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OWNER'S MANUAL
2013
125 Duke EU
200 Duke EU
200 Duke MAL
Art. no. 3211963en
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 accordingly.
We wish you a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.
Chassis number/type label ( p. 20)
Dealer's stamp
1
The owner's manual contained the latest information for this model 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 AG 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, as well as misprints and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.
© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER
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 AG
5230 Mattighofen, Austria
TABLE OF CONTENTS
TABLE OF CONTENTS
1 MEANS OF REPRESENTATION ........................................ 7
Symbols used ...................................................... 7
Formats used....................................................... 7
2 SAFETY ADVICE.............................................................. 8
Use definition...................................................... 8
Safety advice....................................................... 8
Degrees of risk and symbols .................................. 9
Tampering warning............................................... 9
Safe operation ................................................... 10
Protective clothing ............................................. 11
Work rules......................................................... 11
Environment...................................................... 11
Owner's Manual ................................................. 12
3 IMPORTANT NOTES...................................................... 13
Guarantee, warranty ........................................... 13
Operating and auxiliary substances ...................... 13
Spare parts, accessories ..................................... 13
Service ............................................................. 13
Figures ............................................................. 14
Customer service................................................ 14
4 VIEW OF VEHICLE ........................................................ 16
View of vehicle, front left (example) ..................... 16
View of vehicle, rear right (example) .................... 18
5 SERIAL NUMBERS ....................................................... 20
Chassis number/type label .................................. 20
Engine number .................................................. 20
Key number....................................................... 21
6 CONTROLS................................................................... 22
Clutch lever....................................................... 22
3
Hand brake lever................................................ 22
Throttle grip ...................................................... 23
Horn button....................................................... 23
Light switch ...................................................... 24
High beam flasher button ................................... 24
Turn signal switch.............................................. 25
Emergency OFF switch ....................................... 25
Electric starter button......................................... 26
Ignition/steering lock.......................................... 26
Combination instrument ..................................... 27
Overview ....................................................... 27
Activation and test ......................................... 28
warning notes ................................................ 29
Function buttons ........................................... 32
Indicator lamps ............................................. 33
Display ......................................................... 34
filling level display in fuel tank........................ 35
TRIP F display............................................... 36
Coolant temperature indicator ......................... 37
6.11.10 info display ................................................... 38
6.11.11 Riding time/average speed menu ..................... 39
6.11.14 Average fuel consumption 2/service menu ........ 41
6.11.15 Service/range menu........................................ 42
6.11.16 Range/riding time menu ................................. 43
6.11.17 Total distance menu ODO ............................... 44
TABLE OF CONTENTS
6.11.18 Distance menu 1 TRIP 1 ................................ 44
6.11.19 Distance menu 2 TRIP 2 ................................ 45
6.11.20 Setting kilometers or miles ............................. 45
6.11.21 Setting the time............................................. 46
6.11.22 Adjusting the shift speed RPM 1 ..................... 47
6.11.23 Adjusting the shift speed RPM 2 ..................... 47
Opening the filler cap......................................... 48
Closing the filler cap .......................................... 50
Seat lock........................................................... 50
Tool set............................................................. 51
Grab handles ..................................................... 51
Passenger footrests ............................................ 52
Shift lever ......................................................... 52
Foot brake lever ................................................. 53
Side stand......................................................... 54
7 PREPARING FOR USE................................................... 55
Advice on first use ............................................. 55
Running in the engine ........................................ 56
Loading the vehicle ............................................ 57
8 RIDING INSTRUCTIONS................................................ 59
Starting............................................................. 60
Starting off........................................................ 62
Shifting, riding .................................................. 62
Applying the brakes............................................ 65
Stopping, parking............................................... 67
Transport .......................................................... 68
Refueling .......................................................... 69
9 SERVICE SCHEDULE .................................................... 71
Service schedule................................................ 71
10 TUNING THE CHASSIS ................................................. 73
Adjusting the shift lever...................................... 74
11 SERVICE WORK ON THE CHASSIS................................. 75
Removing the passenger seat .............................. 78
Mounting the passenger seat............................... 79
Removing the seat ............................................. 79
Mounting the seat .............................................. 80
Checking for chain dirt accumulation................... 81
11.10 Cleaning the chain ............................................. 81
11.11 Checking the chain tension ................................. 82
11.12 Adjusting the chain tension................................. 83
11.14 Removing the front spoiler .................................. 89
11.15 Fitting front spoiler ............................................ 90
12 BRAKE SYSTEM ........................................................... 91
ABS/antilock brake system.................................. 91
Checking the brake discs .................................... 92
4
TABLE OF CONTENTS
Checking the brake fluid level of the front brake ... 93
Adding front brake fluid x ................................. 94
Checking the front brake linings .......................... 95
Checking the free travel of foot brake lever ........... 96
Checking the rear brake fluid level....................... 98
Adding rear brake fluid x .................................. 99
12.10 Checking the rear brake linings ......................... 101
13 WHEELS, TIRES ......................................................... 102
x ............................ 102
x ............................. 103
x .............................. 104
x .............................. 105
Checking the rear hub rubber dampers x .......... 107
Checking the tire condition ............................... 109
Checking the tire air pressure............................ 110
14 ELECTRICAL SYSTEM ................................................. 112
x .................................. 112
x ................................... 113
Recharging the battery x ................................ 114
Changing the ABS fuses ................................... 117
Changing the headlight bulb ............................. 120
Changing the parking light bulb......................... 123
Checking the headlight setting .......................... 127
Adjusting the headlight range............................ 128
15 COOLING SYSTEM ...................................................... 131
Cooling system ................................................ 131
Checking the antifreeze and coolant level ........... 132
Checking the coolant level ................................ 134
Draining the coolant x .................................... 136
Filling/bleeding the cooling system x ............... 137
16 TUNING THE ENGINE................................................. 140
Checking the play in the throttle cable ............... 140
Adjusting the play in the throttle cable x .......... 141
Checking the clutch lever play........................... 141
Adjusting the clutch cable play x .................... 142
17 SERVICE WORK ON THE ENGINE ................................ 143
Checking the engine oil level............................. 143
Adding engine oil............................................. 146
18 CLEANING, CARE ....................................................... 148
Cleaning the motorcycle ................................... 148
19 STORAGE................................................................... 152
Storage ........................................................... 152
Preparing for use after storage........................... 153
20 TROUBLESHOOTING .................................................. 154
21 TECHNICAL DATA....................................................... 157
Engine ............................................................ 157
125 Duke ................................................... 157
200 Duke EU/MAL....................................... 158
Engine tightening torques ................................. 160
5
TABLE OF CONTENTS
Capacities ....................................................... 162
Engine oil ................................................... 162
Coolant ....................................................... 162
Fuel ........................................................... 162
Chassis ........................................................... 163
Electrical system.............................................. 164
Tires ............................................................... 165
Fork................................................................ 165
Shock absorber ................................................ 165
Chassis tightening torques ................................ 166
22 SUBSTANCES ............................................................ 170
23 AUXILIARY SUBSTANCES ........................................... 173
24 STANDARDS .............................................................. 176
INDEX ............................................................................... 177
6
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).
