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OWNER'S MANUAL
2016
1290 Super Duke R
Art. no. 3213405en
DEAR KTM CUSTOMER
DEAR KTM CUSTOMER
Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports motorcycle that will give you enormous pleasure if you service and maintain it properly.
We hope you enjoy your new vehicle!
Enter the serial numbers of your vehicle below.
Dealer's stamp
1
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from illustrations and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2016 KTM Sportmotorcycle GmbH, Mattighofen Austria
All rights reserved
*3213405en*
3213405en
01/2016
DEAR KTM CUSTOMER
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
2
KTM Sportmotorcycle GmbH
5230 Mattighofen, Austria
This document is valid for the following models:
1290 Super Duke R US (F9975P9, F9975P2)
1290 Super Duke R Special Edition US (F9975P0)
TABLE OF CONTENTS
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
Symbols used ...................................................... 7
Formats used....................................................... 8
2 SAFETY ADVICE.............................................................. 9
Use definition - intended use ................................ 9
Safety advice....................................................... 9
Degrees of risk and symbols ................................ 10
Overview of labels (Super Duke R) ....................... 12
(Super Duke R Special Edition) ........................... 18
Reporting safety defects ..................................... 23
Noise emission warranty ..................................... 23
Operating noise warning ..................................... 24
Consumer rights................................................. 24
Tampering warning............................................. 24
Safe operation ................................................... 25
Protective clothing ............................................. 26
Work rules......................................................... 26
Environment...................................................... 26
Owner's Manual ................................................. 27
3 IMPORTANT NOTES...................................................... 28
Manufacturer and implied warranty...................... 28
Operating and auxiliary substances ...................... 28
Spare parts, accessories ..................................... 28
Service ............................................................. 29
Figures ............................................................. 29
Customer service................................................ 29
4 VIEW OF VEHICLE ........................................................ 30
View of vehicle, front left (example) ..................... 30
3
View of vehicle, rear right (example) .................... 32
5 SERIAL NUMBERS ....................................................... 34
Chassis number ................................................. 34
Type label ......................................................... 34
Key number....................................................... 35
Engine number .................................................. 36
Fork part number ............................................... 36
Shock absorber article number ............................ 37
Steering damper article number .......................... 37
6 CONTROLS................................................................... 38
Clutch lever....................................................... 38
Hand brake lever................................................ 39
Throttle grip ...................................................... 40
Switches on the left side of the handlebar ............ 40
Combination switch........................................ 40
Light switch .................................................. 41
Hazard warning flasher switch......................... 42
Menu switch.................................................. 42
Turn signal switch.......................................... 43
Horn button .................................................. 43
Switches on the right side of the handlebar .......... 44
Emergency OFF switch ................................... 44
Electric starter button .................................... 44
Ignition/steering lock.......................................... 45
Immobilizer ....................................................... 45
Opening the filler cap......................................... 46
Closing the filler cap .......................................... 48
Seat lock........................................................... 49
Baggage lugs ..................................................... 49
TABLE OF CONTENTS
Tool set............................................................. 50
Supporting strap ................................................ 50
Helmet lock....................................................... 51
Passenger footrests ............................................ 51
Shift lever ......................................................... 52
Foot brake lever ................................................. 53
Side stand......................................................... 53
7 COMBINATION INSTRUMENT ....................................... 54
Overview ........................................................... 54
activation and test ............................................. 54
Matrix display .................................................... 55
Segment display ................................................ 55
indicator lamps.................................................. 56
Message on the matrix display............................. 57
Shift warning light ............................................. 58
Service display .................................................. 59
Matrix display menu........................................... 59
"Favorites"..................................................... 59
"Trip 1"......................................................... 60
"Trip 2"......................................................... 60
"General Info" ................................................ 61
"Set Favorites" ............................................... 61
"Settings"...................................................... 62
"Warning"...................................................... 62
"Heating" (optional)........................................ 63
"MTC/ABS".................................................... 63
"Drive Mod" ................................................... 64
Menu overview............................................... 66
"Language".................................................... 67
4
"Distance" ..................................................... 68
"Temp" ......................................................... 68
"Pressure" ..................................................... 69
"Fuel Cons" ................................................... 69
"Clock/Date" .................................................. 70
"Shift Light" .................................................. 70
"Heat Grip".................................................... 71
"DRL" ........................................................... 71
8 ERGONOMICS .............................................................. 72
Handlebar position............................................. 72
Adjusting the handlebar position ...................... 72
Adjusting the basic position of the clutch lever ..... 73
Setting the step plate of the foot brake lever......... 77
Checking the basic position of the shift lever ........ 77
Adjusting the basic position of the shift lever .... 78
Setting the shift lever stub.................................. 79
9 PREPARING FOR USE................................................... 80
Advice on first use ............................................. 80
Running in the engine ........................................ 81
Loading the vehicle ............................................ 82
10 RIDING INSTRUCTIONS................................................ 84
Starting............................................................. 85
Starting off........................................................ 86
Shifting, riding .................................................. 86
TABLE OF CONTENTS
Applying the brakes............................................ 90
Stopping, parking............................................... 92
Transport .......................................................... 93
Refueling .......................................................... 94
11 SERVICE SCHEDULE .................................................... 96
Additional information........................................ 96
Required work ................................................... 96
Recommended work ........................................... 98
12 SUSPENSION SETTING................................................. 99
Fork/shock absorber ........................................... 99
Adjusting the compression damping of the fork..... 99
Adjusting the rebound damping of the fork ......... 100
Compression damping of the shock absorber....... 101
13 SERVICE WORK ON THE CHASSIS............................... 107
Lifting the motorcycle with the rear lifting gear ... 107
Removing the passenger seat ............................ 109
5
Mounting the passenger seat............................. 110
Removing the front rider's seat .......................... 110
Mounting the front rider's seat........................... 111
Mounting the helmet lock on the vehicle ............ 111
13.10 Removing the main silencer .......................... 112
13.11 Installing the main silencer ........................... 115
13.12 Checking the chain for dirt................................ 117
13.13 Cleaning the chain ........................................... 117
13.14 Checking the chain tension ............................... 119
13.15 Adjusting the chain tension............................... 120
14 BRAKE SYSTEM ......................................................... 128
Antilock braking system (ABS) .......................... 128
Checking the brake discs .................................. 130
Checking the front brake fluid level ................... 131
Adding front brake fluid ................................ 132
Checking the front brake linings ........................ 134
Checking the rear brake fluid level..................... 135
Adding rear brake fluid ................................. 136
Checking the brake linings of the rear brake ....... 138
15 WHEELS, TIRES ......................................................... 140
Removing the front wheel .............................. 140
Installing the front wheel .............................. 141
Removing the rear wheel ............................... 144
Installing the rear wheel ................................ 145
Checking the tire condition ............................... 147
TABLE OF CONTENTS
Checking the tire air pressure............................ 149
16 ELECTRICAL SYSTEM ................................................. 150
Daytime running light ( DRL )............................... 150
Removing the battery .................................... 150
Installing the battery ..................................... 152
Recharging the battery .................................. 155
Changing the main fuse.................................... 159
Changing the fuses in the fuse box .................... 162
Changing the headlight bulb ............................. 165
Changing the turn signal bulb ........................... 167
Checking the headlight setting .......................... 168
16.10 Adjusting the headlight range............................ 169
16.11 Activating/deactivating the ignition key .............. 170
17 COOLING SYSTEM ...................................................... 175
Correcting the coolant level in the compensating tank........................................... 176
18 ENGINE TUNING ........................................................ 178
"Drive Mod" ..................................................... 178
Motorcycle traction control ( MTC ) ...................... 178
19 SERVICE WORK ON THE ENGINE ................................ 180
Checking the engine oil level............................. 180
Adding engine oil............................................. 185
20 CLEANING, CARE ....................................................... 188
Cleaning motorcycle ......................................... 188
6
21 STORAGE................................................................... 192
Storage ........................................................... 192
Preparing for use after storage........................... 193
22 TROUBLESHOOTING .................................................. 194
23 TECHNICAL DATA....................................................... 196
Engine ............................................................ 196
Engine tightening torques ................................. 197
Capacities ....................................................... 200
Engine oil ................................................... 200
Coolant ....................................................... 201
Fuel ........................................................... 201
Chassis ........................................................... 201
Electrical system.............................................. 203
Tires ............................................................... 203
Fork................................................................ 204
Shock absorber ................................................ 205
Chassis tightening torques ................................ 206
24 SUBSTANCES ............................................................ 211
25 AUXILIARY SUBSTANCES ........................................... 214
26 STANDARDS .............................................................. 216
27 INDEX OF SPECIAL TERMS ......................................... 217
28 LIST OF ABBREVIATIONS............................................ 218
29 LIST OF SYMBOLS...................................................... 219
Red symbols.................................................... 219
Yellow and orange symbols................................ 219
Green and blue symbols.................................... 219
INDEX ............................................................................... 221
1 MEANS OF REPRESENTATION
1.1
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of your own safety, have these jobs performed by an authorized KTM workshop. There, your motorcycle will be optimally cared for by specially trained experts using the specialist tools required.
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
7
1 MEANS OF REPRESENTATION
1.2
Formats used
The typographical formats used in this document are explained below.
Specific name Identifies a proprietary name.
Name ®
Brand™
Underlined terms
Identifies a protected name.
Identifies a brand available on the open market.
Refer to technical details of the vehicle or indicate technical terms that are explained in the glossary.
8
2 SAFETY ADVICE
2.1
Use definition - intended use
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation and also for use on race courses, but not for offroad use.
Info
The motorcycle is only authorized for operation on public roads in the homologated version.
2.2
Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.
9
2 SAFETY ADVICE
10
2.3
Degrees of risk and symbols
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
11
2 SAFETY ADVICE
2.4
Overview of labels (Super Duke R)
12
L01488-10
4
5
3
3
6
1
2
3
2 SAFETY ADVICE
Type label for USA
Type label for Canada
Information on suspension setting
Information on chain tension
Technical Information
Information on preparations for use
Information on noise emissions
Information on emissions control
Type label for USA
C00937-01
13
2 SAFETY ADVICE
Type label for Canada
Information on suspension setting
C00936-01
L01470-01
14
2 SAFETY ADVICE
Information on chain tension
L01472-01
Technical Information
L01475-01
15
2 SAFETY ADVICE
Information on preparations for use
L01471-01
C00938-01
Information on noise emissions
16
2 SAFETY ADVICE
Information on emissions control
C00939-01
17
2 SAFETY ADVICE
2.5
Overview of labels (Super Duke R Special Edition)
18
E00152-10
4
5
3
3
6
1
2
3
2 SAFETY ADVICE
Type label for USA
Type label for Canada
Information on suspension setting
Information on chain tension
Technical Information
Information on preparations for use
Information on noise emissions
Information on emissions control
Type label for USA
C00937-01
19
2 SAFETY ADVICE
Type label for Canada
Information on suspension setting
C00936-01
L01470-01
20
2 SAFETY ADVICE
Information on chain tension
L01472-01
Technical Information
L01475-01
21
2 SAFETY ADVICE
Information on preparations for use
L01471-01
E00153-01
Information on noise emissions
22
2 SAFETY ADVICE
E00154-01
Information on emissions control
2.6
Reporting safety defects
If you believe that your vehicle has a defect which could cause an accident resulting in injury or death, you should immediately inform the
National Highway Traffic Safety Administration (NHTSA) in addition to notifying KTM North America, Inc.
If NHTSA receives multiple similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or KTM North America, Inc.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1 – 888 – 327 – 4236 or visit the website www.nhtsa.dot.gov, or write to: NHTSA Headquarters, 1200 New Jersey Avenue, SE, West Building, Washington, DC 20590. You can also obtain other information about motor vehicle safety from the Hotline.
2.7
Noise emission warranty
KTM Sportmotorcycle AG warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985 – 3553 www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
23
2 SAFETY ADVICE
Phone: (450) 441 – 4451 x 4250 www.ktmcanada.com
2.8
Operating noise warning
This product should be checked for necessary repair or replacement parts if the motorcycle noise has increased significantly through use.
Otherwise, the owner may become subject to penalties under the applicable ordinances.
2.9
Consumer rights
Warranty claims should be submitted to a KTM workshop. If you are not satisfied, please contact:
KTM North America, Inc., Customer Support, 1119 Milan Ave., Amherst, OH 44001, USA
Phone: (440) 985 – 3553 www.ktmusa.com
KTM Canada, Inc., Customer Support, 1375-1 Marie-Victorin, Saint-Bruno, QC J3V 6B7
Phone: (450) 441 – 4451 x 4250 www.ktmcanada.com
Different rights may apply, according to national or regional legislation.
2.10
Tampering warning
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 maintenance, 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:
24
2 SAFETY ADVICE
1 Removal or puncturing of the main silencer, 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 part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
25
2.11
Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them.
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. An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2 SAFETY ADVICE
2.12
Protective clothing
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements.
26
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.13
Work rules
Special tools are necessary for certain tasks. The tools are not contained in the vehicle but can be ordered under the number in parentheses. E.g.: bearing puller (15112017000)
During assembly, non-reusable parts (e.g. self-locking screws and nuts, seals and seal rings, O-rings, pins, lock washers) must be replaced by new parts.
In some instances, a thread locker (e.g.
Loctite ® ) is required. The manufacturer instructions for use must be followed.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.
After you complete the repair or service work, check the operating safety of the vehicle.
2.14
Environment
If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and respect the rights of others.
When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.
Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to advise you.
2 SAFETY ADVICE
2.15
Owner's Manual
It is important that you read this Owner's Manual carefully and completely before making your first trip. The Owner's Manual contains useful information and many tips on how to operate, handle, and maintain your motorcycle. Only then will you find out how to customize the vehicle ideally for your own use and how you can protect yourself from injury.
Keep the Owner's Manual in an accessible place to enable you to refer to it as needed.
If you would like to know more about the vehicle or have questions on the material you read, please contact an authorized KTM dealer.
The Owner's Manual is an important component of the vehicle and should be handed over to the new owner if the vehicle is sold.
27
3 IMPORTANT NOTES
28
3.1
Manufacturer and implied warranty
The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the
Service & Warranty Booklet and in KTM Dealer.net
, otherwise any warranty coverage will become void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered by the warranty.
Additional information on the manufacturer or implied warranty and the procedures involved can be found in the Service & Warranty Booklet.
3.2
Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3 IMPORTANT NOTES
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components.
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.
29
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4 VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
30
L01493-10
4 VIEW OF VEHICLE
6
7
4
5
1
2
3
8
9
10
11
Rider footrests
Shock absorber, spring preload setting
Cooling system compensating tank
Engine oil level viewer
31
4 VIEW OF VEHICLE
4.2
View of vehicle, rear right (example)
32
L01491-10
4 VIEW OF VEHICLE
5
6
4
5
1
2
3
7
8
9
10
11
Filler cap
Ignition/steering lock ( p. 45)
Fork compression adjustment
Electric starter button ( p. 44)
Fork rebound adjustment
Compression damping of the shock absorber ( p. 101)
Shock absorber rebound damping
33
5 SERIAL NUMBERS
5.1
Chassis number
The chassis number is stamped on the right side of the steering head.
The chassis number is also shown on the type label.
34
5.2
Type label
402324-10
The type label for the USA is located on the steering head.
402302-10
5 SERIAL NUMBERS
The type label for Canada is located on the frame on the left.
5.3
Key number
402293-10
402240-10
Key number Code number can be found on the KEYCODECARD .
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.
With the orange programming key, you can activate or deactivate the black ignition key. Keep the orange programming key in a safe location; it may only be used for learning and programming functions.
35
5 SERIAL NUMBERS
5.4
Engine number
The engine number is stamped on the right side of the engine.
36
5.5
Fork part number
402296-10
The fork part number is stamped on the inside of the axle clamp.
