Weight of rider: > 45 kg (> 99 Ib.) 3.0 Nimm (17.1 Ib/ind Fork length 735 mm (28.94 in) Fork oil per fork leg 240210 mi (8.1120.34 fl. 02.) Fork oil (SAE 4) (4860116681) (* p. 150) ‘Shock absorber part number (03.18.7.03 ‘Shock absorber WP Suspension 3614 BAVP Compression damping ‘Standard Gclicks Rebound damping ‘Standard 12 clicks ‘Spring preload ‘Standard 7 mm (0.28 in) Spring rate Weight of rider: = 35 kg (= 77 1b.) 35 Nim (200 Toi) Weight of rider: 35... 45 kg (77... 99 Ib) 40 Nimm (228 Ib/in) Weight of rider: > 45 kg © 99 1b.) ‘45 Nim (257 Ibiin) Spring length 220 mm (8.66 in) Gas pressure 10 bar (145 psid Static sag 33 mm (1.3 in) Riding sag 90 mm (3.54 in) Fitted length ‘347 mm (13.66 in) ‘Shock absorber oll ‘Shock absorber fluid (SAE 2.5) (5018075181) (* p. 151) ‘Spoke nipple N35 3.Nm (2.2 IDF) = Remaining nuts, chassis, WG 10 Nm (7.4 Tot ft) = Remaining screws, chassis NG 10 Nm (7.4 bf) = ‘Sorew, ball joint of push rod on foot | M6 brake cylinder 10 Nm (7.4 Tot ft) = ‘Screw, foot brake oylinder 6 TO Nm (7.4 Tot A = ‘Serew, fork stub Ne 10 Nm (7.4 Tot) = ‘Serew, front brake disc NG 14 Nm (10.3 bff Loctite® 243™ Sorew, rear brake dise 6 14 Nm (103 Tot Loctte® 243° Serew, throttle grip Ne 45 Nm (3.32 lot Ht) = Nat, rim Tock Ne 10 Nm (7.4 Tbr A = Remaining nuts, chassis Ne 25 Nm (18.4 Ib ft) = Remaining screws, chassis Ne 25 Nm (18.4 Ibf ft) = ‘Serew, bottom triple clamp Ne 15 Nm (11.1 Ff = ‘Serew, brake caliper NB 20 Nm (14-8 Ibf ft) Loctite® 24a™21 TECHNICAL DATA 143 Screw, engine bracket Na 30 Nm (22.1 Ibf ft) = ‘Screw, handlebar clamp NB 20 Nm (14.8 Ibf ft) = ‘Screw, rear sprocket Ne 25 Nm (18.4 1b ft) Loctite® 243 ‘Sorew, side stand fixing wa 40 Nm (29.5 If ft) Loctite® 24a ‘Screw, tal piece Ne ‘35 Nm (25.8 Ibf ft) Loctite® 243™ ‘Serew, top triple clamp a 20 Nm (14.8 1b ft) = Remaining nuts, chassis Mio 45 Nm (83.2 If ft) = Remaining screws, chassis Mio 45 Nm (33.2 IDI ft) = ‘Serew, attom shock absorber io 45 Nm (33.2 Ibf ft) = ‘Screw, foot brake lever wid ‘35 Nm (25.8 Ibt fy Loctite® 2aa™ ‘Screw, front wheel spindle Mio 440 Nm (29.5 IDI ft) = ‘Serew, handlebar support wi0 440 Nm (29.5 If ft) Loctite® 243 ‘Serew, top shock absorber Mio ‘45 New (33.2 Ibt A) = Nut, rear wheel spindle Mi2x1 440 Nm (29.5 Ibf ft) = ‘Nut, swingarm pivot Mi2x1 40 Nm (29.5 bf ft) = Nat, steering stem 20x15 TO Nm (7-4 lor) =22 CLEANING/PROTECTIVE TREATMENT 144 221 Cleaningmotoreyel@ Note ‘Material damage Damage and destruction of components by high-pressure cleaning equipment. = When cleaning the vehicle with a pressure cleaner, do not point the waterjet directly onto electrical components, connectors, cables, bearings, etc. Maintain a minimum distance of 60 cm between the nozzle of the pressure cleaner and the component. Excessive pressure can cause malfunctions or destroy these parts. Warning Environmental hazard Hazardous substances cause environmental damage. = Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations. © Info It you clean the motorcycle regulary, its value and appearance will be maintained over a long period. ‘Avoid direct sunshine on the motorcycle during cleaning, = Seal the exhaust system to prevent penetration by water = First remove coarse dirt particles with a gentle water spray. ® brush. q aa TT Info T Use warm water containing normal motorcycle cleaner and a soft sponge. aon Hosa ooierone rowtael ene. ses = Alter rinsing the motorcycle with a gentle water spray, allow it to dry thoroughly = Remove the plug from the exhaust system, = Empty the carburetor float chamber. (% p. 126) Warning Danger of accidents Reduced braking efficiency due to a wet or dirty brake system, = Clean or dry a dirty or wet brake system by riding and braking gently. = After cleaning, let your child ride the vehicle a short distance until the engine ‘warms up and the brakes are dried by applying the brakes carefully. = Info The neat produced causes water at inaccessible locations in the engine and the brake system to evaporate = Push back the protection covers on the handlebar controls to allow water to evapo- rate. = After the motorcycle has cooled of, lubricate all moving parts and bearings. = Clean the chain. (* p. 62) Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion materials Preserving materials for paints, metal and rubber (* p. 153), = Treat all plastic parts and powder-coated parts with a mild cleaning and care prod- uct. ‘Special cleaner for glossy and matte paint finishes, metal and plastic surfaces (Tp. 153)23 STORAGE 145, Warning Danger of poisoning Fuel is poisonous and a health hazard, = Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If fuel is swallowed, contact a physician immediately. Change clothing that has been contaminated with fuel. Store fuel properly in a suitable canister and keep away from children. Info I you want to garage the motorcycle for a longer period, take the following actions. Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you ‘should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the Start of the new season. = = Clean the motoreyel. (> p. 1449 > ~ = change the gear oi (© p. 131) © ©)_] = neck the antitreeze and coolant level. (* p. 129) ~ When refueling the last time before taking the motorcycle out of service, add fuel additive, Fuel additive (7 p. 152) = Fill up with fuel ‘miosean| ~ Empty the carburetor float chamber. (® p. 126) = Check the tire air pressure. (** p. 58) Store the vehicle in a dry location that is not subject to large fluctuations in tem- perature. © Info Tit recommends raising the motorcycle. = Raise the motorcycle with a lift stand. (* p. 10) = Cover the vehicle with a tarp or similar cover that is permeable to air. = Info Bo not use non-porous materials since they prevent humidity from escaping, thus causing corrosion. [Avoid running the engine for a short time only. Since the engine cannot warm up properly, the water vapor produced during combustion condenses and causes valves and exhaust system to rust. = Remove the motorcycle from the lift stand. (€ p. 10) = Perform checks and maintenance measures when preparing the motorcycle for use. = Take a test ride, 401059-0124 SERVICE SCHEDULE 146 ‘Annually Every 80 operating hours, Every 40 operating hours Every 20 operating hours Once after 10 operating hours Check the front brake linings. (7 p. 69) 7. Check the rear brake linings. (* p. 75) Ss... Check the brake discs. (*" p. 58) s.r. Check brake lines for damage and leakage. .-.. Change the sealing sleeves of the foot brake cylinder. 7. Change the rear brake fluid. (7 p. 74) : heck the rear brake fluid level. (* p. 72) 7. Check the free travel of the foot brake lever. (** p. 71) 7. Check the frame and swingarm. oe. Check swingarm bearing. 7. Check the heim joints on the upper and lower shock absorbers, 7. ‘Service the fork. (Fp. 15) om Service the shock absorber. (* p. 35) > Check the tire condition. (* p. 58) 7. Check the tire air pressure, (* p. 58) 7. heck wheel bearing for play. 7. Check the wheel hubs. - ee Check rim run-out, o... Check the spoke tension. (#" p. 59) =... Check the chain, rear sprocket, engine sprocket, and chain guide. (* p. 63) co. Check the chain tension. (* p. 62) s... Lubricate all moving parts (e. g. hand levers, chain, ..) and check for smooth operation, =. Change the hydraulic clutch fluid. (* p. 127) : Check the fluid level of the hydraulic clutch. (* p. 127) =... Change the front brake fluid. (* p. 68) . Check the front brake fluid level. (* p. 66) Check the free travel of the hand brake lever. ( p. 66) on Grease the steering head bearing. ( p. 25) . Check play of steering head bearing. (* p. 27) o-.. Change the spring of the exhaust control. >. Change the piston. on Change the connecting rod, conrod bearing and crank pin. _ Change the crankshaft bearing. >. Check the transmission and shift mechanism. om Change all engine bearings. . Change the gear oll. (* p. 131) OD >. Check the gear oil level. ( p. 131) _ Change the spark plug, >. ‘Change the spark plug connecter. 7 Check the cylinder and piston. _ Check the Intake membrane. >. Check the exhaust control for functioning and smooth operation. 7. Check the clutch. _ Check all hoses (e.g. fuel, cooling, bleeding, drainage) and sleeves for tearing, tightness and correct ° 7. routing. Check the antifreeze and coolant level. (* p. 129) =24 SERVICE SCHEDULE 147 Every 80 operating hours, Every 20 operating hours, Check the cables for damage and routing without sharp bends. Check the cables for damage, routing without sharp bends and corect adjustment Clean the air filter and ar filter box. (* p. 51) Change the glass fiber yarn filling of the main silencer. (* p. 50) Check the screws and nuts for tightness. Check/set the carburetor components. Check ile. Final inspection: check the vehicle for operating safely and take a test ride. Make the service entry in the KTM Dealer.net and in the Service and Warranty Booklet. © One-time interval '* Periodic interval