1.2
Formats used
The typographical formats used in this document are explained below.
Specific name
Identifies a proprietary name.
Name ®
Brand™
Identifies a protected name.
Identifies a brand available on the open market.
7
2 SAFETY ADVICE
2.1
Use definition
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation but not for use on race courses or offroad.
Info
The motorcycle is authorized for public road traffic in the homologous version only.
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.
8
2 SAFETY ADVICE
2.3
Degrees of risk and symbols
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
9
2.4
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:
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 any part of the intake system.
3 Lack of proper maintenance.
4 Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
10
2.5
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.
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
2.6
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.
11
In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing protective clothing.
2.7
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.
2.8
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
2.9
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.
12
3 IMPORTANT NOTES
3.1
Guarantee, warranty
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's service record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
13
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 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
3.4
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.
3 IMPORTANT NOTES
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.
14
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
15
4 VIEW OF VEHICLE
4.1
View of vehicle, front left (example)
16
B01385-10
4 VIEW OF VEHICLE
5
6
3
4
1
1
2
7
8
9
10
Rear mirror
Seat
Passenger seat
17
4 VIEW OF VEHICLE
4.2
View of vehicle, rear right (example)
18
B01386-10
4 VIEW OF VEHICLE
7
8
5
6
9
10
3
4
2
2
1
2
2
High beam flasher button ( p. 24)
Ignition/steering lock ( p. 26)
Electric starter button ( p. 26)
Chassis number/type label ( p. 20)
19
5 SERIAL NUMBERS
5.1
Chassis number/type label
The chassis number
The type label
1 is stamped on the right of the steering head.
2 is on the right of the frame behind the steering head.
20
5.2
Engine number
B00699-10
The engine number
1 is stamped on the left side of the engine under the engine sprocket.
B00700-10
5 SERIAL NUMBERS
5.3
Key number
The key number
1 can be found on the
KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe place.
21
B00755-10
6 CONTROLS
6.1
Clutch lever
The clutch lever
1 is fitted on the left side of the handlebar.
6.2
Hand brake lever
B00701-10
The hand brake lever
1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
B00702-10
22
6 CONTROLS
6.3
Throttle grip
The throttle grip
1 is fitted on the right side of the handlebar.
6.4
Horn button
B00703-10
The horn button
1 is fitted on the left side of the handlebar.
Possible states
• Horn button in neutral position
• Horn button pressed – The horn is operated in this position.
B00706-11
23
6 CONTROLS
6.5
Light switch
The light switch
Possible states
1 is fitted on the left side of the handlebar.
Low beam on – Light switch is turned downward. In this position, the low beam and tail light are switched on.
High beam on – Light switch is turned upward. In this position, the high beam and the tail light are switched on.
6.6
B00704-10
High beam flasher button
The high beam flasher button
1 is fitted on the left side of the handlebar.
Possible states
• High beam flasher button in neutral position
• High beam flasher button pressed – In this position, the headlight flasher (high beam) is actuated.
24
B00705-10
6 CONTROLS
6.7
Turn signal switch
6.8
25
B00706-10
Emergency OFF switch
The turn signal switch
1 is fitted on the left side of the handlebar.
Possible states
Turn signal off
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.
The emergency OFF switch
1 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.
Emergency OFF switch on – This position is required for operation; the ignition circuit is closed.
B00707-10
6 CONTROLS
6.9
Electric starter button
The electric starter button
1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button in basic position
• Electric starter button pressed – In this position, the electric starter is actuated.
26
B00708-10
6.10
Ignition/steering lock
B00709-01
The ignition/steering lock is in front of the upper triple clamp.
Possible states
Ignition OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The ignition key can be removed.
Ignition 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 ignition key can be removed.
6 CONTROLS
6.11
Combination instrument
6.11.1
Overview
3
4
1
2
401685-10
27
6 CONTROLS
6.11.2
Activation and test
Activation
The combination instrument is activated when the ignition is switched on.
Test
The segments of the tachometer and the gear display light up and switch off in sequence.
The speed display counts from 0 to 199 and back.
The remaining display segments outside the info display light up briefly.
The READY TO RACE >> logo appears on the info display.
The display then changes to the last selected mode.
28
401686-01
6 CONTROLS
6.11.3
warning notes
Low Oil Pressure appears on the info display if the oil pressure is too low.
29
401309-01
Low Fuel Level appears on the info display if the fuel level reaches the reserve mark.
401310-01
6 CONTROLS
30
High Coolant Temperature appears on the info display if the coolant temperature rises above the specified value.