402295-10
5 SERIAL NUMBERS
5.6
Shock absorber article number
The shock absorber article number is stamped on the top of the shock absorber above the adjusting ring towards the engine side.
37
5.7
402298-10
Steering damper article number
Steering damper item number is embossed on the underside of the steering damper.
H01060-10
6 CONTROLS
6.1
Clutch lever
(Super Duke R)
Clutch lever is fitted on the handlebar on the left.
L01405-10
(Super Duke R Special Edition)
Clutch lever is fitted on the handlebar on the left.
The clutch is activated hydraulically and adjusts itself automatically.
E00132-10
38
6 CONTROLS
6.2
Hand brake lever
(Super Duke R)
The hand brake lever is fitted on the right side of the handlebar.
39
L01408-11
(Super Duke R Special Edition)
The hand brake lever is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
E00133-10
6 CONTROLS
6.3
Throttle grip
(Super Duke R)
The throttle grip is fitted on the right side of the handlebar.
L01408-10
(Super Duke R Special Edition)
The throttle grip is fitted on the right side of the handlebar.
6.4
6.4.1
E00133-11
Switches on the left side of the handlebar
Combination switch
The combination switch is fitted on the left side of the handlebar.
40
6 CONTROLS
6.4.2
Light switch
3
4
5
Overview of the left combination switch
1
2
Hazard warning flasher switch ( p. 42)
Turn signal switch ( p. 43) p. 43)
L01406-10
L01407-10
The light switch is fitted on the combination switch on the left.
Possible states
Low beam on – Light switch in position and tail light are switched on.
. In this position, the low beam
High beam on – Light switch in position beam and tail light are switched on.
. In this position, the high
Headlight flasher – Push the light switch into position .
41
6 CONTROLS
6.4.3
Hazard warning flasher switch
L01406-11
The hazard warning flasher switch is fitted on the combination switch on the left.
The hazard warning flasher is used to indicate emergency situations.
Info
The hazard warning flasher can be activated or deactivated while the ignition is switched on or up to 60 seconds after the ignition is switched off.
Only keep the hazard warning flasher activated as long as necessary as it depletes the battery.
Possible states
Hazard warning flasher on – All four turn signals and the green turn signal indicator lights in the combination instrument flash.
42
6.4.4
Menu switch
The menu switch is fitted in the middle of the left combination switch.
The menu buttons are used to control the matrix display on the combination instrument.
Button
Button
is the UP button.
is the DOWN button.
Button
Button
is the SET button.
is the BACK button.
L01406-12
6 CONTROLS
6.4.5
Turn signal switch
L01406-13
The turn signal switch is fitted on the combination switch on the left.
Possible states
Turn signal off – Press the turn signal switch.
Turn signal, left, on – Turn signal switch pressed to the left. The turn signal switch returns automatically to the central position after use.
Turn signal, right, on – Turn signal switch pressed to the right. The turn signal switch returns automatically to the central position after use.
To switch off the turn signal, press the turn signal switch towards the switch case.
43
6.4.6
Horn button
The horn button is fitted on the combination switch on the left.
Possible states
• Horn button in basic position.
• Horn button pressed – The horn is operated in this position.
L01406-14
6 CONTROLS
6.5
6.5.1
Switches on the right side of the handlebar
Emergency OFF switch
The emergency OFF switch is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine cannot be started. A message appears on the matrix display.
Emergency OFF switch on – This position is required for operation; the ignition circuit is closed.
44
6.5.2
Electric starter button
L01409-10
The electric starter button is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position.
• Electric starter button is pressed – In this position, the electric starter is actuated.
L01409-11
6 CONTROLS
6.6
Ignition/steering lock
L01410-10
The ignition/steering lock is located in front of the upper triple clamp.
Info
The ignition may only be switched on using a black ignition key.
With the orange programming key, you can activate or deactivate the black ignition key.
Possible states
Ignition off OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The black ignition key can be removed.
Ignition on ON – In this position, the ignition circuit is closed and the engine can be started.
Steering locked – In this position, the ignition circuit is interrupted and the steering locked. The black ignition key can be removed.
45
6.7
Immobilizer
401815-10
The electronic immobilizer secures the vehicle against unauthorized use.
The immobilizer is activated automatically and the engine electronics are locked when the ignition key is withdrawn.
The immobilizer indicator lamp can indicate errors by flashing.
If the optional alarm system is installed, the immobilizer indicator lamp the alarm system is switched on.
flashes when
Info
The ignition key contains electronic components. Never attach multiple ignition keys to a single key ring; this may cause mutual interference.
6 CONTROLS
46
A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle.
The black ignition keys are activated when delivered.
Another two spare ignition keys (key number on the KEYCODECARD ) can be ordered from an authorized KTM workshop; they need to be activated for use.
6.8
Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
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.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
6 CONTROLS
– Lift cover of the filler cap and insert ignition key in the fuel tank lock.
47
L01418-10
Note
Danger of damage Ignition key breakage.
– To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced.
– Turn ignition key
– Fold open filler cap clockwise.
.
L01419-10
6 CONTROLS
6.9
Closing the filler cap
– Fold down filler cap .
– Turn ignition key clockwise.
L01420-10
L01421-10
– Press down the filler cap and turn back ignition key until the fuel tank lock locks.
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your health.
– After closing the filler cap, ensure that it is locked properly. Change clothing that has been contaminated with fuel. Immediately clean contaminated areas on the skin with soap and water.
– Remove ignition key and close cover .
48
6 CONTROLS
6.10
Seat lock
The seat lock is located on the left side of the vehicle.
It can be unlocked using the ignition key.
L01423-11
6.11
Baggage lugs
L01431-10
The baggage lugs are located on the bottom of the passenger seat.
Info
When the passenger seat is mounted, the lugs are accessible if they are turned outward.
No more than one small piece of luggage with the specified weight may be attached to the turned-out baggage lugs.
Maximum luggage weight 5 kg (11 lb.)
49
6 CONTROLS
6.12
Tool set
The storage compartment under the passenger seat contains tool set .
50
6.13
Supporting strap
500308-10
The supporting strap is attached to the passenger seat.
The supporting strap is provided for the passenger to hold on to.
L01448-10
6 CONTROLS
6.14
Helmet lock
Warning
Danger of accidents Impairment of vehicle handling and vehicle operation if a helmet or helmet lock is attached to the vehicle.
– Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out.
The steel cable from being stolen.
in the tool set can be used to lock a helmet to the vehicle to prevent it
6.15
Passenger footrests
L01449-10
The passenger footrests can be folded up and down.
Possible states
• Passenger footrests folded up – For operation without a passenger.
• Passenger footrests folded down – For operation with a passenger.
51
L01411-10
6 CONTROLS
6.16
Shift lever
The shift lever is fitted on the left side of the engine.
402299-10
The gear positions can be seen in the figure.
The idle position is between the first and second gears.
402299-11
52
6 CONTROLS
6.17
Foot brake lever
Foot brake lever is located in front of the right footrest.
The rear brake is engaged with the foot brake lever.
53
6.18
Side stand
402301-10
402029-10
The side stand is located on the left side of the vehicle.
The side stand is used for parking the motorcycle.
Info
The side stand must be folded up during motorcycle use.
The side stand is coupled with the safety starting system; see the instructions in the
"Stopping, parking" chapter.
Possible states
• Side stand folded out – The vehicle can be supported on the side stand. The safety starting system is active.
• Side stand folded in – This position is mandatory when riding the motorcycle. The safety starting system is inactive.
7 COMBINATION INSTRUMENT
7.1
Overview
3
4
5
1
2
Tachometer
Segment display
7.2
401800-10
activation and test
401801-01
Activation
The combination instrument is activated when the ignition is switched on.
Info
The brightness of the displays is controlled by a brightness sensor in the combination instrument.
Test
The segment display, the indicator lamps, and the tachometer are briefly activated for a function test.
The welcome text and information on the next service ( p. 59) appear on the matrix dis-
play.
Info
If the battery was removed, the time and date must be set.
54
7 COMBINATION INSTRUMENT
7.3
Matrix display
55
The matrix display is controlled using the menu switch ( p. 42).
After the ignition is switched on, the display shows when the next service ( p. 59) is due.
If the General warning lamp
lights up among the indicator lamps ( p. 56), the corre-
sponding message appears in the matrix display. The Set button is used to confirm receipt of the information and the message is cleared.
Messages appear 10 s
7.4
401821-01
Segment display
L02903-10
6
7
8
3
4
1
2
5
Fuel level
Time
Unit for the speedometer
Gear display
Speed
"Drive Mod"
Coolant temperature
Ice warning
7 COMBINATION INSTRUMENT
7.5
indicator lamps
401813-01
56
Possible states
The high beam indicator lamp lights up blue – The high beam is switched on.
The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system.
The oil pressure warning lamp lights up red – Engine oil pressure is too low.
The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown on the matrix display.
The left turn signal lamp flashes green simultaneously with the turn signal
– The left turn signal is switched on.
The idle indicator lamp lights up green – The transmission is shifted to idle.
The right turn signal lamp flashes green simultaneously with the turn signal
– The right turn signal is switched on.
The engine warning lamp lights up/flashes yellow – The engine control unit has detected a fault.
The ABS lamp lights up/flashes yellow – ABS is not active. The ABS lamp also lights up when an error is detected.
The TC lamp lights up/flashes yellow – Traction control is not enabled or is currently intervening. The TC lamp also lights up when an error is detected.
7 COMBINATION INSTRUMENT
7.6
Message on the matrix display
Possible states
Engine malfunction – The engine control unit has detected a fault. Visit an authorized KTM workshop.
General message – General message on operating safety. Visit an authorized KTM workshop.
ABS warning – ABS is not available. Visit an authorized KTM workshop.
57
401850-01
Traction control – Traction control is not available. Visit an authorized KTM workshop.
Engine oil pressure – Engine oil pressure is too low. Switch off the engine immediately. Contact an authorized KTM workshop.
Engine oil level – The engine oil level is too low. Check the engine oil level and correct it.
Lighting system – Lights up if an element of the lighting system has failed.
Change the faulty light, or visit an authorized KTM workshop.
Cooling water temperature – The cooling water temperature is too high.
Switch off the engine. Contact an authorized KTM workshop.
Fuel reserve – The fuel supply is dwindling. Refuel at the next opportunity.
Icy road symbol – The roads may be icy. Adjust your speed to the road conditions.
Battery voltage – The battery voltage is too low. Recharge the battery with a suitable battery charger.
7 COMBINATION INSTRUMENT
Service – A service is due. Contact an authorized KTM workshop.
Emergency OFF switch – The emergency OFF switch is off.
7.7
The messages are displayed in the "Warning" menu.
Shift warning light
401855-01
The shift warning light flashes or lights up when the transmission should be shifted.
In the "Shift Light" menu, the engine speed for the shift warning light can be set. The shift warning light flashes at "RMP1" and lights up at "RPM2" .
Engine oil temperature
"RPM1" shift warning light
"RPM2" shift warning light
> 35 °C (> 95 °F)
Flashes
Lights up
Engine oil temperature
The shift warning light always lights up at
≤ 35 °C ( ≤ 95 °F)
6,500 rpm
58
7 COMBINATION INSTRUMENT
7.8
Service display
After the ignition is switched on, the service display appears briefly.
The service intervals depend on the distance traveled or the elapsed time. The event that occurs first applies.
The exact service intervals can be found in the service schedule.
59
7.9
7.9.1
401821-01
Matrix display menu
"Favorites"
– Press the UP or DOWN button until the "Favorites" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button to select the menu item and activate it with the SET button.
– Pressing the BACK button twice always opens the "Favorites" menu.
You can directly open five menus in the "Favorites" menu.
The "Favorites " menu can be configured in the "Set Favorites" menu.
L01440-10
7 COMBINATION INSTRUMENT
7.9.2
"Trip 1"
401826-01
– Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display.
"Trip 1" shows the distance since the last reset, such as between two refueling stops.
"Trip 1" runs continuously and counts the distance up to 9999 .
"Ø Speed 1" indicates the average speed based on "Trip 1" and "Trip Time 1" .
"Ø Cons 1" indicates the average fuel consumption based on "Trip 1" and "Trip Time 1" .
"Trip Time 1" indicates the riding time based on "Trip 1" and starts running as soon as a speed signal comes in.
"Fuel Range" indicates the possible range with the fuel reserve.
Press and hold the button for
3 – 5 seconds.
All entries in the "Trip 1" menu are cleared.
60
7.9.3
"Trip 2"
401825-01
– Press the UP or DOWN button until the "Trip 2" menu appears on the matrix display.
"Trip 2" shows the distance since the last reset, such as between two refueling stops.
"Trip 2" runs continuously and counts the distance up to 9999 .
"Ø Speed 2" indicates the average speed based on "Trip 2" and "Trip Time 2" .
"Ø Cons 2" indicates the average fuel consumption based on "Trip 2" and "Trip Time 2" .
"Trip Time 2" indicates the riding time based on "Trip 2" and starts running as soon as a speed signal comes in.
"Fuel Range" indicates the possible range with the fuel reserve.
Press and hold the button for
3 – 5 seconds.
All entries in the "Trip 2" menu are cleared.
7 COMBINATION INSTRUMENT
7.9.4
"General Info"
– Press the UP oder DOWN button until the "General Info" menu appears on the matrix display.
"Air Temp" indicates the ambient air temperature.
"Date" indicates the date.
"ODO" indicates the total distance covered.
"Battery" indicates the battery voltage.
"Oil Temp" indicates the engine oil temperature.
61
401824-01
7.9.5
"Set Favorites"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Set Favorites" menu appears on the matrix display. Pressing the SET button opens the menu.
– Press the UP or DOWN button to select the menu. Press the SET button to set the menu for quick selection.
The "Favorites " menu can be configured in the "Set Favorites" menu.
L01441-10
7 COMBINATION INSTRUMENT
7.9.6
"Settings"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
Settings for units or various values are made in the "Settings" menu. Several functions can be enabled or disabled.
62
402431-10
7.9.7
"Warning"
Condition
• Message or warning
– Press the UP or DOWN button until the "Warning" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Use the UP or DOWN button to navigate through the warnings.
In the "Warning" menu, warnings that occurred are displayed and stored until they are no longer active.
L01435-10
7 COMBINATION INSTRUMENT
7.9.8
"Heating" (optional)
63
– Press UP or DOWN button until the "Heating" menu appears on the matrix display. Pressing the SET button opens the menu.
– Use the SET button to select a heating level or to switch off the heated grips.
7.9.9
"MTC/ABS"
402434-02
L01436-10
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "MTC/ABS" menu appears on the matrix display.
In the "MTC/ABS" menu, "MTC" and "ABS" can be switched off.
In "ABS Mode" , a choice can be made between "Road" and "SUP MOT" .
Info
After the ignition is switched on, traction control and ABS are enabled again.
In the "ROAD" ABS mode, the ABS controls both wheels.
In the "SUP MOT" ABS mode, the ABS only controls the front wheel. There is no ABS intervention on the rear wheel. The ABS lamp flashes slowly to remind you that the
"SUP MOT" ABS mode is enabled.
In the "SUP MOT" ABS mode, the rear wheel may block and there is a risk of crashing.
7 COMBINATION INSTRUMENT
7.9.10
"Drive Mod"
L01437-10
64
– Press the UP or DOWN button until the "Drive Mod" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Use the UP or DOWN button to navigate through the menu. The SET button can be used to select engine and traction control settings that are coordinated with each other.
SPORT – homologated performance with very direct response; the traction control allows greater slip on the rear wheel
STREET – homologated performance with balanced response; the traction control allows normal slip on the rear wheel
RAIN – reduced homologated performance for better ridability; the traction control allows normal slip on the rear wheel
65
7 COMBINATION INSTRUMENT
7.9.11
Menu overview
66
L01438-10
7 COMBINATION INSTRUMENT
KTM start screen
Menu buttons
"Favorites"
"Trip 1"
"Trip 2"
"General Info"
"Set Favorites"
"Settings"
"Warning" (only active if there are messages)
"Heat Grip" (optional)
"MTC/ABS"
"Drive Mod"
7.9.12
"Language"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the SET button again to select the language.