Coolant temperature 125 °C (257 °F)
401311-01
Side Stand Down appears on the info display if the side stand is folded down.
401312-01
Low Battery appears on the info display if the battery voltage falls below the specified value.
Battery voltage 10.80 V
401313-01
6 CONTROLS
Service Not Reset appears on the info display for 10 seconds when the ignition is switched on and the distance interval between service appointments has been exceeded or the service interval display was not reset during a service appointment.
31
401461-01
6 CONTROLS
6.11.4
Function buttons
32
You can change the display mode with the MODE button
1
.
Possible display modes are total distance traveled ( TRIP 1), distance 1 (ODO) and distance 2 ( TRIP 2).
Pressing and holding the SET button
2 resets the distance 1 ( distance 2 (
TRIP 2) functions to 0.0 and briefly pressing the SET button display to the next display mode.
The ABS can be switched off using button
3
.
TRIP 1) and
2 changes the info
401685-12
6 CONTROLS
6.11.5
Indicator lamps
401686-01
Possible states
The turn signal indicator light flashes green simultaneously with the turn signal – The turn signal is switched on.
The engine diagnosis warning lamp ( MIL) lights up red – The OBD (onboard diagnosis) has detected an emission- or safety-critical error.
The shift warning lights up/flashes red – The set shift speed has been reached.
The idling speed indicator lamp lights up green – The transmission is shifted to idle.
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. (OPTIONAL)
The general warning lamp lights up yellow – An operating safety (warning) message was detected. This is also shown in the info display.
ABS warning lamp lights up/flashes yellow – Status or error messages relating to ABS (antilock brake system).
33
6 CONTROLS
6.11.6
Display
The speed
1 is shown in kilometers per hour km/h or in miles per hour mph.
The tachometer
The gear display
2 shows the engine speed in revolutions per minute.
3 shows the engaged gear.
The coolant temperature appears in segment
4
.
The time appears in segment
5
.
The filling level in the fuel tank is displaced in segment
The info display
7 shows additional information.
6
.
Info
After reconnecting the battery or changing the fuse, the time must be reset.
The intensity of the LED display depends on the ambient brightness.
34
401685-11
6 CONTROLS
6.11.7
filling level display in fuel tank
35
The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel tank.
401292-01
6 CONTROLS
6.11.8
TRIP F display
36
If the fuel level drops to the reserve mark, the display mode automatically changes to
TRIP F
and starts to count from 0.0, regardless of the previous display mode.
Info
At the same time as the display mode TRIP F, the general warning lamp lights up and the warning note
Low Fuel Level appears on the info display.
401293-01
6 CONTROLS
6.11.9
Coolant temperature indicator
The temperature display consists of 13 bars. The more bars that light up, the hotter the coolant. When all bars light up, the following warning note appears on the info display:
High Coolant Temperature.
Possible states
• Engine cold – Up to three bars light up.
• Engine warm – Four to ten bars light up.
• Engine hot – Eleven to thirteen bars light up.
37
401292-01
6 CONTROLS
6.11.10 info display
Various warning notes appear on info display
1
.
If the general warning lamp lights up, the corresponding warning note is shown on the info display.
38
401291-10
6 CONTROLS
6.11.11 Riding time/average speed menu
401334-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the SET button briefly and repeatedly until the desired info display appears.
The riding time and average speed are displayed in this menu.
Info
If the ignition was switched off for over 60 minutes, the display is reset to 0.
Press the SET button briefly.
Next display mode on the info display
6.11.12 Average speed/average fuel consumption 1 menu
401465-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the SET button briefly and repeatedly until the desired info display appears.
In this menu, the average speed and the average fuel consumption 1 are displayed in
L/100 km (or L/100 miles).
39
6 CONTROLS
40
Info
The average fuel consumption 1 is displayed after several 100 meters of travel after the ignition is switched on.
If the ignition was switched off for over 60 minutes, the display of the average speed and average fuel consumption 1 is reset to 0.
Press the SET button briefly.
Next display mode on the info display
6.11.13 Average fuel consumption 1/average fuel consumption 2 menu
401466-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the SET button briefly and repeatedly until the desired info display appears.
In this menu, the average fuel consumption 1 in L/100 km (or L/100 miles) and the average fuel consumption 2 in km/L (or miles/L) are displayed.
Info
The average fuel consumption 1 and 2 are displayed after several 100 meters of travel after the ignition is switched on.
If the ignition was switched off for over 60 minutes, the display of the average fuel consumption 1 and 2 is reset to 0.
Press the SET button briefly.
Next display mode on the info display
6 CONTROLS
6.11.14 Average fuel consumption 2/service menu
401467-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the SET button briefly and repeatedly until the desired info display appears.
The average fuel consumption 2 in km/L (or miles/L) and the distance to the next service are displayed in this menu.
Info
The average fuel consumption 2 is displayed after several 100 meters of travel after the ignition is switched on.
If the ignition was switched off for over 60 minutes, the display of the average fuel consumption 2 is reset to 0.
41
Press the SET button briefly.
Next display mode on the info display
6 CONTROLS
6.11.15 Service/range menu
401468-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the SET button briefly and repeatedly until the desired info display appears.
This menu shows the distance to the next service and the range.
Info
The range depends on the average fuel consumption and the fuel quantity in the fuel tank.
The range is displayed after several 100 meters of travel after the ignition is switched on.
If the ignition was switched off for over 60 minutes, the display of the range and riding time is reset to 0.
Press the
SET button briefly.
Next display mode on the info display
42
6 CONTROLS
6.11.16 Range/riding time menu
401469-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the SET button briefly and repeatedly until the desired info display appears.
The range and the riding time are displayed in this menu.
Info
The range depends on the average fuel consumption and the fuel quantity in the fuel tank.
The range is displayed after several 100 meters of travel after the ignition is switched on.
If the ignition was switched off for over 60 minutes, the display of the range and riding time is reset to 0.
Press the
SET button briefly.
Next display mode on the info display
43
6 CONTROLS
6.11.17 Total distance menu ODO
401303-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the MODE button briefly and repeatedly until ODO appears on the display.
ODO shows the total distance covered.
Info
This value is retained, even if the battery is disconnected and/or the fuse blows.
Press the MODE button.
Next display mode on the display
6.11.18 Distance menu 1 TRIP 1
401304-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the MODE button briefly and repeatedly until TRIP 1 appears on the display.
TRIP 1 shows the distance covered since the last reset. For example, the distance from one refueling stop to the next.
TRIP 1 is always running and counts up to 999.9.
44
6 CONTROLS
Press the SET button for 5 - 10 seconds.
Press the
MODE button.
Display of TRIP 1 is reset
Next display mode on the display
6.11.19 Distance menu 2 TRIP 2
401305-01
Condition
Alternative 1
• The ignition is on.
• The motorcycle is stationary.
Alternative 2
• The ignition is on.
• The motorcycle is moving.
– Press the MODE button briefly and repeatedly until TRIP 2 appears on the display.
TRIP 2 shows the distance covered since the last reset. For example, the distance from one refueling stop to the next.
TRIP 2 is always running and counts up to 999.9.
Display of TRIP 2 is reset Press the SET button for 5 - 10 seconds.
Press the MODE button.
Next display mode on the display
45
6.11.20 Setting kilometers or miles
Info
Make the country-specific setting.
Condition
The ignition is on.
6 CONTROLS
The motorcycle is stationary.
– Press the MODE button briefly and repeatedly until ODO appears on the display.
– Press the MODE button for 5 - 10 seconds.
The display changes from km/h to mph or from mph to km/h.
46
401303-01
6.11.21 Setting the time
401303-01
Condition
The ignition is on.
The motorcycle is stationary.
– Press the MODE button briefly and repeatedly until ODO appears on the display.
– Press the MODE and SET buttons for 5 - 10 seconds.
The time display begins to flash.
– Set the hours display using the MODE button.
– Set the minutes display using the SET button.
– Press the MODE and SET buttons for 5 - 10 seconds.
The time is set.
6 CONTROLS
6.11.22 Adjusting the shift speed RPM 1
401307-01
Condition
The ignition is on.
The motorcycle is stationary.
– Press the MODE button briefly and repeatedly until TRIP 2 appears on the display.
– Press the MODE button for 5 - 10 seconds.
The display RPM 1 appears.
Info
The engine speed can be set at intervals of 50.
RPM 1 is the engine speed above which the shift warning light starts to flash.
– Set the speed with the MODE and SET buttons.
Info
The MODE button increases the value.
The SET button decreases the value.
– Do not activate the two buttons for approx. 15 seconds.
The display
RPM 1 goes out and the set speed is stored.
Info
Upon delivery, the speed of RPM 1 is set to 10000.
47
6.11.23 Adjusting the shift speed RPM 2
Condition
The ignition is on.
The motorcycle is stationary.
6 CONTROLS
401308-01
– Press the MODE button briefly and repeatedly until TRIP 2 appears on the display.
– Press the SET button for 5 - 10 seconds.
The display RPM 2 appears.
Info
The engine speed can be set at intervals of 50.
RPM 2 is the engine speed above which the shift warning light lights up constantly.
The speed
RPM 2 must always be higher than the speed RPM 1.
– Set the speed with the MODE and SET buttons.
Info
The MODE button increases the value.
The SET button decreases the value.
– Do not activate the two buttons for approx. 15 seconds.
The display RPM 2 goes out and the set speed is stored.
Info
Upon delivery, the speed of RPM 2 is set to 11000.
48
6.12
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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
6 CONTROLS
49
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations and keep it out of the reach of 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.
B00710-10
– Lift the cover
1 of the filler cap and insert the ignition key in the lock.
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 the ignition key 90° clockwise.
– Open the filler cap.
– Remove the ignition key.
6 CONTROLS
6.13
Closing the filler cap
B00711-01
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your health.
– When closing the filler cap, ensure that it is closed correctly. Change clothing that came into contact with fuel. Immediately clean skin that came into contact with fuel using soap and water.
– Close the filler cap.
– Push down the filler cap until the lock engages.
50
6.14
Seat lock
The seat lock
1 is located to the left of the seat.
It can be locked with the ignition key.
B00712-01
6 CONTROLS
6.15
Tool set
The tool set
1 is located under the passenger seat.
6.16
Grab handles
B00758-10
The grab handles
1 are used for moving the motorcycle around.
If you carry a passenger, the passenger can hold onto the grab handles during the trip.
B00717-10
51
6 CONTROLS
6.17
Passenger footrests
The passenger footrests can be folded in and out.
Possible states
• Passenger footrests folded up – For operation without a passenger.
• Passenger footrests folded down – For operation with a passenger.
6.18
Shift lever
B00713-01
Shift lever
1 is mounted on the left side of the engine.
52
B00715-10
6 CONTROLS
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
6.19
Foot brake lever
B00716-10
Foot brake lever
1 is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
B00718-10
53
6 CONTROLS
6.20
Side stand
B00714-10
The side stand
1 is on the left side of the vehicle.
The side stand is used to park the motorcycle.
Info
The side stand must be folded up during motorcycle use.
Side stand is coupled with the safety start system; see the riding instructions.
Possible states
• Side stand folded out – The vehicle can be leaned on the side stand. The safety start system is active.
• Side stand folded in – This position is mandatory for all trips. The safety start system is inactive.
54
7 PREPARING FOR USE
7.1
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 Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
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.
55
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
7 PREPARING FOR USE
56
– 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 record at vehicle handover.