The menu languages are US English, UK English, German, Italian, French, and Spanish.
67
402431-10
7 COMBINATION INSTRUMENT
7.9.13
"Distance"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Distance" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select kilometers "km" or miles "mi" for the distance.
68
402431-11
7.9.14
"Temp"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Temp" is highlighted in black on the matrix display.
Pressing the SET button again sets the unit of measure.
Select "°C" or "°F" for the temperature indicator.
402431-12
7 COMBINATION INSTRUMENT
7.9.15
"Pressure"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Pressure" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select "bar" or "psi" for the tire pressure display.
69
402431-13
7.9.16
"Fuel Cons"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Fuel Cons" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select one of the available consumption displays.
402431-14
7 COMBINATION INSTRUMENT
7.9.17
"Clock/Date"
70
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Clock/Date" is highlighted in black on the matrix display. Pressing the SET button again opens the menu.
– Use the UP or DOWN button to navigate through the menu. Use the SET button to set the time and date.
If the battery was disconnected, the time and date must be set in the matrix display.
401990-01
7.9.18
"Shift Light"
L01433-10
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Shift Light" is highlighted in black on the matrix display. Pressing the SET button again opens the menu.
– Press the UP or DOWN button to select the function. Use the SET button to set the engine speed for the shift warning light.
When the engine speed reaches "RPM 1" , the shift warning light flashes.
When the engine speed reaches "RPM 2" , the shift warning light lights up continuously.
Switch the "Shift Light" function on or off.
7 COMBINATION INSTRUMENT
7.9.19
"Heat Grip"
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "Heat Grip" is highlighted in black on the matrix display. Pressing the SET button again switches the heated grips menu on or off.
Switch the heated grips menu on and off.
71
L01439-15
7.9.20
"DRL"
L01439-16
Condition
• The vehicle is stationary.
– Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
– Press the UP or DOWN button until "DRL" is highlighted in black on the matrix display.
Pressing the SET button again switches the daytime running light on or off.
Switch the daytime running light on or off.
Info
Note the legal regulations regarding the daytime running light.
8 ERGONOMICS
8.1
Handlebar position
72
On the upper triple clamp there are two holes at a distance of apart.
Hole distance 15 mm (0.59 in)
The handlebar can be mounted in two different positions. In this way, the handlebar can be mounted in the most comfortable position for the rider.
Info
KTM recommends the front handlebar position when using the vehicle on a race track.
402000-11
8.2
Adjusting the handlebar position
Warning
Danger of accidents Handlebar breakage.
– If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handlebar.
L01476-10
– Remove screws screws
. Take off handlebar clamp . Position the handlebar so that
are accessible.
Info
Protect the components against damage by covering them.
Do not kink the cables and lines.
– Remove screws . Take off instrument support .
– Move the instrument support into the desired position screws .
or . Mount and tighten
8 ERGONOMICS
8.3
73
Guideline
Screw, instrument support M10 40 Nm
(29.5 lbf ft)
– Position the handlebar.
Info
Make sure the cables and wiring are positioned correctly.
Loctite ® 243™
– Position the handlebar clamp. Mount and evenly tighten screws .
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Adjusting the basic position of the clutch lever
(Super Duke R)
– Push the clutch lever lever forward.
– Adjust the basic position of the clutch lever to your hand size by turning adjusting screw .
L01414-10
Info
Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
8 ERGONOMICS
E00145-10
74
(Super Duke R Special Edition)
– To adjust the length of the clutch lever, loosen screw lever.
, and position the clutch
– Tighten screw
– Check handle
.
.
» If the handle is not engaged in a horizontal position:
– Loosen screw .
– Position handle
– Tighten screw
.
.
Guideline
Screw on handle M4 6 Nm
(4.4 lbf ft)
– Push the clutch lever lever forward.
– Adjust the basic position of the clutch lever to your hand size by turning adjusting screw .
Info
Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
8 ERGONOMICS
8.4
75
Adjusting the basic position of the hand brake lever
(Super Duke R)
– Push the hand brake lever forward.
– Adjust the basic position of the hand brake lever to your hand size by turning adjusting screw .
L01415-10
Info
Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
E00146-10
(Super Duke R Special Edition)
– To adjust the length of the hand brake lever, loosen screw hand brake lever.
, and position the
– Tighten screw
– Check handle
.
.
» If the handle is not engaged in a horizontal position:
– Loosen screw .
– Position handle
– Tighten screw
.
.
Guideline
Screw on handle M4 6 Nm
(4.4 lbf ft)
8
8.5
ERGONOMICS
76
– Push the hand brake lever forward.
– Adjust the basic position of the hand brake lever to your hand size by turning adjusting wheel .
Info
Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the handlebar.
The range of adjustment is limited.
Only turn the adjusting screw by hand, and do not use force.
Do not make any adjustments while riding.
Adjusting the basic position of the foot brake lever
– Loosen nut .
– Press the foot brake lever down to be able to turn push rod more easily.
– Turn the push rod until the foot brake lever is in the desired position.
Info
The range of adjustment is limited.
The screw must be screwed into the ball joint by at least five turns.
– Lock nut .
L01443-10
8 ERGONOMICS
8.6
Setting the step plate of the foot brake lever
– Remove screw together with the foot plate of the foot brake lever.
– To adjust the length of the foot brake lever, position the step plate of the foot brake lever using screw in a drill hole .
Guideline
Standard Middle hole
– Tighten screw .
Guideline
Screw, step plate for foot brake lever
M6 10 Nm
(7.4 lbf ft)
Loctite ® 243™
77
L01461-10
8.7
Checking the basic position of the shift lever
Info
When driving, the shift lever must not touch the rider's boot when in the basic position.
When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.
8
8.8
ERGONOMICS
– Sit on the vehicle in the riding position and determine distance edge of your boot and the shift lever.
between the upper
Distance between shift lever and upper edge of boot
10… 20 mm (0.39… 0.79 in)
» If the distance does not meet specifications:
– Adjust the basic position of the shift lever.
78
400692-10
Adjusting the basic position of the shift lever
– Loosen nut , holding the threaded rod .
L01417-10
Info
Nut has a left-handed thread.
– Loosen nut , holding the threaded rod
– Turn threaded rod
.
to adjust the shift lever.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle components during the shift procedure.
– Tighten nut , holding the threaded rod .
Guideline
Nut, shift rod M8 12 Nm (8.9 lbf ft)
8 ERGONOMICS
8.9
79
– Tighten nut , holding the threaded rod .
Guideline
Nut, shift rod M8LH 12 Nm (8.9 lbf ft)
Setting the shift lever stub
– Remove screw along with the shift lever stub.
– Position the shift lever stub with the screw in one of the drilled holes the desired lever length.
depending on
Guideline
Standard Middle hole
– Tighten the screw.
Guideline
Screw, shift lever stub M6 10 Nm
(7.4 lbf ft)
Loctite ® 243™
L01460-10
9 PREPARING FOR USE
9.1
Advice on first use
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
– Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally impaired.
Warning
Risk of injury Missing or poor protective clothing presents an increased safety risk.
– Wear protective clothing (helmet, boots, gloves, pants and jacket with protectors) every time you ride the vehicle. Always wear protective clothing that is in good condition and meets the legal requirements.
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Non-approved or non-recommended tires and wheels impact the handling characteristic.
– Only use tires/wheels approved by KTM with the corresponding speed index.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.
80
9 PREPARING FOR USE
81
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
– Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
– Before your first trip, read the entire Owner's Manual carefully.
– Get to know the controls.
– Adjust the motorcycle to your requirements, as described in the "Ergonomics" chapter.
– Get used to handling the motorcycle on a suitable piece of land before making a longer trip. Try also to ride as slowly as possible and in a standing position to get a better feeling for the motorcycle.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
– Run the engine in.
9.2
Running in the engine
– During the running-in phase, do not exceed the specified engine speed.
Guideline
Maximum engine speed
During the first: 1,000 km (620 mi)
After the first: 1,000 km (620 mi)
6,500 rpm
10,250 rpm
9 PREPARING FOR USE
Tip
During the running-in phase, set the shift warning light to the specified engine speed.
– Avoid fully opening the throttle!
9.3
Loading the vehicle
Warning
Danger of accidents Unstable handling characteristics.
– Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
– Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidents Unstable handling characteristics at high speed.
– Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage.
Maximum speed with luggage 130 km/h (80.8 mph)
Warning
Danger of accidents Destruction of luggage carrier system.
– If the motorcycle is fitted with luggage cases, note the manufacturer's specifications concerning the maximum payload.
Warning
Danger of accidents Poor visibility for other road users due to slipped baggage.
– If the tail light is covered, you are less visible to traffic behind you, especially when it is dark. Check that your baggage is fixed properly at regular intervals.
82
9 PREPARING FOR USE
Warning
Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload.
– Adapt your speed according to your payload.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
– Check the way your baggage is fixed regularly.
Warning
Danger of burns A hot exhaust system can burn baggage.
– Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.
– If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.
– Do not exceed the maximum permissible weight and the maximum permissible axle loads.
Guideline
Maximum permissible overall weight
Maximum permissible front axle load
Maximum permissible rear axle load
406 kg (895 lb.)
160 kg (353 lb.)
260 kg (573 lb.)
83
10 RIDING INSTRUCTIONS
10.1
Checks and maintenance measures when preparing for use
Info
Before every trip, check the condition of the vehicle and ensure that it is roadworthy.
The vehicle must be in perfect technical condition when it is being operated.
–
Check the engine oil level. ( p. 180)
–
Check the front brake fluid level. ( p. 131)
–
Check the rear brake fluid level. ( p. 135)
–
Check the front brake linings. ( p. 134)
–
Check the brake linings of the rear brake. ( p. 138)
– Check that the brake system is functioning properly.
–
Check the coolant level in the compensating tank. ( p. 175)
–
Check the chain for dirt. ( p. 117)
–
Check the chain tension. ( p. 119)
–
Check the tire condition. ( p. 147)
–
Check the tire air pressure. ( p. 149)
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check that the electrical equipment is functioning properly.
– Check that luggage is properly secured.
– Check the setting of the rear mirror.
– Check the fuel level.
84
10 RIDING INSTRUCTIONS
10.2
Starting
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
– Always warm up the engine at low engine speeds.
85
– Press the emergency OFF switch to the position ON .
– Switch on the ignition by turning the black ignition key to the position ON .
After you switch on the ignition, you can hear the fuel pump working for about two seconds. The function check of the combination instrument is run at the same time.
The ABS warning lamp lights up and goes back out after starting off.
– Shift the transmission to idle .
The green idling speed indicator lamp lights up.
L01442-10
10 RIDING INSTRUCTIONS
– Press the electric starter button .
L01409-01
86
Info
Do not press the electric starter button until the combination instrument function check is finished.
When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the engine cannot start.
Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again.
This motorcycle is equipped with a safety starting system. You can only start the engine if the transmission is in neutral or if the clutch lever is pulled when a gear is engaged. If the side stand is folded out and you shift into gear, the engine stops.
– Remove the motorcycle from the side stand.
10.3
Starting off
– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throttle gently.
10.4
Shifting, riding
Warning
Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.
– Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
– Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
10 RIDING INSTRUCTIONS
Warning
Danger of accidents Malfunctions caused by incorrect ignition key position.
– Do not change the ignition key position during a journey.
Warning
Danger of accidents Distraction from traffic activity by adjustments to the vehicle.
– Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury Falling off of the passenger.
– The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles. The feet must be positioned on the passenger footrests. Note the regulations governing the minimum age of passengers.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
– Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on.
Warning
Danger of accidents Reduced road grip with cold tires.
– On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road grip is ensured.
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.
87
10 RIDING INSTRUCTIONS
Warning
Danger of accidents Unstable handling characteristics.
– Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
– Check the way your baggage is fixed regularly.
Warning
Danger of accidents Lack of roadworthiness.
– After a fall, check the vehicle as usual before preparing for use.
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
– Never operate the vehicle without an air filter as dust and dirt will enter the engine and lead to increased wear.
88
Note
Engine failure Overheating damages the engine.
– If the coolant temperature warning is displayed, stop immediately and take care not to endanger yourself or other traffic participants in the process.
– Allow the engine and cooling system to cool down.
– Check and, if necessary, correct the coolant level on the cooling system while it is in a cooled state.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine, and contact an authorized KTM workshop.
10 RIDING INSTRUCTIONS
– Shift into a higher gear when conditions allow (incline, road situation, etc.).
– Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever, and open the throttle.
89
402299-11
Info
You can see the positions of the 6 forward gears in the figure. The idle position is between the first and second gears. First gear is used for starting off or for steep inclines.
– 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.
– Accelerate only up to a speed suitable for the road surface and weather conditions. Particularly in bends, do not shift, and accelerate very carefully.
– Brake if necessary and close the throttle at the same time in order to shift down.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and open the throttle or shift again.
– If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the electric starter button. You do not have to shift into neutral.
– Switch off the engine if running at idle or standing for a long time.
– If the oil pressure warning lamp lights up during a trip, stop immediately and switch off the engine. Contact an authorized KTM workshop.
– If the engine warning lamp lights up during a trip, please contact an authorized KTM workshop as soon as possible.
Info
From the flash rhythm you can deduce a two-digit number, the so-called blink code. The blink code tells you which component is affected by a malfunction.
– If the general warning lamp lights up during a trip, the matrix display shows a message for 10 seconds.
10 RIDING INSTRUCTIONS
90
Info
Very important messages are stored in the "Warning" menu.
– If the icy road symbol appears in the combination instrument, the roads may be icy.
Adjust your speed to the road conditions.
10.5
Applying the brakes
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.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
– Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Failure of brake system.
– If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Longer stopping distance due to higher overall weight.
– Take the longer stopping distance into account when carrying a passenger and baggage.
Warning
Danger of accidents Delayed brake action on salted roads.
– There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the deposits from the discs by carefully applying the brakes.
10 RIDING INSTRUCTIONS
Warning
Danger of accidents Greater stopping distance due to ABS.
– Braking should be appropriate to the driving situation and the road conditions.
Warning
Danger of accidents Very forceful braking can cause the wheels to block.
– ABS must be switched on to be effective.
Warning
Danger of accidents Vehicle rollover
– It is not always possible to prevent vehicle rollover in extreme riding situations (e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your driving ability.
91
– When braking, release the throttle and apply the front and rear brakes at the same time.
Info
When the ABS is enabled, you can achieve maximum braking power even on low grip surfaces such as sandy, wet, or slippery terrain without locking of the wheels.
Warning
Danger of accidents Locking of the wheels due to braking action of the engine.
– Pull the clutch during emergency braking, full brake application and when braking on a slippery surface.
Warning
Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface.
– Braking should be completed before you enter into a bend.
– Always finish braking before you go into a bend. Change down to a lower gear appropriate to your road speed.
10 RIDING INSTRUCTIONS
– Use the braking effect of the engine on long downhill stretches. Change down one or two gears, but do not over-rev the engine. In this way, you have to brake far less and the brakes do not overheat.
92
10.6
Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle unattended while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the vehicle, lock the steering and remove the ignition key.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
– Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these components to cool down before starting work on them.
Note
Material damage The vehicle may be damaged by incorrect procedure when parking.
Significant damage may be caused if the vehicle rolls away or falls over.
The components for parking the vehicle are designed only for the weight of the vehicle.
– Park the vehicle on a firm and level surface.
– Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.
– Apply the brakes on the motorcycle.
10 RIDING INSTRUCTIONS
– Shift the transmission to idle .
– Switch off the ignition by turning the black ignition key to the position OFF .