– Before your first trip, read the entire operating instructions carefully.
– Get to know the controls.
– 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 to get a better feel for the vehicle.
– Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
7.2
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) 7,500 rpm
Tip
During the running-in phase, set the shift warning light to the specified engine speed.
– Adjust the shift speed RPM 1. ( p. 47)
– Adjust the shift speed RPM 2. ( p. 47)
– Avoid fully opening the throttle!
7 PREPARING FOR USE
7.3
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 Risk of breakage of suitcase system.
– If you have fitted suitcases on your motorcycle, read 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 in the dark. Check that your baggage is fixed properly at regular intervals.
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.
57
7 PREPARING FOR USE
– If you carry any baggage, make sure it is fixed 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 overall maximum permitted weight and the axle loads.
Guideline
Maximum permissible overall weight 335 kg (739 lb.)
Maximum permissible front axle load
Maximum permissible rear axle load
125 kg (276 lb.)
210 kg (463 lb.)
58
8 RIDING INSTRUCTIONS
8.1
Checks and maintenance 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 used.
– Check the engine oil level. ( p. 143)
– Check the brake fluid level of the front brake. ( p. 93)
– Check the rear brake fluid level. ( p. 98)
– Check the front brake linings. ( p. 95)
– Check the rear brake linings. ( p. 101)
– Check the brake system function.
– Check the coolant level. ( p. 134)
– Check for chain dirt accumulation. ( p. 81)
– Check the chain tension. ( p. 82)
– Check the tire condition. ( p. 109)
– Check the tire air pressure. ( p. 110)
– Check the settings of all controls and ensure that they can be operated smoothly.
– Check the functioning of the electrical equipment.
– Check that baggage is correctly secured.
– Sit on the motorcycle and check the rear mirror setting.
– Check the fuel level.
59
8 RIDING INSTRUCTIONS
8.2
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 Unfiltered intake air has a negative effect on the service life of the engine.
– Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
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.
60
8 RIDING INSTRUCTIONS
B00782-10
61
– Sit on the vehicle, take the weight off of the side stand, and move up all the way.
– Turn the emergency OFF switch to the position .
– Switch on the ignition by turning the ignition key to the position .
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.
– Shift gear to neutral.
The green idling speed indicator lamp N lights up.
The ABS warning lamp lights up and goes back out after starting off.
– Press the electric starter button .
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 starter for a maximum of 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 is pulled when a gear is engaged. If the side stand is folded out and you shift into gear and release the clutch, the engine stops.
8 RIDING INSTRUCTIONS
Switching off ABS
KTM recommends riding with ABS at all times. However, situations may arise in which
ABS is not advantageous.
Condition
Vehicle stationary, engine running.
– Press the
1 button for 3 – 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
62
401685-15
8.3
Starting off
– Pull the clutch lever, engage 1st gear, release the clutch lever slowly, and simultaneously open the throttle carefully.
Tip
If the engine dies while starting off, only pull the clutch lever and press the electric starter button. You do not need to shift into neutral.
8.4
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.
8 RIDING INSTRUCTIONS
63
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 able to hold himself or herself properly on the passenger seat, to hold onto the rider or to hold onto the handrails and place his or her feet onto the passenger footrests. Note the regulations governing the minimum age of passengers in your country.
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.
8 RIDING INSTRUCTIONS
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 Overheating of engine.
– If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have engine failure.
64
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
B00716-10
– When conditions allow (incline, road situation, etc.), you can shift into a higher gear.
– Release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch and open the throttle.
Info
You can see the positions of the 6 forward gears in the figure. The neutral or idle position is between the first and second gears. First gear is used for starting off or for steep inclines.
The operating temperature is reached when 4 bars of the temperature indicator light up.
8 RIDING INSTRUCTIONS
65
– Accelerate only up to a speed suitable for the road surface and weather conditions. Particularly in bends, do not shift, and accelerate very carefully.
– To shift down, brake if necessary and close the throttle at the same time.
– Pull the clutch lever and shift into a lower gear, release the clutch lever slowly and open the throttle or shift again.
– Switch off the engine if you expect to be standing for a long time.
– If the engine diagnosis warning lamp lights up during a trip, stop immediately, switch off the engine, and contact an authorized KTM workshop.
8.5
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.
8 RIDING INSTRUCTIONS
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.
66
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 Excessively forceful braking can cause the wheels to block.
– ABS must be switched on to be effective.
– When braking, release the throttle and apply the front and rear brakes at the same time.
Info
When ABS is active, 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.
– Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
– On long downhill stretches, use the braking effect of the engine. 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.
8 RIDING INSTRUCTIONS
8.6
Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
– Never leave the vehicle 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
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.
Note
Material damage Damage and destruction of components by excessive load.
– The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
67
– Brake the motorcycle.
– Shift gear to neutral.
8 RIDING INSTRUCTIONS
– Switch off the ignition by turning the ignition key to the position .
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 and the battery will discharge. You should therefore always switch off the engine with the ignition key - the emergency OFF switch is intended for emergencies only.
– 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 fully to the left, pressing down the ignition key to position and turning it to position .
To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the ignition key.
68
8.7
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.
8 RIDING INSTRUCTIONS
– Switch off the engine and remove the ignition key.
– Use tension belts or other suitable devices to secure the motorcycle against accidents or falling over.
69
401448-01
8.8
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.
– Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
– Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact 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.)
8 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.
– Open the filler cap. ( p. 48)
– Fill the fuel tank with fuel up to the lower edge
1 of the fuel filler.
Total fuel tank capacity, approx.
11 l (2.9 US gal)
– Close the filler cap. ( p. 50)
Super unleaded (ROZ 95/RON 95/PON
70
B00719-10
9 SERVICE SCHEDULE
9.1
Service schedule
Check the functioning of the electrical equipment.
Read out the fault memory using the KTM diagnostics tool.
Change the engine oil and oil filter, clean the oil screen.
Check the front brake linings. ( p. 95)
Check the rear brake linings. ( p. 101)
Check the brake discs. ( p. 92)
Check the brake lines for damage and leakage.
Check the rear brake fluid level. ( p. 98)
x
Check the shock absorber and fork for leaks. Perform a fork and shock absorber service if needed and depending on vehicle use.
Every 10,000 km (6,214 mi) or every 2 years
Every 5,000 km (3,107 mi) or annually
Once after 1,000 km (621.4 mi)
○
○
○
●
●
●
●
●
●
○
○
○
○
○
○
●
●
●
●
●
●
●
●
●
●
●
●
Check the swingarm bearing.
x
Check the wheel bearing for play.
x
Check the tire condition. ( p. 109)
Check the tire air pressure. ( p. 110)
Check the chain, rear sprocket, and engine sprocket. ( p. 85)
Check the chain tension. ( p. 82)
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.
Clean the dust boots of the fork legs.
Check the brake fluid level of the front brake. ( p. 93)
Check the steering head bearing play.
x
○
○
○
○
○
○
●
●
●
●
●
●
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●
●
●
●
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71
9 SERVICE SCHEDULE
Every 10,000 km (6,214 mi) or every 2 years
Every 5,000 km (3,107 mi) or annually
Once after 1,000 km (621.4 mi)
Change the spark plugs.
Check the valve clearance.
x x
○
●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and bellows for cracking, leaks, and correct routing.
Check the antifreeze and coolant level. ( p. 132)
x
○ ●
○ ● ●
●
●
Check the cables for damage and routing without sharp bends.
x
● ●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
x
○ ● ●
● ●
Change the air filter. Clean the air filter box.
x
Check the screws and nuts for tightness.
x
Change the front brake fluid.
x
○ ● ●
●
Change the rear brake fluid.
x
Check the headlight setting. ( p. 127)
○ ●
●
●
Check that the radiator fan is functioning properly.
x
Final check: Check the vehicle for roadworthiness and take a test ride.
Read out the fault memory using the KTM diagnostics tool after a test ride.
Make the service entry in KTM DEALER.NET and in the service record.
x x
○
○
○
○
●
●
●
●
●
●
●
●
○ One-time interval
● Periodic interval
72
10 TUNING THE CHASSIS
10.1
Adjusting the spring preload of the shock absorber
x
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.
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 baggage and a passenger, thus ensuring an ideal compromise between maneuverability and stability.
B00720-10
– Turn adjusting ring
1 to adjust the spring preload.
Guideline
Spring preload
Standard
Full payload
3 clicks
6 clicks
Hook wrench (T106S)
Info
The spring preload can be set to 10 different positions.
73
10 TUNING THE CHASSIS
10.2
Adjusting the shift lever
Info
The adjustment range of the shift lever is limited.
B00780-10
– Loosen nuts
1
.
– Adjust the shift lever by turning shift rod
2
.
Guideline
Shift rod adjustment range
A
100… 112 mm (3.94… 4.41 in)
Info
Make the same adjustments on both sides.
At least five screw threads must be screwed into the seating.
– Check adjusting angle
B
.
Guideline
Adjusting angle shift lever
B shift rod, deflector,
– Tighten nuts
1
.
90°
Info
After the nuts have been tightened, the bearings of the shift rod must be centrally and identically aligned to each other in order to ensure freedom of movement in the bearing shells.
– Check the shift lever to ensure it is functioning properly and can move freely.
74
11 SERVICE WORK ON THE CHASSIS
11.1
Raising the motorcycle with the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
75
– Mount the support of the wheel stand.
– Insert the adapter in the rear wheel stand.
Adapter (61029055130)
Rear wheel stand (61029055400)
– Stand the motorcycle upright, align the lifting gear with the swingarm and the adapters, and lift the motorcycle.
B01387-01
11.2
Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
– Always place the vehicle on a firm and even surface.
11 SERVICE WORK ON THE CHASSIS
– Secure the motorcycle against falling over.
– Remove the rear wheel stand and lean the vehicle on the side stand
– Remove the support of the wheel stand.
1
.
76
B00714-10
11.3
Raising the motorcycle with the front wheel stand
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
– Raise the motorcycle with the rear wheel stand. ( p. 75)
Condition
– Remove cap
1
.
C00196-10
11 SERVICE WORK ON THE CHASSIS
77
– Move the handlebar to the straight-ahead position. Attach the lifting gear to the steering stem.
Adapter (61029955620)
Front wheel stand (61029055500)
Info
Always raise the rear of the motorcycle first.
– Raise the front of the motorcycle.
C00197-01
11.4
Taking the motorcycle off of the front wheel stand
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 wheel stand.
B01388-01
11 SERVICE WORK ON THE CHASSIS
– Mount cap
1
.
C00196-10
11.5
Removing the passenger seat
– Insert the ignition key in seat lock
1 and turn it clockwise.
– Raise the rear of the seat, push it towards the rear, and remove it upwards.
– Remove the ignition key from the seat lock.
B00712-01
78
11 SERVICE WORK ON THE CHASSIS
11.6
Mounting the passenger seat
B00724-10
79
– Attach hooks
1 on the passenger seat to brackets
2 on the subframe, and lower it at the rear while pushing forward.
– Press down the passenger seat until it clicks into place.
Warning
Danger of accidents The passenger seat can come loose from the anchoring if it is not mounted correctly.
– After mounting the passenger seat, check that it is locked correctly by pulling up.
– Finally, check that the passenger seat is correctly mounted.
11.7
Removing the seat
Preparatory work
– Remove the passenger seat. ( p. 78)
Main work
– Remove screws
1
.
– Raise the rear of the seat, pull it towards the rear, and remove it upwards.