Info
If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power continues to flow to most power consumers. This discharges the battery. You should therefore always switch off the engine with the ignition key – the emergency OFF switch is intended for emergencies only.
93
– Park the motorcycle on a firm surface.
– Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.
– Lock the steering by turning the handlebar to the left, pressing the black ignition key down in the position OFF and turning it to the position LOCK . To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the black ignition key.
10.7
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
– Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being run. Always let the vehicle cool first.
10 RIDING INSTRUCTIONS
– Switch off the engine.
– Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over.
94
401475-01
10.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
– Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
– The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
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 is contaminated with fuel.
Note
Material damage Premature clogging of the fuel filter.
– In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system. (Your authorized KTM workshop will be glad to help.)
10 RIDING INSTRUCTIONS
– Only refuel with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
– Do not allow fuel to get into the ground water, the ground, or the sewage system.
– Switch off the engine.
–
– Fill the fuel tank with fuel up to the lower edge of the filler neck.
Total fuel tank capacity, approx.
18 l (4.8 US gal)
–
Close the filler cap. ( p. 48)
Super unleaded (ROZ 95/RON 95/PON
95
L01422-10
11 SERVICE SCHEDULE
11.1
Additional information
Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately.
96
11.2
Required work
Read out the fault memory using the KTM diagnostics tool.
Check the fuel pressure.
Check that the electrical equipment is functioning properly.
Change the engine oil and oil filter and clean the oil screens.
Check the brake discs. ( p. 130)
Check the front brake linings. (
Check the rear brake fluid level. (
Check the brake linings of the rear brake. (
Check the tire air pressure. (
Check the shock absorber and fork for leaks. Perform a fork service and shock absorber service as needed and depending on how the vehicle will be used.
Clean the dust boots of the fork legs.
Check the chain, rear sprocket, motor sprocket, and chain guide. (
Check the chain tension. ( p. 119)
Every two years
Every year
Every 30,000 km (18,600 mi)
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
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11 SERVICE SCHEDULE
Check the brake lines for damage and leakage.
Check the front brake fluid level. ( p. 131)
Measure the wheel bearing play and grease the wheel bearings.
Check that the rear wheel nut (right side) is tightened to the specified torque.
Check the coolant level in the compensating tank. ( p. 175)
Check that the radiator fan is functioning properly.
Change the air filter, clean the air filter box.
Check the cables for damage and routing without sharp bends. (fuel tank removed)
Change the spark plugs (air filter removed).
Check the valve clearance (air filter and spark plugs removed).
Change the SAS membrane.
Change the front brake fluid.
Change the rear brake fluid.
Check the steering head bearing play.
Check the headlight setting. ( p. 168)
Final check: Check the vehicle for roadworthiness and take a test ride.
Read out the error memory after the test ride using the KTM diagnostics tool.
Check the CO adjustment with the KTM diagnostics tool.
Reset the service interval display.
Make the service entry in the KTM Dealer.net
and in the Service and Warranty Booklet.
97
Every two years
Every year
Every 30,000 km (18,600 mi)
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
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11 SERVICE SCHEDULE
○ One-time interval
● Periodic interval
11.3
Recommended work
Check/clean the oil nozzle for clutch lubrication.
Check the swingarm bearing.
Check the wheel bearings.
routing.
Every four years
Every two years
Every year
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
○
Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth operation.
Empty the drainage hoses.
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect
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Check/correct the fluid level of the hydraulic clutch. ( p. 125)
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Change the hydraulic clutch fluid.
Check the screws and nuts for tightness.
Change the coolant.
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● Periodic interval
98
12 SUSPENSION SETTING
12.1
Fork/shock absorber
99
The fork and the shock absorber offer many options of adapting the suspension to the riding style and the payload.
Info
The recommendations for the suspension setting are shown in Table is located on the underside of the front rider's seat.
. The table
These adjustments are guidelines and should always be the basis for a suspension setting.
If the guidelines are not adhered to, the riding characteristics could deteriorate, particularly at high speeds.
500347-10
12.2
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
– Turn the white adjusting screw all the way clockwise.
Info
Adjusting screw is located at the upper end of the left fork leg.
The compression damping is located in the left fork leg COMP (white adjusting screw). The rebound damping is located in the right fork leg REB (red adjusting screw).
– Turn counterclockwise by the number of clicks corresponding to the fork type.
500310-10
12 SUSPENSION SETTING
Guideline
Compression damping
Comfort
Standard
Sport
Full payload
17 clicks
12 clicks
7 clicks
7 clicks
100
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.3
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
– Turn the red adjusting screw all the way clockwise.
Info
Adjusting screw is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg REB (red adjusting screw).
The compression damping is located in the left fork leg COMP (white adjusting screw).
– Turn counterclockwise by the number of clicks corresponding to the fork type.
500311-10
12 SUSPENSION SETTING
Guideline
Rebound damping
Comfort
Standard
Sport
Full payload
17 clicks
12 clicks
7 clicks
7 clicks
101
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.4
Compression damping of the shock absorber
500313-01
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect when riding over an asphalt edge: the rear wheel suspension compresses quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses slowly.
These two ranges can be adjusted separately, although the transition between high-speed and low-speed is gradual. Thus, changes in the high-speed range affect the compression damping in the low-speed range and vice versa.
12 SUSPENSION SETTING
102
12.5
Adjusting the low-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the low-speed setting can be seen in slow to normal compression of the shock absorber.
500312-10
– Turn adjusting screw clockwise with a screwdriver up to the last perceptible click.
Info
Do not loosen fitting !
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Compression damping, low-speed
Comfort
Standard
Sport
Full payload
18 clicks
15 clicks
10 clicks
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12 SUSPENSION SETTING
103
12.6
Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
Info
The effect of the high-speed setting can be seen in fast compression of the shock absorber.
500314-10
– Turn adjusting screw all the way clockwise with a socket wrench.
Info
Do not loosen fitting !
– Turn counterclockwise by the number of turns corresponding to the shock absorber type.
Guideline
Compression damping, high-speed
Comfort
Standard
Sport
Full payload
1.5 turns
1.5 turns
1 turn
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12 SUSPENSION SETTING
104
12.7
Adjusting the rebound damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
– The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will be glad to help.)
500315-10
– Turn adjusting screw clockwise up to the last perceptible click.
– Turn counterclockwise by the number of clicks corresponding to the shock absorber type.
Guideline
Rebound damping
Comfort
Standard
Sport
Full payload
15 clicks
12 clicks
9 clicks
9 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.8
Adjusting the spring preload of the shock absorber
Warning
Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.
– Following modifications, ride slowly at first to get the feel of the new ride behavior.
12 SUSPENSION SETTING
Info
The spring preload defines the initial situation of the spring process on the shock absorber.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any luggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.
105
Preparatory work
Condition
– The swingarm is unloaded.
Main work
– Loosen screw .
– Turn adjusting ring counterclockwise with the hook wrench from the tool set until the spring is no longer under tension.
Hook wrench, shock absorber (61329083000)
L01456-10
12 SUSPENSION SETTING
– Tighten the spring by turning adjusting ring to the specified measurement .
Guideline
Spring preload
Comfort
Standard
Sport
Full payload
5 mm (0.2 in)
5 mm (0.2 in)
6 mm (0.24 in)
7 mm (0.28 in)
106
Info
Turn clockwise to increase the spring preload; turn counterclockwise to reduce the spring preload.
– Tighten screw .
Guideline
Screw, shock absorber adjusting ring M5 5 Nm (3.7 lbf ft)
402002-10
13 SERVICE WORK ON THE CHASSIS
13.1
Lifting the motorcycle with the rear lifting gear
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Place the adapter into the rear lifting gear.
Lifting gear, rear (61329955000)
– Position the motorcycle upright, place the lifting gear in the axle, and raise the motorcycle.
107
L01445-01
13.2
Removing the rear of motorcycle from the lifting gear
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
13 SERVICE WORK ON THE CHASSIS
– Secure the motorcycle against falling over.
– Remove the rear wheel stand and lean the vehicle on side stand .
108
402029-10
13.3
Lifting the motorcycle with the front lifting gear
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
Preparatory work
–
Lift the motorcycle with the rear lifting gear. ( p. 107)
Main work
– Move the handlebar to the straight-ahead position. Align the front lifting gear with the fork legs.
Front wheel stand (61029055300)
Info
Always raise the motorcycle at the rear first.
– Raise the motorcycle at the front.
L01446-01
13 SERVICE WORK ON THE CHASSIS
13.4
Taking the motorcycle from the front lifting gear
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
– Secure the motorcycle against falling over.
– Remove the front lifting gear.
L01478-01
13.5
Removing the passenger seat
– Insert the ignition key in seat lock and turn it clockwise.
– Lift the passenger seat at the front and pull it out of the holder toward the front.
– Remove the passenger seat.
– Remove the ignition key.
L01428-10
109
13 SERVICE WORK ON THE CHASSIS
13.6
Mounting the passenger seat
110
– Attach the recesses of the passenger seat in the guides pushing it back.
– Position locking pin front.
and lower at the front while in the lock housing and push down the passenger seat at the
The locking pin engages with an audible click.
– Check that the passenger seat is correctly mounted.
401922-10
13.7
Removing the front rider's seat
Preparatory work
–
Remove the passenger seat. ( p. 109)
Main work
– Raise the rear of the front rider's seat.
– Detach the front of the front rider's seat and remove it.
B02310-10
13 SERVICE WORK ON THE CHASSIS
13.8
Mounting the front rider's seat
Main work
– Attach recesses on the front rider's seat to the fuel tank and push the front rider's seat forward while lowering it.
Catch is located in the recess.
– Check that the front rider's seat is correctly mounted.
111
401921-10
Finishing work
–
Mount the passenger seat. ( p. 110)
13.9
Mounting the helmet lock on the vehicle
Warning
Danger of accidents Impairment of vehicle handling and vehicle operation if a helmet or helmet lock is attached to the vehicle.
– Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out.
13 SERVICE WORK ON THE CHASSIS
–
Remove the passenger seat. ( p. 109)
– Position steel cable from the tool set with the loop around catch .
Steel cable (60012015000)
– Pass the steel cable through the helmet opening.
– Position the other loop of the steel cable around catch .
– Carefully position the helmet on the back of the vehicle.
–
Mount the passenger seat. ( p. 110)
L01450-10
13.10
Removing the main silencer
(Super Duke R)
– Remove screw .
– Take off the exhaust clamp.
112
202958-10
13 SERVICE WORK ON THE CHASSIS
– Remove screw with washer.
– Take off the main silencer.
202959-11
– Remove seal ring .
202960-11
(Super Duke R Special Edition)
– Remove screw .
– Take off the exhaust clamp.
E00147-10
113
13 SERVICE WORK ON THE CHASSIS
– Remove screw with washer.
– Take off the main silencer.
E00148-10
– Remove seal ring .
E00149-11
114
13 SERVICE WORK ON THE CHASSIS
13.11
Installing the main silencer
(Super Duke R)
– Mount seal ring .
202960-10
– Position the main silencer.
– Mount screw with the washer but do not tighten yet.
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
202959-11
115
13 SERVICE WORK ON THE CHASSIS
– Position the exhaust clamp.
– Mount and tighten screw .
Guideline
Screw, exhaust clamp on main silencer M6
– Tighten screw .
Guideline
Remaining screws, chassis M8
202958-11
(Super Duke R Special Edition)
– Mount seal ring .
116
8 Nm (5.9 lbf ft)
25 Nm
(18.4 lbf ft)
E00149-10
– Position the main silencer.
– Mount screw with the washer but do not tighten yet.
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
E00148-10
13 SERVICE WORK ON THE CHASSIS
– Position the exhaust clamp.
– Mount and tighten screw .
Guideline
Screw, exhaust clamp on main silencer M6
– Tighten screw .
Guideline
Remaining screws, chassis M8
E00147-11
13.12
Checking the chain for dirt
– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
–
400678-01
13.13
Cleaning the chain
Warning
Danger of accidents Oil or grease on the tires reduces their grip.
– Remove oil and grease with a suitable cleaning material.
117
8 Nm (5.9 lbf ft)
25 Nm
(18.4 lbf ft)
13 SERVICE WORK ON THE CHASSIS
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
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
The service life of the chain depends largely on its maintenance.
– Clean the chain regularly.
– Rinse off loose dirt with a soft jet of water.
– Remove old grease remains with chain cleaner.
– After drying, apply chain spray.
Chain lube for road use ( p. 214)
400725-01
118
13 SERVICE WORK ON THE CHASSIS
119
13.14
Checking the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary.
L01425-10
– Place the motorcycle onto the side stand.
– Shift the transmission to idle .
– In the area of markings and on the chain sliding guard, push the chain sliding guard upward and determine the chain tension.
Info
The lower chain section must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
The upper edge of the chain is located between markings and .
» If the chain tension does not meet the specification:
–
Adjust the chain tension. ( p. 120)
13 SERVICE WORK ON THE CHASSIS
– Check the locking caps for damage and tightness.
» If the locking caps are damaged or loose:
– Replace locking caps.
Link fork locking cap (61304041100)
120
H00380-11
13.15
Adjusting the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it if necessary.
Preparatory work
–
Check the chain tension. ( p. 119)
–
Lift the motorcycle with the rear lifting gear. ( p. 107)
13 SERVICE WORK ON THE CHASSIS
Main work
– Loosen screw .
– Set the chain tension by turning the hub housing.
Hook wrench (61329085000)
Handle for ring wrench (60012060000)
L01452-10
121
Info
Turn clockwise to increase the chain tension; turn counterclockwise to reduce the chain tension.
–
Check the chain tension. ( p. 119)
The chain tension is equal to the specified value.
Info
Chain wear is not always even, so you should check the setting at different chain positions.
– Tighten screw .
Guideline
Screw, eccentric M16
Finishing work
–
Remove the rear of the motorcycle from the lifting gear. ( p. 107)
70 Nm
(51.6 lbf ft)
13 SERVICE WORK ON THE CHASSIS
122
13.16
Checking the chain, rear sprocket, motor sprocket, and chain guide
– Check the rear sprocket and motor sprocket for wear.
» If the rear sprocket or engine sprocket is worn:
– Change the drivetrain kit.
Info
The motor sprocket, rear sprocket, and chain should always be replaced together.
100132-10
13 SERVICE WORK ON THE CHASSIS
– Shift the transmission to idle .
– Pull the lower chain section with specified weight .
Guideline
Weight, chain wear measurement 15 kg (33 lb.)
– Measure the distance of 18 chain links in the lower chain section.
123
Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.
402004-10
Maximum distance chain section
at the longest 272 mm (10.71 in)
» If distance is greater than the specified measurement:
– Change the drivetrain kit.
Info
When the chain is replaced, the rear sprocket and engine sprocket should also be changed.
New chains wear out faster on an old, worn rear sprocket or engine sprocket.
For safety reasons, the chain has no chain joint.
13 SERVICE WORK ON THE CHASSIS
124
– Check the chain sliding guard for wear at the recess.
» When rivet of the chain is no longer visible at the bottom edge of the chain sliding guard:
of the recess
– Change the chain sliding guard.
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the screws on the chain sliding guard.
Guideline
Screw, chain sliding guard M5 5 Nm (3.7 lbf ft)
L01424-10
13 SERVICE WORK ON THE CHASSIS
– Check the chain sliding piece for wear.
» If the lower edge of the chain pins is in line with or below the chain sliding piece:
– Change the chain sliding piece.
– Check that the chain sliding piece is firmly seated.
» If the chain sliding piece is loose:
– Tighten the screw on the chain sliding piece.
Guideline
Remaining screws, chassis M8 25 Nm
(18.4 lbf ft)
125
L01489-01
13.17
Checking/correcting the fluid level of the hydraulic clutch
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
13 SERVICE WORK ON THE CHASSIS
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
The fluid level rises with increasing wear of the clutch facing discs.