B00725-10
11 SERVICE WORK ON THE CHASSIS
11.8
Mounting the seat
Main work
– Attach seat recesses
A at screws
1 and lower at the rear.
– Mount and tighten screws
2
.
Guideline
Screw, seat M6 11 Nm (8.1 lbf ft)
80
B00727-10
Finishing work
– Mount the passenger seat. ( p. 79)
11 SERVICE WORK ON THE CHASSIS
11.9
Checking for chain dirt accumulation
– Check the chain for coarse dirt accumulation.
» If the chain is very dirty:
400678-01
11.10
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.
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.
81
11 SERVICE WORK ON THE CHASSIS
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. 173)
400725-01
11.11
Checking the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.
82
11 SERVICE WORK ON THE CHASSIS
– Lean the motorcycle on the side stand.
– Shift gear to neutral.
– In the area of chain sliding guard, press the chain upward toward the swingarm and determine chain tension
A
.
83
Info
The upper chain section
B must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Chain tension 5… 7 mm (0.2… 0.28 in)
» If the chain tension does not meet specifications:
– Adjust the chain tension. ( p. 83)
B00731-10
11.12
Adjusting the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
– If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.
11 SERVICE WORK ON THE CHASSIS
Preparatory work
– Check the chain tension. ( p. 82)
Main work
– Loosen nut
1
.
– Loosen nuts
2
.
– Adjust the chain tension by turning adjusting screws
3 on the left and right.
Guideline
Chain tension 5… 7 mm (0.2… 0.28 in)
Turn adjusting screws right chain adjuster
4
3 on the left and right so that the markings on the left and are in the same position in relation to reference marks rear wheel is then correctly aligned.
C
. The
84
B01389-10
Info
The upper chain section must be taut.
Chain wear is not always even, so you should check the setting at different chain positions.
– Tighten nuts
2
.
– Make sure that chain adjusters
4 are fitted correctly on adjusting screws
3
.
– Tighten nut
1
.
Guideline
Nut, rear wheel spindle M14x1.5
60 Nm
(44.3 lbf ft)
11 SERVICE WORK ON THE CHASSIS
11.13
Checking the chain, rear sprocket, and engine sprocket
– Check the rear sprocket and engine sprocket for wear.
» If the rear sprocket and engine sprocket are worn:
– Change the power set.
x
Info
The engine sprocket, rear sprocket, and chain should always be replaced together.
85
100132-10
11 SERVICE WORK ON THE CHASSIS
– Shift gear to neutral.
– Pull the lower chain section with specified weight
A
.
Guideline
Weight, chain wear measurement 15 kg (33 lb.)
– Measure the distance
B of 20 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.
86
1 2 3 18 19 20
401288-10
Maximum distance chain section
B at the longest 301.6 mm (11.874 in)
» If the distance
B is greater than the specified measurement:
– Change the power set.
x
Info
When the chain is replaced, the rear sprocket and engine sprocket should also be changed.
New chains wear out faster on old, worn sprockets.
11 SERVICE WORK ON THE CHASSIS
– Remove screws
2 and
3 and release screw
1
. Push the chain guard aside.
87
C00198-10
– Check the chain sliding guard for wear.
» If drill hole
D becomes visible on the chain sliding guard in area
C
:
– Change the chain sliding guard.
x
– Check that the chain sliding guard is firmly seated.
» If the chain sliding guard is loose:
– Tighten the chain sliding guard.
C00199-10
11 SERVICE WORK ON THE CHASSIS
– Position the chain guard and tighten screw
1
.
Guideline
Screw, chain guard
EJOT PT ®
– Tighten screw
2
.
Guideline
Screw, chain guard
– Tighten screw
3
.
Guideline
Remaining screws, chassis
EJOT PT ®
M5
4 Nm (3 lbf ft)
4 Nm (3 lbf ft)
5 Nm (3.7 lbf ft)
88
C00198-10
11 SERVICE WORK ON THE CHASSIS
11.14
Removing the front spoiler
– Remove screws
1
.
B00770-10
– Remove screws
2
.
– Take off the front spoiler.
B00771-10
89
11 SERVICE WORK ON THE CHASSIS
11.15
Fitting front spoiler
– Position the front spoiler. Mount screws
1 but do not tighten yet.
90
B00770-10
– Mount and tighten screws
2
.
Guideline
Remaining screws, chassis
– Tighten screw
1
.
Guideline
Remaining screws, chassis
B00771-10
M6
M6
10 Nm (7.4 lbf ft)
10 Nm (7.4 lbf ft)
12 BRAKE SYSTEM
12.1
ABS/antilock brake system
91
401687-10
The ABS unit
1
, which consists of a hydraulic unit, ABS control unit, and return pump, is installed under the seat. A wheel speed sensor
2 is located at the front and rear wheels.
Warning
Danger of accidents Functional limitations of the ABS
– The rear wheel may only be spun with the front brake applied (burn out) if the
ABS is switched off.
– If the vehicle has been modified, such as shortened or lengthened spring deflections, different rim diameters, different tires, the wrong tire air pressure, different brake linings, etc., the ABS will not function optimally. Optimal functioning of the ABS is only ensured if the brake system only contains spare parts and tires that have been approved and/or recommended by KTM.
– Service work and repairs must be performed properly. (Your authorized KTM workshop will be glad to help.)
The ABS is a safety system that prevents locking of the wheels when the vehicle is traveling straight ahead without the action of lateral forces.
Warning
Danger of accidents Rolling over of the vehicle
– It is not always possible to prevent rolling over of the vehicle 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 riding ability.
The ABS operates with two independent brake circuits (front and rear brakes). During normal operation, the brake system operates like a conventional brake system without ABS.
When the ABS control unit detects the tendency of a wheel to lock, the ABS begins regulating the braking pressure. The control process causes the hand and foot brake levers to vibrate slightly.