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
C00940-01
(Super Duke R)
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
– Check the fluid level.
The fluid level must be between the MIN and MAX markings.
» If the fluid level does not meet specifications:
– Remove the screw cap with the membrane.
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 211)
– Refit screw cap with membrane.
Info
Clean up overflowed or spilled brake fluid immediately with water.
(Super Duke R Special Edition)
– Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
126
13 SERVICE WORK ON THE CHASSIS
– Check the fluid level.
The fluid level must be between the MIN and MAX markings.
» If the fluid level does not meet specifications:
– Remove the screw cap with the membrane.
– Correct the fluid level of the hydraulic clutch.
Brake fluid DOT 4 / DOT 5.1 ( p. 211)
– Refit screw cap with membrane.
V00181-01
Info
Clean up overflowed or spilled brake fluid immediately with water.
127
14 BRAKE SYSTEM
128
14.1
Antilock braking system (ABS)
The ABS unit return pump, is installed on the right vehicle side below the fuel tank. A wheel speed sensor
, which consists of a hydraulic unit, brake electronics control unit, and is located at both the front and the rear wheel.
Warning
Danger of accidents Changes to the vehicle impair the function of the ABS.
– Only allow the rear wheel to spin with the front brake applied if the ABS is switched off (burn out).
– Do not make any changes to the suspension travel.
– Only use spare parts on the brake system which have been approved and recommended by KTM.
– Only use tires/wheels approved by KTM with the corresponding speed index.
– Maintain the specified tire air pressure.
– Service work and repairs must be performed professionally. (Your authorized
KTM workshop will be glad to help.)
401999-10
ABS is a safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces.
Warning
Danger of accidents Vehicle rollover
– It is not always possible to prevent vehicle rollover in extreme riding situations
(e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your driving ability.
ABS has two operating modes: the "ROAD" and "SUP MOT" ABS modes.
In the "ROAD" ABS mode, the ABS controls both wheels.
14 BRAKE SYSTEM
129
In the "SUP MOT" ABS mode, the ABS only controls the front wheel. There is no ABS intervention on the rear wheel. The ABS lamp
"SUP MOT" ABS mode is enabled.
flashes slowly to remind you that the
Info
In the "SUP MOT" ABS mode, the rear wheel may block and there is a risk of crashing.
The ABS operates with two independent brake circuits (front and rear brakes). When the brake electronics control unit detects a locking tendency in a wheel, ABS begins regulating the brake pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.
The ABS lamp must light up after the ignition is switched on and go out after starting off. If it does not go out after starting off or if it is lit while riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled and the wheels may lock during braking. The brake system itself stays functional; only ABS control is not available.
The ABS lamp may also light up if the rotating speeds of the front and rear wheels differ greatly under extreme riding conditions, for example when making "wheelies" or if the rear wheel spins. This causes the ABS to switch off.
To reactivate the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reactivated when the vehicle is switched on again. The ABS lamp goes out when you start off.
In the "MTC/ABS" menu, ABS can be switched off manually.
Info
After the ignition is switched back on, ABS is reactivated.
14 BRAKE SYSTEM
14.2
Checking the brake discs
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
– Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
100135-10
130
– Check the thickness of the front and rear brake discs at multiple points on each brake disc to ensure it is at least thickness .
Info
Wear will reduce the thickness of the brake disc at the contact surface the brake linings.
of
Brake discs - wear limit (Super Duke R)
Front 4.5 mm (0.177 in)
Brake discs - wear limit (Super Duke R Special Edition) front
Brake discs - wear limit
4.2 mm (0.165 in) rear 4.5 mm (0.177 in)
» If the brake disc thickness is less than the specified value.
– Change the brake disc.
– Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc exhibits damage, cracking, or deformation:
– Change the brake disc.
14 BRAKE SYSTEM
14.3
Checking the front brake fluid level
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
131
(Super Duke R)
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the brake fluid reservoir .
» If the brake fluid has dropped below marking MIN
– Add front brake fluid.
:
L01427-10
14 BRAKE SYSTEM
(Super Duke R Special Edition)
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in the brake fluid reservoir .
» If the brake fluid has dropped below marking MIN
– Add front brake fluid.
:
132
E00140-10
14.4
Adding front brake fluid
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
14 BRAKE SYSTEM
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
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
L01430-10
Preparatory work
–
Check the front brake linings. ( p. 134)
Main work
(Super Duke R)
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
– Remove cover
.
with membrane .
– Add brake fluid to the MAX marking .
Brake fluid DOT 4 / DOT 5.1 ( p. 211)
– Position cover with membrane
– Mount and tighten screws .
.
Info
Clean up overflowed or spilled brake fluid immediately with water.
133
14 BRAKE SYSTEM
V00179-10
(Super Duke R Special Edition)
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
– Remove cover
.
with membrane .
– Add brake fluid to the MAX marking .
Brake fluid DOT 4 / DOT 5.1 ( p. 211)
– Position cover with membrane .
– Mount and tighten screws .
Info
Clean up overflowed or spilled brake fluid immediately with water.
134
14.5
Checking the front brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly.
14 BRAKE SYSTEM
– Check all brake linings on both brake calipers to ensure they have minimum thickness .
Minimum thickness ≥ 1 mm ( ≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings.
– Check all brake linings on both brake calipers for damage and cracking.
» If there is damage or cracking:
– Change the front brake linings.
500317-10
14.6
Checking the rear brake fluid level
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
135
14 BRAKE SYSTEM
(Super Duke R)
– Stand the vehicle upright.
– Check the brake fluid level in the brake fluid reservoir .
» If the fluid level reaches the MIN marking
– Add rear brake fluid.
:
500318-10
(Super Duke R Special Edition)
– Stand the vehicle upright.
– Check the brake fluid level in the brake fluid reservoir .
» If the fluid level reaches the MIN marking
– Add rear brake fluid.
:
E00143-10
14.7
Adding rear brake fluid
Warning
Danger of accidents Failure of the brake system.
– If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
136
14 BRAKE SYSTEM
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
– Avoid contact with skin and eyes, and keep out of the reach of children.
– Wear suitable protective clothing and goggles.
– If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
– Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be glad to help.)
137
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
Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.
Only use clean brake fluid from a sealed container.
Preparatory work
–
Check the brake linings of the rear brake. ( p. 138)
14 BRAKE SYSTEM
500319-10
V00180-10
Main work
(Super Duke R)
– Stand the vehicle upright.
– Remove screw cap with membrane
– Add brake fluid to the MAX marking .
.
Brake fluid DOT 4 / DOT 5.1 ( p. 211)
– Mount and tighten screw cap with membrane .
Info
Clean up overflowed or spilled brake fluid immediately with water.
(Super Duke R Special Edition)
– Stand the vehicle upright.
– Remove screw cap with membrane
– Add brake fluid to the MAX marking .
.
Brake fluid DOT 4 / DOT 5.1 ( p. 211)
– Mount and tighten screw cap with membrane .
Info
Clean up overflowed or spilled brake fluid immediately with water.
14.8
Checking the brake linings of the rear brake
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
– Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
138
14 BRAKE SYSTEM
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
– If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly reduced and the brake discs are destroyed. Check the brake linings regularly.
– Check the brake linings for minimum thickness .
Minimum thickness ≥ 1 mm ( ≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings.
– Check the brake linings for damage and cracking.
» If there is damage or cracking:
– Change the rear brake linings.
500320-10
139
15 WHEELS, TIRES
15.1
Removing the front wheel
140
Preparatory work
–
Lift the motorcycle with the rear lifting gear. ( p. 107)
–
Lift the motorcycle with the front lifting gear. ( p. 108)
Main work
– Remove screws from both brake calipers.
– Press back the brake linings with a light lateral tilting of the brake calipers on the brake disc. Pull the brake calipers carefully back from the brake discs and hang them to one side.
Info
Do not pull the hand brake lever when the brake caliper has been removed.
309487-10
309488-10
– Loosen screws and .
– Unscrew screw about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking efficiency due to damaged brake discs.
– Always lay down the wheel in such a way that the brake discs are not damaged.
– Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the fork.
15 WHEELS, TIRES
– Remove spacers .
309489-10
15.2
Installing the front wheel
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the front wheel bearing.
– Clean and grease the shaft seal rings and mating surfaces of the spacers.
309490-10
141
15 WHEELS, TIRES
– Insert the wide spacer on the left in the direction of travel.
Info
The arrow indicates the direction of travel of the front wheel.
– Insert the narrow spacer on the right in the direction of travel.
309491-10
309492-10
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
– Clean screw and wheel spindle .
– Lift the front wheel into the fork, position it, and insert the wheel spindle.
– Mount and tighten screw .
Guideline
Bolt, front axle M25x1.5
45 Nm
(33.2 lbf ft)
Thread greased
142
15 WHEELS, TIRES
309487-11
143
– Position the brake calipers and check that the brake linings are seated correctly.
– Mount screws on both brake calipers but do not tighten yet.
– Operate the hand brake lever repeatedly until the brake linings are in contact with the brake disc and there is a pressure point. Fix the hand brake lever in the activated position.
The brake calipers straighten.
– Tighten screws on both brake calipers.
Guideline
Screw, front brake caliper M10 45 Nm
(33.2 lbf ft)
Loctite ® 243™
– Remove the fixation of the hand brake lever.
–
Take the motorcycle from the front lifting gear. ( p. 109)
–
Remove the rear of the motorcycle from the lifting gear. ( p. 107)
– Operate the front brake and compress the fork a few times firmly.
The fork legs straighten.
– Tighten screws .
Guideline
Screw, axle clamp M8 15 Nm
(11.1 lbf ft)
309493-10
15 WHEELS, TIRES
15.3
Removing the rear wheel
Preparatory work
–
Lift the motorcycle with the rear lifting gear. ( p. 107)
– Remove the main silencer.
Main work
– Remove the inside locking wire
– Remove the outside locking wire
.
.
L01463-10
– Have an assistant operate the rear brake.
– Release nut and remove with washer and taper ring .
144
L01464-10
15 WHEELS, TIRES
– Take off the rear wheel.
203022-10
15.4
Installing the rear wheel
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
– Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents No braking effect when operating the rear brake.
– After installing the rear wheel, always operate the foot brake until the pressure point is reached.
145
15 WHEELS, TIRES
Main work
– Check the rear wheel bearing for damage and wear.
» If the rear wheel bearing is damaged or worn:
– Change the rear wheel bearing.
– Clean and grease the threads of the wheel axle and axle nut.
– Slide the rear wheel onto the axle.
Driving pins engage in drilled holes of the rim.
146
203023-11
– Mount taper ring , washer , and nut
– Have an assistant operate the rear brake.
.
– Tighten nut .
Guideline
Nut, rear axle M50x1.5
250 Nm
(184.4 lbf ft)
Lock the locking wire with locking varnish
203021-11
15 WHEELS, TIRES
– Mount the outside locking wire
– Mount the inside locking wire
.
.
The pins of the locking wires engage in the drilled holes of the wheel axle.
147
L01463-11
Finishing work
–
Remove the rear of the motorcycle from the lifting gear. ( p. 107)
– Install the main silencer.
15.5
Checking the tire condition
Warning
Danger of accidents Uncontrollable vehicle handling in the event of a flat tire.
– In the interest of safety, replace damaged or worn tires immediately. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of crashing Poor vehicle handling due to different tire tread patterns on front and rear wheels.
– The front and rear wheels must be fitted with tires with similar tread patterns to prevent loss of control over the vehicle.
Warning
Danger of accidents Non-approved or non-recommended tires and wheels impact the handling characteristic.
– Only use tires/wheels approved by KTM with the corresponding speed index.
15 WHEELS, TIRES
Warning
Danger of accidents Reduced road grip with new tires.
– New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved until the tires have been run in.
148
Info
Tire type, tire condition, and tire air pressure influence the braking and handling characteristics of the vehicle.
Worn tires are particularly unfavorable on wet surfaces.
400602-10
– Check the front and rear tires for cuts, run-in objects, and other damage.
» If the tires have cuts, run-in objects or other damage:
– Change the tires.
– Check the depth of the tread.
Info
Adhere to the legally required minimum tread depth.
Minimum tread depth ≥ 2 mm ( ≥ 0.08 in)
» If the tread depth is less than the minimum tread depth:
– Change the tires.
– Check the tire age.
15 WHEELS, TIRES
149
Info
The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the DOT number. The first two digits indicate the week of manufacture and the last two digits the year of manufacture.
KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.
» If the tire is more than 5 years old:
– Change the tires.
15.6
Checking the tire air pressure
Info
Low tire air pressure leads to abnormal wear and overheating of the tire.
Correct tire air pressure ensures optimal riding comfort and maximum tire service life.
400695-01
– Remove the dust cap.
– Check the tire air pressure when the tires are cold.
Tire air pressure, solo/with passenger/full payload
Front: with cold tires 2.5 bar (36 psi)
Rear: with cold tires 2.9 bar (42 psi)
» If the tire pressure does not meet specifications:
– Correct the tire pressure.
– Mount the dust cap.
16 ELECTRICAL SYSTEM
16.1
Daytime running light (DRL)
150
The daytime running light/parking light is integrated in the main headlight.
The daytime running light can be switched on when visibility conditions are good. Activate the daytime running light in the combination instrument. Control is provided by the brightness sensor in the combination instrument. When visibility conditions are good, the low beam is switched off and the daytime running light is switched on. It is four times brighter than the parking light. When the daytime running light is switched off, it serves as a parking light.
Info
Note the legal regulations regarding the daytime running light.
C00941-01
16.2
Removing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
16 ELECTRICAL SYSTEM
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the passenger seat. ( p. 109)
–
Remove the front rider's seat. ( p. 110)
Main work
– Remove screw .
– Lift cover at the rear and pull toward the rear.
– Fold up the cover.
151
L01482-10
– Disconnect negative cable
– Remove positive terminal cover of the battery.
and disconnect the positive cable from the battery.
– Take the battery out of the battery compartment.
L01483-10
16 ELECTRICAL SYSTEM
16.3
Installing the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety equipment may be damaged.
– Never operate the vehicle with a discharged battery or without a battery.
152
Main work
– Fold up cover
– Place battery
.
in the battery compartment.
L01484-10
16 ELECTRICAL SYSTEM
– Position the positive cable and mount and tighten the screw.
Guideline
Screw, battery terminal M6
L01483-11
– Mount positive terminal cover
– Position negative cable
.
and mount and tighten the screw.
Guideline
Screw, battery terminal M6
4.5 Nm
(3.32 lbf ft)
4.5 Nm
(3.32 lbf ft)
153
16 ELECTRICAL SYSTEM
– Position cover .
Screw heads engage in recesses
– Mount and tighten screw .
.
154
L01486-10
Finishing work
–
Mount the front rider's seat. ( p. 111)
–
Mount the passenger seat. ( p. 110)
– Set the time and date.
16 ELECTRICAL SYSTEM
155
16.4
Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
– Keep batteries out of the reach of children.
– Wear suitable protective clothing and goggles.
– Avoid contact with battery acid and battery gases.
– Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
– In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15 minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
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.
16 ELECTRICAL SYSTEM
156
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage may damage electronic components. Charge the battery according to the instructions on the battery housing.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the passenger seat. ( p. 109)
–
Remove the front rider's seat. ( p. 110)
Main work
– Remove screw .
– Lift cover at the rear and pull toward the rear.
– Fold up the cover.
L01482-10
16 ELECTRICAL SYSTEM
157
– Disconnect negative cable tronics.
– Remove positive terminal cover of the battery to avoid damage to the motorcycle's elec-
.
L01483-12
602678-01
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.
Info
Charge the battery with a maximum of 10% of the capacity specified on the battery housing.
– Switch off and disconnect the battery charger from the battery after charging.
Guideline
The charging current, charging voltage, and charging time must not be exceeded.
Charge the battery regularly when the motorcycle is not in use
3 months
16 ELECTRICAL SYSTEM
– Mount positive terminal cover
– Position negative cable
.
and mount and tighten the screw.
Guideline
Screw, battery terminal M6 4.5 Nm
(3.32 lbf ft)
158
L01483-12
– Position cover .
Screw heads engage in recesses
– Mount and tighten screw .
.
L01486-11
16 ELECTRICAL SYSTEM
Finishing work
–
Mount the front rider's seat. ( p. 111)
–
Mount the passenger seat. ( p. 110)
– Set the time and date.
16.5
Changing the main fuse
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never bypass or repair fuses.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the passenger seat. ( p. 109)
–
Remove the front rider's seat. ( p. 110)
Main work
– Remove screw .
– Lift cover at the rear and pull toward the rear.
– Fold up the cover.
L01482-10
159
16 ELECTRICAL SYSTEM
– Remove protection caps .
500327-11
C00935-10
– Remove the faulty main fuse .
Info
A defective fuse is indicated by a burned-out fuse wire .
A spare fuse is located in the starter relay.
The main fuse protects all power consumers of the vehicle.
– Install a new main fuse.
– Check that the electrical equipment is functioning properly.
– Mount the protection caps.
Tip
Insert a new spare fuse into the starter relay to have it available when needed.
160
16 ELECTRICAL SYSTEM
– Position cover .
Screw heads engage in recesses
– Mount and tighten screw .
.
161
L01486-11
Finishing work
–
Mount the front rider's seat. ( p. 111)
–
Mount the passenger seat. ( p. 110)
– Set the time and date.
16 ELECTRICAL SYSTEM
16.6
Changing the fuses in the fuse box
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never bypass or repair fuses.
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the passenger seat. ( p. 109)
–
Remove the front rider's seat. ( p. 110)
Main work
– Remove screw .
– Lift cover at the rear and pull toward the rear.
– Fold up the cover.
L01482-10
162
16 ELECTRICAL SYSTEM
– Open fuse box cover .
500329-11
M01426-10
– Check the fuses.
Info
A defective fuse is indicated by a burned-out fuse wire .
– Remove the defective fuse.
Guideline
Fuse res - 10 A - spare fuses
Fuse 1 - 10 A - power supply for control units and components
Fuse 2 - 10 A - permanent positive for auxiliary equipment (ACC1)
Fuse 3 - 15 A - ABS hydraulic unit
Fuse 4 - 25 A - ABS return pump
Fuse 5 - not used
Fuse res - 15 A - spare fuse
Fuse res - 25 A - spare fuse
– Use spare fuses with the correct rating only.
163
16 ELECTRICAL SYSTEM
Tip
Insert a spare fuse so that it is available if needed.
– Check that the power consumer is functioning properly.
– Close the fuse box cover.
– Position cover .
Screw heads engage in recesses
– Mount and tighten screw .
.
164
L01486-11
16 ELECTRICAL SYSTEM
Finishing work
–
Mount the front rider's seat. ( p. 111)
–
Mount the passenger seat. ( p. 110)
165
16.7
Changing the headlight bulb
Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
– Remove screws .
– Fold the headlight mask forward.
500331-10
16 ELECTRICAL SYSTEM
– Detach connector
– Take off rubber cap
.
.
500335-10
500336-10
– Detach retaining clamp
– Remove bulb .
.
– Position the new bulb in the headlight housing.
Low beam/high beam (H4/socket U37R) ( p. 203)
Info
Insert the headlight bulb so that the catches latch into the recesses.
– Attach retaining clamp
– Mount rubber cap .
.
– Plug in connector .
500335-10
166
16 ELECTRICAL SYSTEM
– Fold the headlight mask up.
– Mount and tighten screws .
Guideline
Remaining screws, chassis
167
M5 5 Nm (3.7 lbf ft)
500331-10
16.8
Changing the turn signal bulb
Note
Damage to reflector Reduced brightness.
– Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before mounting.
L01485-10
– Remove the screw on the front of the turn signal housing.
– Carefully take off diffuser .
– Push bulb of the socket.
lightly into the socket, turn approx. 30° counterclockwise, and pull it out
Info
Do not touch the reflector with your fingers and keep it free from grease.
– Lightly push the new lamp into the socket and turn all the way clockwise.
Turn signal (RY10W / socket BAU15s) ( p. 203)
16 ELECTRICAL SYSTEM
– Check that the turn signal is functioning properly.
– Position the diffuser.
Info
Insert catch into recess .
– Insert the screw and first turn counterclockwise until it engages in the thread with a small jerk. Tighten the screw lightly.
168
16.9
Checking the headlight setting
– Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark at the height of the center of the low beam headlight.
– Make another mark at a distance under the first mark.
Guideline
Distance 5 cm (2 in)
400726-10
– Position the vehicle perpendicular to the wall at a distance on the low beam.
from the wall and switch
Guideline
Distance 5 m (16 ft)
– The rider, with luggage and passenger if applicable, now mounts the motorcycle.
– Check the headlight setting.
The light-dark boundary must lie exactly on the lower mark when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if applicable.
» If the boundary between light and dark does not meet specifications:
–
Adjust the headlight range. ( p. 169)
16 ELECTRICAL SYSTEM
169
16.10
Adjusting the headlight range
Preparatory work
–
Check the headlight setting. ( p. 168)
Main work
– Using the cross-head screwdriver headlight.
from the tool set, adjust the headlight range of the
Cross-head screwdriver (53012024100)
L01451-10
Info
Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.
If you have a payload, you may have to correct the headlight range.
– Set the headlight to marking .
Guideline
The light-dark boundary must lie exactly on the lower mark applicable.
when the motorcycle is ready to operate with the rider mounted along with any luggage and a passenger if
400726-11
16 ELECTRICAL SYSTEM
16.11
Activating/deactivating the ignition key
Info
The orange programming key must only be used for activating and deactivating!
If a black ignition key is lost or needs to be replaced, the individual black ignition keys need to be enabled or disabled using the orange programming key. This prevents the vehicle from being operated with the lost black ignition key.
You can activate or deactivate up to four black ignition keys. Only the black ignition keys programmed during an activation procedure are valid. All black ignition keys not programmed during the activation procedure are invalid, but can be reprogrammed in a further activation procedure.
170
Loss of a black ignition key (additional black ignition keys are available):
The following procedure deactivates all activated black ignition keys that are not included in the procedure.
– Press the emergency OFF switch to the position ON .
401114-10
L01453-01
– Insert the orange programming key in the ignition lock.
– Switch on the ignition by turning the orange programming key to the position ON .
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Pull out the orange programming key.
– Insert the black ignition key in the ignition lock.
– Switch on the ignition by turning the black ignition key to the position ON .
Immobilizer indicator lamp lights up.
16 ELECTRICAL SYSTEM
171
– Switch off the ignition by turning the black ignition key to the position OFF .
– Remove the black ignition key.
– Insert the orange programming key in the ignition lock.
– Switch on the ignition by turning the orange programming key to the position ON .
The immobilizer indicator lamp flashes according to the number of functional black ignition keys including the orange programming key. In this case, it flashes twice.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Pull out the orange programming key.
The lost black ignition key is deactivated.
The existing black ignition key is reactivated.
Loss of all black ignition keys (no black ignition keys are available):
This procedure is important to prevent misuse of the lost black ignition key.
– Press the emergency OFF switch to the position ON .
401114-11
16 ELECTRICAL SYSTEM
L01453-01
172
– Insert the orange programming key in the ignition lock.
– Switch on the ignition by turning the orange programming key to the position ON .
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Switch on the ignition by turning the orange programming key to the position ON .
The immobilizer indicator lamp flashes according to the number of functional black ignition keys including the orange programming key. In this case, it flashes once since all black ignition keys are deactivated.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Pull out the orange programming key.
All black ignition keys are deactivated.
– Order a new black ignition key according to the key number on the KEYCODECARD and activate it.
To activate up to three black ignition keys:
– Press the emergency OFF switch to the position ON .
– Insert the orange programming key in the ignition lock.
– Switch on the ignition by turning the orange programming key to the position ON .
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Pull out the orange programming key.
– Insert the black ignition key in the ignition lock.
– Switch on the ignition by turning the black ignition key to the position ON .
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the black ignition key to the position OFF .
– Remove the black ignition key.
– If two other black ignition keys are to be activated, repeat the last steps with the respective ignition key.
16 ELECTRICAL SYSTEM
173
– If the last black ignition key was activated, insert the orange programming key into the ignition lock.
– Switch on the ignition by turning the orange programming key to the position ON .
The immobilizer indicator lamp flashes according to the number of functional black ignition keys including the orange programming key.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Pull out the orange programming key.
Info
Activation of the ignition key is finished.
To activate four black ignition keys:
– Press the emergency OFF switch to the position ON .
– Insert the orange programming key in the ignition lock.
– Switch on the ignition by turning the orange programming key to the position ON .
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the orange programming key to the position OFF .
– Pull out the orange programming key.
– Insert the black ignition key in the ignition lock.
– Switch on the ignition by turning the black ignition key to the position ON .
Immobilizer indicator lamp lights up.
– Switch off the ignition by turning the black ignition key to the position OFF .
– Remove the black ignition key.
– If three other black ignition keys are to be activated, repeat the last steps with the respective ignition key.
16 ELECTRICAL SYSTEM
Info
After the fourth black ignition key has been activated, programming is finished.
174
17 COOLING SYSTEM
175
17.1
Checking the coolant level in the compensating tank
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Coolant must not come into contact with the skin, eyes, or clothing. 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 is contaminated with coolant. Keep coolant out of reach of children.
L01454-10
Condition
The engine is cold.
The radiator is completely full.
– Park the motorcycle on a horizontal surface.
– Check the coolant level in the compensating tank .
The coolant level must be between MIN and MAX .
» If there is no coolant in the compensating tank:
– Check the cooling system for leaks.
Info
Do not start up the motorcycle!
– Add coolant/bleed the cooling system.
» If the coolant in the compensating tank is not at the required level, but the tank is not empty:
17 COOLING SYSTEM
176
–
Correct the coolant level in the compensating tank. ( p. 176)
17.2
Correcting the coolant level in the compensating tank
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
– Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Coolant must not come into contact with the skin, eyes, or clothing. 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 is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
The radiator is completely full.
Preparatory work
–
Check the coolant level in the compensating tank. ( p. 175)
17 COOLING SYSTEM
Main work
– Pull off the compensating tank toward the bottom and maneuver it out.
177
L01487-10
– Remove cover of the compensating tank.
– Add coolant to the MAX marking.
– Mount the cover of the compensating tank.
– Mount the compensating tank.
L01455-10
18 ENGINE TUNING
18.1
"Drive Mod"
L01437-10
Possible states
• SPORT – Homologated performance with very direct response; the traction control allows greater slip on the rear wheel
• STREET – Homologated performance with balanced response; the traction control allows normal slip on the rear wheel
• RAIN – Reduced homologated performance for better ridability; the traction control allows normal slip on the rear wheel
Various vehicle tunings can be selected in the "Drive Mod" menu. You can choose from
"SPORT" , "STREET" , and "RAIN" .
The drive mode selected last is displayed on the right in the segment display.
Info
The drive mode selection has no influence on the ABS.
178
18.2
Motorcycle traction control (MTC)
The motorcycle traction control (MTC) reduces the engine torque in case of loss of traction in the rear wheel.
Info
When traction control is switched off, the rear wheel may spin during high acceleration and on surfaces with low grip.
After the ignition is switched back on, traction control is enabled again.
Traction control is controlled via the "Drive Mod"
( p. 178) menu on the combination
instrument. Traction control can be switched off in the "MTC/ABS" menu.
L01436-10
18 ENGINE TUNING
Info
When traction control is active, the TC lamp flashes.
When traction control is switched off, the TC lamp is lit.
179
19 SERVICE WORK ON THE ENGINE
19.1
Checking the engine oil level
Info
Oil consumption depends on the riding style and the operating conditions.
401696-11
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Check the engine oil level in the engine oil level viewer.
Info
After switching off the engine, wait one minute before checking the level.
The engine oil level should be in the upper area of the engine oil level viewer.
» When the engine oil level is in area
– Do not add engine oil.
of the engine oil level viewer:
» When the engine oil level is in area
– Engine oil can be added.
of the engine oil level viewer:
» When the engine oil level is in area
–
of the engine oil level viewer:
180
19 SERVICE WORK ON THE ENGINE
19.2
Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
– Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
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.
Main work
– Stand the motorcycle on its side stand on a horizontal surface.
– Place a suitable container under the engine.
– Remove the oil drain plugs with the magnet, O-rings, and oil screen.
181
500338-10
19 SERVICE WORK ON THE ENGINE
– Remove screws . Remove the oil filter cover with the O-ring.
182
500339-10
– Pull oil filter out of the oil filter housing.
Circlip pliers reverse (51012011000)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.
500340-10
– Insert the new oil filter .
– Lubricate the O-ring of the oil filter cover. Mount the oil filter cover .
500341-10
19 SERVICE WORK ON THE ENGINE
– Mount and tighten screws .
Guideline
Remaining engine screws M5 6 Nm (4.4 lbf ft)
183
500342-10
– Thoroughly clean magnet and oil screen of the oil drain plugs.
100773-12
– Mount and tighten the oil drain plugs with the magnet, O-rings, and oil screen.
Guideline
Oil drain plug M20x1.5
20 Nm
(14.8 lbf ft)
500338-10
19 SERVICE WORK ON THE ENGINE
500343-10
– Add the oil quantity in two separate operations.
Engine oil 3.60 l (3.8 qt.) Outside temperature:
≥ 0 °C ( ≥ 32 °F)
Outside temperature:
< 0 °C (< 32 °F)
– Remove screw plug and fill in engine oil.
Engine oil (1st quantity), approx.
3.0 l (3.2 qt.) Outside temperature:
≥ 0 °C ( ≥ 32 °F)
Outside temperature:
< 0 °C (< 32 °F)
– Mount screw plug .
184
Engine oil
(SAE 10W/50)
Engine oil (SAE
Engine oil
(SAE 10W/50)
Engine oil (SAE
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
– Start the engine and check that it is oil-tight.
19 SERVICE WORK ON THE ENGINE
– Remove the screw plug and add the remaining engine oil to the upper marking the engine oil level viewer.
– Mount the screw plug.
on
185
500344-10
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
– Start the engine and check that it is oil-tight.
Finishing work
–
Check the engine oil level. ( p. 180)
19.3
Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
The engine may be damaged if the engine oil level is too high.
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
–
Check the engine oil level. ( p. 180)
19 SERVICE WORK ON THE ENGINE
Main work
– Remove screw plug .
186
500345-10
500344-10
– Add engine oil to the upper marking on the engine oil level viewer.
Condition
Outside temperature: ≥ 0 °C ( ≥ 32 °F)
Engine oil (SAE 10W/50) ( p. 211)
Condition
Outside temperature: < 0 °C (< 32 °F)
Engine oil (SAE 5W/40) ( p. 212)
Info
In order to achieve optimal engine performance, it is not advisable to mix different engine oils.
KTM recommends changing the engine oil.
– Mount the screw plug.
19 SERVICE WORK ON THE ENGINE
187
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
– When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed space without an effective exhaust extraction system.
– Start the engine and check that it is oil-tight.
Finishing work
–
Check the engine oil level. ( p. 180)
20 CLEANING, CARE
188
20.1
Cleaning motorcycle
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 water jet 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
If you clean the motorcycle regularly, its value and appearance will be maintained over a long period.
Avoid direct sunshine on the motorcycle during cleaning.
401061-01
– Close off the exhaust system to keep water from entering.
– First remove coarse dirt particles with a gentle spray of water.
– Spray very dirty areas with a normal motorcycle cleaner and then clean with a brush.
Info
Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.
If the vehicle was operated in road salt, clean it with cold water. Warm water would enhance the corrosive effects of salt.
20 CLEANING, CARE
189
– After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
– Remove the closure of the exhaust system.
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, ride the vehicle a short distance until the engine warms up.
Info
The heat produced causes water at inaccessible locations in the engine and on the brake system to evaporate.
– Push back the protection caps of the handlebar controls to allow any water that has penetrated to evaporate.
– After the motorcycle has cooled off, lubricate all moving parts and bearings.
–
– Treat bare metal parts (except for brake discs and exhaust system) with corrosion inhibitor.
Preserving materials for paints, metal and rubber ( p. 215)
– Treat the painted parts with a mild paint polish.
Perfect Finish and high gloss polish for paints ( p. 215)
Info
Do not polish plastic parts that are matte when the vehicle is delivered as this would seriously impair the material quality.
– Treat the plastic parts and powder-coated parts with a mild cleaning and care product.
20 CLEANING, CARE
190
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
– Oil the ignition/steering lock, tank lock, and seat lock.
20.2
Checks and maintenance steps for winter operation
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive road salt.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.
401060-01
–
Clean the motorcycle. ( p. 188)
– Clean the brakes.
Info
After EVERY trip on salted roads, thoroughly wash the brake calipers and brake linings with cold water and dry carefully. This should be done after the parts are cooled down and while they are installed.
After riding on salted roads, thoroughly wash the motorcycle with cold water and dry it well.
– Treat the engine, the swingarm, and all other bare or galvanized parts (except brake discs) with a wax-based corrosion inhibitor.
Info
Corrosion inhibitor must not come into contact with the brake discs. This would severely lower the braking effect.
20 CLEANING, CARE
–
191
21 STORAGE
192
21.1
Storage
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
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.
401058-01
– When refueling for the last time before taking the motorcycle out of service, add fuel additive.
–
–
Clean the motorcycle. ( p. 188)
– Change the engine oil and oil filter and clean the oil screens.
– Check the coolant fill level and antifreeze.
–
Check the tire air pressure. ( p. 149)
– Remove the battery.
Guideline
Storage temperature of battery without direct sunshine
0… 35 °C (32… 95 °F)
– Recharge the battery.
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.
–
Lift the motorcycle with the rear lifting gear. ( p. 107)
21 STORAGE
193
–
Lift the motorcycle with the front lifting gear. ( p. 108)
– Cover the vehicle with a tarp or similar cover that is permeable to air.
Info
Do 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 the exhaust system to rust.
21.2
Preparing for use after storage
–
Take the motorcycle from the front lifting gear. ( p. 109)
–
Remove the rear of the motorcycle from the lifting gear. ( p. 107)
– Install the battery.
Info
If the battery was disconnected, the time and date must be set.
–
Perform checks and maintenance measures when preparing for use. ( p. 84)
– Take a test ride.
401059-01
22 TROUBLESHOOTING
Faults
The combination instrument shows nothing on the display
The engine does not crank when the electric starter button is pressed
The engine only turns if the clutch lever is drawn
The engine turns although a gear is engaged
The engine turns but does not start
Possible cause
Fuse 1 is blown
The main fuse is blown
The battery is discharged
The ignition/steering lock is faulty
The emergency OFF switch is off
Operating error
The battery is discharged
The safety start system is faulty
CAN bus communication error
Fault in EFI control unit.
Fault in the MCU control unit.
The vehicle is in gear
The safety start system is faulty
The safety start system is faulty
The coupling of the fuel hose connection is not connected
194
Action
–
Change the fuses in the fuse box. ( p. 162)
–
Change the main fuse. ( p. 159)
– Recharge the battery.
– Check the open-circuit current.
– Check the ignition/steering lock.
– Press the emergency OFF switch to the position ON .
–
Carry out the start procedure. ( p. 85)
– Recharge the battery.
– Check the open-circuit current.
– Read out the fault memory using the KTM diagnostics tool.
– Read out the fault memory using the KTM diagnostics tool.
– Read out the fault memory using the KTM diagnostics tool.
– Read out the fault memory using the KTM diagnostics tool.
– Shift the transmission to idle .
– Read out the fault memory using the KTM diagnostics tool.
– Read out the fault memory using the KTM diagnostics tool.
– Reconnect the coupling of the fuel hose connection.
22 TROUBLESHOOTING
Faults
The engine turns but does not start
The engine dies during the trip
The engine warning lamp lights up/flashes
The ABS warning lamp lights up
High oil consumption
The battery is discharged
195
Possible cause
Defect in the fuel injection system
The fuel quality is insufficient
Lack of fuel
Defect in the fuel injection system
Defect in the fuel injection system
The ABS fuse is blown
Large difference in wheel speeds of the front and rear wheels
Malfunction in ABS
The engine oil level is too high
The engine oil is too thin (low viscosity)
The hazard warning flasher is switched on
The battery is not being charged by the alternator
The ignition was not switched off while the vehicle was parked
Action
– Read out the fault memory using the KTM diagnostics tool.
– Add suitable fuel.
–
– Read out the fault memory using the KTM diagnostics tool.
– Read out the fault memory using the KTM diagnostics tool.
–
Change the fuses in the fuse box. ( p. 162)
– Stop the vehicle, switch off the ignition, and start it again.
– Read out the fault memory using the KTM diagnostics tool.
–
Check the engine oil level. ( p. 180)
– Change the engine oil and oil filter and clean the oil screens.
– Switch off the hazard warning flasher.
– Recharge the battery.
– Check the charging voltage.
– Recharge the battery.
23 TECHNICAL DATA
23.1
Engine
Design
Displacement
Stroke
Bore
Compression ratio
Idle speed
Control
Valve - valve plate diameter
Intake
Exhaust
Valve clearance
Exhaust at: 20 °C (68 °F)
Intake at: 20 °C (68 °F)
Crankshaft bearing
Conrod bearing
Piston
Piston ring
Engine lubrication
Primary transmission
Clutch
Transmission
Transmission ratio
196
2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled
1,301 cm³ (79.39 cu in)
71 mm (2.8 in)
108 mm (4.25 in)
13.2:1
1,300… 1,500 rpm
DOHC, 4 valves per cylinder, chain-driven
42 mm (1.65 in)
34 mm (1.34 in)
0.25… 0.30 mm (0.0098… 0.0118 in)
0.10… 0.15 mm (0.0039… 0.0059 in)
Sleeve bearing
Sleeve bearing
Forged light alloy
1 upper compression (rectangular) ring, 1 lower compression ring,
1 oil scraper ring
Dry sump lubrication system with three rotor pumps
40:76
Antihopping clutch in oil bath/hydraulically operated
6-speed claw gears
23 TECHNICAL DATA
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Mixture preparation
Ignition system
Alternator
Spark plug
Inside spark plug
Outside spark plug
Electrode gap, spark plug
Cooling
Cold start device
23.2
Engine tightening torques
Screw, damping plate
Screw, retaining bracket, valve cover, rear
Hose clip, intake flange
Remaining engine screws
Screw, bearing retainer
Screw, bearing shells retaining bracket
EJOT ALtracs ® M6x14
EJOT ALtracs ® M6x10
M4
M5
M5
M5
197
12:35
15:32
18:30
20:27
24:27
27:26
Electronically controlled fuel injection
Contactless controlled fully electronic ignition with digital ignition adjustment
12 V, 450 W
NGK LKAR9BI9
NGK LMAR7A-9
0.9 mm (0.035 in)
Water cooling, permanent circulation of coolant by water pump
Electric starter
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
1.5 Nm (1.11 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
Loctite ® 243™
–
–
–
Loctite ® 243™
Loctite ® 243™
23 TECHNICAL DATA
Screw, engine oil level viewer
Screw, gear sensor
Screw, pulse generator
Bleeder screw, water pump cover
Freewheel ring bolt
Nut, cylinder head
Plug, vacuum connection
Remaining engine screws
Screw, camshaft bearing support
Screw, clutch cover
Screw, clutch spring
Screw, coolant connection on cylinder head
Screw, engine case
Screw, engine case
Screw, engine case
Screw, freewheel holder
Screw, locking lever
Screw, oil pump cover
Screw, shift drum locating
Screw, shift lever
Screw, starter motor
Screw, stator
Screw, valve cover
Screw, water pump cover
M5
M5
M5
M6
M6 – 10.9
M6
M6
M6
M6 – 10.9
M6
M6
M6
M6
M6
M6
M6
M6x60
M6x80
M6x90
M6
M6
M6
M6
M6
4 Nm (3 lbf ft)
6 Nm (4.4 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
15 Nm (11.1 lbf ft)
9 Nm (6.6 lbf ft)
5 Nm (3.7 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
12 Nm (8.9 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
18 Nm (13.3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
–
Loctite ® 243™
Loctite ® 243™
–
Loctite ® 648™
–
–
–
–
Loctite ® 243™
–
–
–
–
–
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
–
Loctite ® 243™
–
–
198
23 TECHNICAL DATA
Screw, water pump wheel
Stud, chain shaft
Nozzle 100
Plug, crankshaft retainer
Screw, camshaft bearing support
M6
M6
M6x0.75
M8
M8 – 10.9
Screw, camshaft bearing support M8 – 10.9
Screw, engine case
Screw, timing chain guide rail
Stud, exhaust flange
Timing chain tensioning rail screw
Screw, engine bearer
Oil pressure sensor
Plug, cam lever axis
Plug, clutch lubrication
M8
M8
M8
M8
M10
M10x1
M10x1
M10x1
Screw plug, spreading transmission lock M10x1
Screw, conrod bearing M10x1
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
4 Nm (3 lbf ft)
15 Nm (11.1 lbf ft)
Step 1
8.5 Nm (6.27 lbf ft)
Step 2
14.5 Nm (10.7 lbf ft)
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
18 Nm (13.3 lbf ft)
15 Nm (11.1 lbf ft)
10 Nm (7.4 lbf ft)
15 Nm (11.1 lbf ft)
45 Nm (33.2 lbf ft)
10 Nm (7.4 lbf ft)
15 Nm (11.1 lbf ft)
10 Nm (7.4 lbf ft)
12 Nm (8.9 lbf ft)
Step 1
25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
199
Loctite ® 243™
–
Loctite ® 243™
–
Only applies when using:
Hex key bit (61229025000)
–
–
Loctite ® 243™
–
–
–
–
–
Loctite ® 243™
–
–
23 TECHNICAL DATA
Screw, timing chain tensioner release
Spark plug
Cylinder head screw
M10x1
M10x1
M11x1.5
Coolant temperature sensor
Rotor screw
Spark plug
Nut of engine sprocket
Oil drain plug
Nut, inner clutch hub
Plug, timing-chain tensioner
Screw in alternator cover
Nut, primary gear
23.3
Capacities
23.3.1
Engine oil
Engine oil 3.60 l (3.8 qt.)
M12x1.5
M12x1.5
M12x1.5
M20x1.5
M20x1.5
M22x1.5
M24x1.5
M24x1.5
M33LHx1.5
10 Nm (7.4 lbf ft)
11 Nm (8.1 lbf ft)
Tightening sequence:
Using a crisscross pattern
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Step 4
90°
12 Nm (8.9 lbf ft)
90 Nm (66.4 lbf ft)
18 Nm (13.3 lbf ft)
100 Nm (73.8 lbf ft)
20 Nm (14.8 lbf ft)
120 Nm (88.5 lbf ft)
25 Nm (18.4 lbf ft)
8 Nm (5.9 lbf ft)
130 Nm (95.9 lbf ft)
–
–
Lubricated with engine oil
–
–
–
Loctite ® 243™
–
–
–
Loctite ® 243™
Loctite ® 243™
200
Outside temperature: ≥ 0 °C
( ≥ 32 °F)
Engine oil (SAE 10W/50)
23 TECHNICAL DATA
Engine oil 3.60 l (3.8 qt.)
23.3.2
Coolant
Coolant 3.20 l (3.38 qt.)
23.3.3
Fuel
Total fuel tank capacity, approx. 18 l (4.8 US gal)
Fuel reserve, approx.
23.4
Chassis
Frame
Fork
Shock absorber
Suspension travel
Front
Rear
Brake system
Front
Rear
Brake discs - diameter
Outside temperature: < 0 °C
(< 32 °F)
Engine oil (SAE 5W/40)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 213)
3.5 l (3.7 qt.)
201
Lattice frame made of chrome molybdenum steel tubing, powdercoated
WP Performance Systems 4860 ROTA SPLIT
WP Performance Systems 4618 BAVP DCC
125 mm (4.92 in)
156 mm (6.14 in)
Double disc brake with radially mounted four-pot brake calipers, floating brake discs
Single disc brake with dual-piston brake caliper, fixed brake disc
23 TECHNICAL DATA
Front
Rear
Brake discs - wear limit (Super Duke R)
Front
Brake discs - wear limit (Super Duke R Special Edition) front
Brake discs - wear limit rear
Tire air pressure, solo/with passenger/full payload
Front: with cold tires
Rear: with cold tires
Secondary drive ratio
Chain
Steering head angle
Wheelbase
Seat height unloaded
Ground clearance unloaded
Weight without fuel approx.
Maximum permissible front axle load
Maximum permissible rear axle load
Maximum permissible overall weight
320 mm (12.6 in)
240 mm (9.45 in)
4.5 mm (0.177 in)
4.2 mm (0.165 in)
4.5 mm (0.177 in)
2.5 bar (36 psi)
2.9 bar (42 psi)
17:38
5/8 x 5/16” (525) X ‑ ring
65.1°
1,482 mm (58.35 in)
835 mm (32.87 in)
141 mm (5.55 in)
189 kg (417 lb.)
160 kg (353 lb.)
260 kg (573 lb.)
406 kg (895 lb.)
202
23 TECHNICAL DATA
23.5
Electrical system
Battery YTX14-BS
Fuse
Fuse
Fuse
Fuse
Low beam/high beam
Parking light
Instrument lights and indicator lamps
Turn signal
Tail light
Brake light
License plate lamp
58011109110
58011109115
58011109125
58011109130
H4/socket U37R
LED
LED
RY10W / socket BAU15s
LED
LED
LED
23.6
Tires
Front tires
120/70 ZR 17 M/C 58W TL
Dunlop Sportmax Sportsmart²
Additional information is available in the Service section under: http://www.ktm.com
12 V
10 W
Rear tires
190/55 ZR 17 M/C 75W TL
Dunlop Sportmax Sportsmart²
Battery voltage: 12 V
Nominal capacity: 12 Ah
Maintenance-free
10 A
15 A
25 A
30 A
12 V
60/55 W
203
23 TECHNICAL DATA
23.7
Fork
Fork part number
Fork
Compression damping
Comfort
Standard
Sport
Full payload
Rebound damping
Comfort
Standard
Sport
Full payload
Spring length with preload spacer(s)
Spring rate
Medium (standard)
Fork length
Air chamber length
Fork oil per fork leg 660 ml (22.31 fl. oz.)
14.18.8N.22
WP Performance Systems 4860 ROTA SPLIT
17 clicks
12 clicks
7 clicks
7 clicks
17 clicks
12 clicks
7 clicks
7 clicks
253 mm (9.96 in)
9.5 N/mm (54.2 lb/in)
776 mm (30.55 in)
110 +10 mm (4.33
+0.39
in)
Fork oil (SAE 4) (48601166S1) ( p. 212)
204
23 TECHNICAL DATA
23.8
Shock absorber
Shock absorber article number
Shock absorber
Compression damping, low-speed
Comfort
Standard
Sport
Full payload
Compression damping, high-speed
Comfort
Standard
Sport
Full payload
Rebound damping
Comfort
Standard
Sport
Full payload
Spring preload
Comfort
Standard
Sport
Full payload
Spring rate
15.18.7O.22
WP Performance Systems 4618 BAVP DCC
18 clicks
15 clicks
10 clicks
10 clicks
1.5 turns
1.5 turns
1 turn
1 turn
15 clicks
12 clicks
9 clicks
9 clicks
5 mm (0.2 in)
5 mm (0.2 in)
6 mm (0.24 in)
7 mm (0.28 in)
205
23 TECHNICAL DATA
Medium (standard)
Spring length
Gas pressure
Riding sag
Static sag (standard)
Static sag (race track operation)
Fitted length
Shock absorber fluid ( p. 213)
23.9
Chassis tightening torques
Remaining screws, chassis
Remaining screws, chassis
Remaining screws, chassis
Remaining screws, chassis
Screw, fuel tank cover, quick connect nipple
Screw, tail light
Screw, combination switch, left
Screw, side stand switch
Remaining nuts, chassis
Remaining screws, chassis
Screw, cable channel
Screw, chain sliding guard
Screw, combination switch, right
EJOT PT ® K50x12
EJOT PT ® K50x14
EJOT PT ® K50x16
EJOT PT ® K50x18
EJOT PT ® K60
EJOT PT ® K50x14
M4
M4
M5
M5
M5
M5
M5
170 N/mm (971 lb/in)
185 mm (7.28 in)
10 bar (145 psi)
45 mm (1.77 in)
24 mm (0.94 in)
18 mm (0.71 in)
383 mm (15.08 in)
SAE 2.5
1 Nm (0.7 lbf ft)
1 Nm (0.7 lbf ft)
2 Nm (1.5 lbf ft)
2 Nm (1.5 lbf ft)
2 Nm (1.5 lbf ft)
2.5 Nm (1.84 lbf ft)
2.5 Nm (1.84 lbf ft)
2 Nm (1.5 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
3.5 Nm (2.58 lbf ft)
–
–
–
–
–
–
–
–
–
–
–
–
–
206
23 TECHNICAL DATA
Screw, cover part
Screw, filler cap
Screw, fuel level indicator
Screw, shock absorber adjusting ring
Ground fitting on frame
Nut, ABS unit attachment
Nut, cable on starter motor
Remaining nuts, chassis
Remaining screws, chassis
Screw, ball joint of push rod on foot brake cylinder
M6
M6
M6
Screw, battery terminal
Screw, clutch assembly
M6
M6
Screw, connecting piece, rear brake line M6
Screw, cooler retaining bracket M6
M5x12
M5
M5
M5
M6
M6
M6
Screw, exhaust clamp on main silencer M6
Screw, exhaust clamp on manifold M6
Screw, foot brake cylinder M6
Screw, fuel pump
Screw, headlight mask, rear wall
Screw, license plate holder on lower rear panel
Screw, radiator hose clamp
M6
M6
M6
Screw, sensor box
Screw, shift lever stub
M6
M6
M6
3.5 Nm (2.58 lbf ft)
3 Nm (2.2 lbf ft)
3 Nm (2.2 lbf ft)
5 Nm (3.7 lbf ft)
10 Nm (7.4 lbf ft)
5 Nm (3.7 lbf ft)
4 Nm (3 lbf ft)
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
5 Nm (3.7 lbf ft)
4.5 Nm (3.32 lbf ft)
5 Nm (3.7 lbf ft)
10 Nm (7.4 lbf ft)
7 Nm (5.2 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
12 Nm (8.9 lbf ft)
3 Nm (2.2 lbf ft)
6 Nm (4.4 lbf ft)
10 Nm (7.4 lbf ft)
–
–
–
–
–
–
–
–
–
Loctite ® 243™
–
Loctite ® 243™
–
–
Loctite ® 243™
–
–
–
Loctite ® 243™
–
–
Loctite ® 243™
Loctite ® 243™
207
23 TECHNICAL DATA
Screw, shift rod
Screw, shift shaft deflector on shift shaft
Screw, side stand stub
Screw, steering damper, holder, on frame
Screw, step plate for foot brake lever
Screw, wheel speed sensor, front
Screw, wheel speed sensor, rear
Nut, manifold on cylinder head
M6
M6
M6
M6
M6
M6
M6
M8
Nut, rear sprocket
Nut, shift rod
Nut, shift rod
Nut, valve, angled
Remaining nuts, chassis
Remaining screws, chassis
Screw, axle clamp
Screw, bottom triple clamp
Screw, foot brake lever
Screw, front brake disc
Screw, front rider footrest bracket
Screw, handlebar clamp
M8
M8
M8
M8
M8
M8
M8
M8
M8LH
M8
M8
M8
5 Nm (3.7 lbf ft)
18 Nm (13.3 lbf ft)
6 Nm (4.4 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.4 lbf ft)
4 Nm (3 lbf ft)
4 Nm (3 lbf ft)
Tightening sequence:
Tighten the nuts evenly. Do not warp the metal plate.
25 Nm (18.4 lbf ft)
36 Nm (26.6 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
4 Nm (3 lbf ft)
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
12 Nm (8.9 lbf ft)
20 Nm (14.8 lbf ft)
30 Nm (22.1 lbf ft)
25 Nm (18.4 lbf ft)
20 Nm (14.8 lbf ft)
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
–
–
–
–
–
–
–
–
–
–
–
Loctite ® 243™
Loctite ® 2701™
Loctite ® 243™
–
208
23 TECHNICAL DATA
Screw, ignition lock (tamper-proof screw)
Screw, rear brake caliper
Screw, rear brake disc
M8
Screw, shift lever on footrest bracket
Screw, shift shaft deflector on frame
Screw, side stand bracket
Screw, side stand spring
M8
M8
Screw, steering damper on holder M8
Screw, steering damper on triple clamp M8
Screw, top triple clamp M8
M8
M8
M8
M8
Remaining nuts, chassis
Remaining screws, chassis
Screw, engine bearer
Screw, front brake caliper
M10
M10
M10
M10
Screw, instrument support
Screw, side stand
Screw, side stand bracket
Screw, side stand retaining plate
Banjo bolt, brake line
Banjo bolt, brake line, connecting piece, rear
Nut, rear hub shock absorber carrier
Lambda sensor
Screw, bottom shock absorber
M10
M10
M10
M10
M10x1
M10x1
M10x1.25
M12x1.25
M14x1.5
25 Nm (18.4 lbf ft)
25 Nm (18.4 lbf ft)
30 Nm (22.1 lbf ft)
20 Nm (14.8 lbf ft)
10 Nm (7.4 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
15 Nm (11.1 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
40 Nm (29.5 lbf ft)
35 Nm (25.8 lbf ft)
45 Nm (33.2 lbf ft)
45 Nm (33.2 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
45 Nm (33.2 lbf ft)
25 Nm (18.4 lbf ft)
80 Nm (59 lbf ft)
–
Loctite ® 2701™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 2701™
–
–
–
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
–
–
Loctite ® 243™
Loctite ® 243™
Loctite ® 243™
–
Thread greased
209
23 TECHNICAL DATA
Screw, top shock absorber
Screw, eccentric
Nut, swingarm pivot
Nut, seat lock
Screw, steering head, top
Bolt, front axle
Nut, steering head
M14x1.5
M16
M19x1.5
M22x1.5
M22x1.5
M25x1.5
M28x1.0
Nut, rear axle, shock absorber side
Nut, rear axle
M35x1.5
M50x1.5
210
80 Nm (59 lbf ft)
70 Nm (51.6 lbf ft)
130 Nm (95.9 lbf ft)
6 Nm (4.4 lbf ft)
50 Nm (36.9 lbf ft)
45 Nm (33.2 lbf ft)
Step 1
10 Nm (7.4 lbf ft)
Step 2 (loosen, counterclockwise)
60°
200 Nm (147.5 lbf ft)
250 Nm (184.4 lbf ft)
Thread greased
–
Thread greased
–
–
Thread greased
–
Loctite ® 262™ /lock the locking wire with locking varnish
Lock the locking wire with locking varnish
24 SUBSTANCES
211
Brake fluid DOT 4 / DOT 5.1
Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties.
Recommended supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex ®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using inferior antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: − 25… − 45 °C ( − 13…
− 49 °F) anti-corrosion/antifreeze distilled water
Recommended supplier
Motorex ®
– COOLANT M3.0
Engine oil (SAE 10W/50)
Standard/classification
–
–
24 SUBSTANCES
212
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
Fully synthetic engine oil
Recommended supplier
Motorex ®
– Power Synt 4T
Engine oil (SAE 5W/40)
Standard/classification
–
–
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
Synthetic engine oil
Recommended supplier
Motorex ®
– Power Synt 4T
Fork oil (SAE 4) (48601166S1)
Standard/classification
–
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
24 SUBSTANCES
213
Shock absorber fluid (SAE 2.5) (50180751S1)
Standard/classification
–
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
25 AUXILIARY SUBSTANCES
Chain cleaner
Recommended supplier
Motorex ®
– Chain Clean
Chain lube for road use
Guideline
Recommended supplier
Motorex ®
– Chainlube Road
Fuel additive
Recommended supplier
Motorex ®
– Fuel Stabilizer
Long-life grease
Recommended supplier
Motorex ®
– Bike Grease 2000
Motorcycle cleaner
Recommended supplier
Motorex ®
– Moto Clean
214
25 AUXILIARY SUBSTANCES
Perfect Finish and high gloss polish for paints
Recommended supplier
Motorex ®
– Moto Polish & Shine
Preserving materials for paints, metal and rubber
Recommended supplier
Motorex ®
– Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
Motorex ®
– Quick Cleaner
Universal oil spray
Recommended supplier
Motorex ®
– Joker 440 Synthetic
215
26 STANDARDS
216
JASO T903 MA
Different technical development directions required a new specification for 4-stroke motorcycles – the JASO T903 MA Standard. Earlier, engine oils from the automobile industry were used for 4-stroke motorcycles because there was no separate motorcycle specification.
Whereas long service intervals are demanded for automobile engines, high performance at high engine speeds are in the foreground for motorcycle engines. In most motorcycles, the gearbox and the clutch are lubricated with the same oil as the engine. The JASO MA Standard meets these special requirements.
SAE
The SAE viscosity classes were defined by the Society of Automotive Engineers and are used for classifying oils according to their viscosity. The viscosity describes only one property of oil and says nothing about quality.
27 INDEX OF SPECIAL TERMS
ABS ABS
MTC Motorcycle Traction Control
Safety system that prevents locking of the wheels when driving straight ahead without the influence of lateral forces
Auxiliary function of the motor control, which reduces engine torque with spinning rear wheel
217
28 LIST OF ABBREVIATIONS
Art. no.
ca.
cf.
e.g.
etc.
i.a.
no.
poss.
Article number circa compare for example et cetera inter alia number possibly
218
29 LIST OF SYMBOLS
29.1
Red symbols
Red symbols indicate an error condition that requires immediate intervention.
The immobilizer indicator lamp lights up or flashes red – Status or error message for immobilizer/alarm system.
219
The oil pressure warning lamp lights up red – Engine oil pressure is too low.
29.2
Yellow and orange symbols
Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.
The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown on the matrix display.
The engine warning lamp lights up/flashes yellow – The engine control unit has detected a fault.
The ABS lamp lights up/flashes yellow – ABS is not active. The ABS lamp also lights up when an error is detected.
The TC lamp lights up/flashes yellow – Traction control is not enabled or is currently intervening. The TC lamp also lights up when an error is detected.
29.3
Green and blue symbols
Green and blue symbols reflect information.
The high beam indicator lamp lights up blue – The high beam is switched on.
29 LIST OF SYMBOLS
The left turn signal lamp flashes green simultaneously with the turn signal – The left turn signal is switched on.
220
The idle indicator lamp lights up green – The transmission is shifted to idle.
The right turn signal lamp flashes green simultaneously with the turn signal – The right turn signal is switched on.
INDEX
INDEX
A
ABS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Accessories
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Antilock braking system
. . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Applying the brakes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Auxiliary substances
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
B
Baggage lugs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 131
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Brake linings
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 134
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Brake system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-139
Brakes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
221
C
Capacity
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Chain tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Chassis number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Clutch
fluid level, checking/correcting . . . . . . . . . . . . . . . . . . . 125
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 73
Combination instrument . . . . . . . . . . . . . . . . . . . .
"ABS"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
activation and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
"Clock/Date"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
"Distance"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
"Drive Mod"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 178
"DRL"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
"Favorites"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
INDEX
"Fuel Cons"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
"General Info"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
"Heat Grip"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
"Heating"
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
"Language"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
matrix display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Message on the matrix display . . . . . . . . . . . . . . . . . . . . 57
"MTC"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
"Pressure"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
service display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
"Set Favorites"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
"Settings"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
shift warning light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
"Shift Light"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
"Temp"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
"Trip 1"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
"Trip 2"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
"Warning"
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Coolant level
compensating tank, checking . . . . . . . . . . . . . . . . . . . . 175
compensating tank, correcting . . . . . . . . . . . . . . . . . . . 176
Customer service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
222
E
Electric starter button
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Emergency OFF switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Engine number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Environment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F
Figures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 76
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99 compression damping, setting . . . . . . . . . . . . . . . . . . . . 99
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Fork part number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Front rider's seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INDEX
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Fuses
in fuse box, changing . . . . . . . . . . . . . . . . . . . . . . . . . 162
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 75
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72 setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Hazard warning flasher
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hazard warning flasher switch
. . . . . . . . . . . . . . . . . . . . . . . . 42
Headlight
Daytime running light . . . . . . . . . . . . . . . . . . . . . . . . . 150
headlight range, adjusting . . . . . . . . . . . . . . . . . . . . . . 169
Headlight adjustment
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Headlight bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mounting on the vehicle . . . . . . . . . . . . . . . . . . . . . . . 111
Horn button
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
I
Ignition key
activating/deactivating . . . . . . . . . . . . . . . . . . . . . . . . . 170
223
Ignition lock
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Immobilizer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Implied warranty
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Intended use
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
K
Key number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
L
Labels
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 18
Light switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Luggage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Main silencer
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Matrix display
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
lifting with front lifting gear . . . . . . . . . . . . . . . . . . . . . 108
INDEX
taking from the front lifting gear . . . . . . . . . . . . . . . . . . 109
Motorcycle traction control
. . . . . . . . . . . . . . . . . . . . . . . . . 178
MTC
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Oil screens
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Operating substances
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Owner's Manual
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
P
Parking
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Passenger footrests
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Passenger seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Preparing for use
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
checks and maintenance measures when preparing for use . 84
Protective clothing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
R
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
224
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Refueling
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
86 starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
S
Safe operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat lock
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Service schedule
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96-98
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 78
basic position, checking . . . . . . . . . . . . . . . . . . . . . . . . 77
Shift lever stub
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Shifting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
compression damping, general . . . . . . . . . . . . . . . . . . . 101
high-speed compression damping, setting . . . . . . . . . . . 103
low speed compression damping, setting . . . . . . . . . . . . 102
Shock absorber article number
. . . . . . . . . . . . . . . . . . . . . . . 37
Side stand
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Spare parts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INDEX
Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Steering damper article number
. . . . . . . . . . . . . . . . . . . . . . . 37
Steering lock
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Step plate of foot brake lever
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Stopping
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Storage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Supporting strap
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Suspension setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . 99-106
Switch
on the left side of the handlebar . . . . . . . . . . . . . . . . . . . 40
on the right side of the handlebar . . . . . . . . . . . . . . . . . . 44
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
chassis tightening torques . . . . . . . . . . . . . . . . . . . . . . 206
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
engine tightening torques . . . . . . . . . . . . . . . . . . . . . . 197
fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Throttle grip
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
225
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Tool set
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Transport
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 194-195
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Turn signal switch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Type label
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
U
Use definition
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
V
Vehicle
loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
W
Warranty
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . . . 190
Work rules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
*3213405en*
3213405en
01/2016
KTM Sportmotorcycle GmbH
5230 Mattighofen/Austria http://www.ktm.com
Photo: Mitterbauer/KTM
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