12 BRAKE SYSTEM
92
The ABS warning lamp
3 must light up briefly after the ignition is switched on and should then go out after starting off. If it does not go out after starting off or if it lights up 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 warning 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 reenable the ABS, the vehicle must be stopped and the ignition switched off. The ABS is reenabled when the vehicle is switched on again. The ABS warning lamp goes out when you start off.
Button
4 can be used to switch ABS off manually (see Starting).
12.2
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.)
400480-10
– Check the thickness of the front and rear brake discs at several places on the disk to see if it conforms to measurement
A
.
Info
Wear reduces the thickness of the brake disc in area
1 of the brake disc.
Brake discs - wear limit
Front
Rear
3.6 mm (0.142 in)
3.6 mm (0.142 in)
» If the brake disc thickness is less than the specified value:
12 BRAKE SYSTEM
– Change the brake discs.
x
– Check the front and rear brake discs for damage, cracking, and deformation.
» If the brake disc shows signs of damage, cracking, or deformation:
– Change the brake discs.
x
12.3
Checking the brake fluid level of the front brake
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.)
93
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Check the brake fluid level in viewer
1
.
» If the brake fluid is below the MIN marking:
– Add front brake fluid.
C00200-10
12 BRAKE SYSTEM
12.4
Adding front brake fluid
x
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.)
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.
94
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
12 BRAKE SYSTEM
C00201-10
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
– Remove screws
1
.
– Remove cover
2 with membrane
– Add brake fluid to level
A
.
3
.
Guideline
Level
A
5 mm (0.2 in)
Brake fluid DOT 4 / DOT 5.1 ( p. 170)
– Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
95
12.5
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.
12 BRAKE SYSTEM
96
– Check the brake linings for minimum thickness
A
.
Minimum thickness
A
≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the front brake linings.
x
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the front brake linings.
x
B00739-10
12.6
Checking the free travel of foot brake lever
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications.
12 BRAKE SYSTEM
– Disconnect spring
1
.
– Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel
A
.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
» If the free travel does not meet specifications:
– Adjust the free travel of the foot brake lever.
– Reconnect spring
1
.
x
97
B00735-10
12.7
Adjusting the free travel of the foot brake lever
x
Warning
Danger of accidents Brake system failure.
– If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications.
12 BRAKE SYSTEM
– Disconnect spring
– Release nut
2
1
.
and use screw
3 to adjust the specified free travel
A
.
Guideline
Free travel at foot brake lever 3… 5 mm (0.12… 0.2 in)
Info
The range of adjustment is limited.
– Hold screw
3
– Attach spring and tighten nut
1
.
2
.
98
B00737-10
12.8
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.)
12 BRAKE SYSTEM
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.)
99
– Stand the vehicle upright.
– Check the brake fluid level in the brake fluid reservoir.
» If the fluid level reaches the MIN mark
– Add rear brake fluid.
1
:
C00202-10
12.9
Adding rear brake fluid
x
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.
12 BRAKE SYSTEM
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.)
100
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
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
– Stand the vehicle upright.
– Remove screw cap
1 with membrane
2
.
– Add brake fluid to level
A
.
Brake fluid DOT 4 / DOT 5.1 ( p. 170)
– Refit screw cap with membrane.
Info
Clean up overflowed or spilt brake fluid immediately with water.
C00203-10
12 BRAKE SYSTEM
12.10
Checking the rear 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.
– Check the brake linings for minimum thickness
A
.
Minimum thickness
A
≥ 1 mm (≥ 0.04 in)
» If the minimum thickness is less than specified:
– Change the rear brake linings.
x
– Check the brake linings for damage and cracking.
» If there is wear or tearing:
– Change the rear brake linings.
x
B01390-10
101
13 WHEELS, TIRES
13.1
Removing the front wheel
x
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 75)
– Raise the motorcycle with the front wheel stand. ( p. 76)
Main work
– Remove screws
1 and push the fender to the side.
– Remove screw
2 and pull wheel speed sensor
3 out of the hole.
– Loosen screws
4 and screw
5
.
– Unscrew screw
5 about six turns and press your hand on the screw to push the wheel spindle out of the axle clamp. Remove screw
5
.
Warning
Danger of accidents Reduced braking effect caused by damaged brake discs.
– Always lay the wheel down 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.
Info
Do not pull the hand brake lever when the front wheel is removed.
102
B01391-10
13 WHEELS, TIRES
13.2
Installing the front wheel
x
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.
Main work
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the wheel bearing.
– Clean and grease the shaft seal rings x
1 and mating surfaces
A of the spacers.
– Insert the spacers.
B01392-10
103
13 WHEELS, TIRES
B01391-11
– Clean the thread of the wheel spindle and screw
2
.
– Position the front wheel and insert the wheel spindle.
The brake linings are correctly positioned.
– Mount and tighten screw
2
.
Guideline
Screw, front wheel spindle M8 25 Nm
(18.4 lbf ft)
– Insert wheel speed sensor
3 into the hole. Mount and tighten screw
4
.
Guideline
Screw, wheel speed sensor M6 8 Nm (5.9 lbf ft)
– Mount and tighten screws
5
.
– Take the motorcycle off of the front wheel stand. ( p. 77)
– Pull the front wheel brake and push down hard on the fork several times to align the fork legs.
– Tighten screws
6
.
Guideline
Screw, fork stub M8 15 Nm
(11.1 lbf ft)
Finishing work
– Take the motorcycle off of the rear wheel stand. ( p. 75)
104
13.3
Removing the rear wheel
x
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 75)
Main work
– Remove screw
1 and pull wheel speed sensor
2 out of the hole.
13 WHEELS, TIRES
105
– Remove nut
3 and the washer. Remove chain adjuster
– Holding the rear wheel, withdraw wheel spindle
5
.
4
.
– Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
Warning
Danger of accidents Reduced braking effect caused by damaged brake discs.
– Always lay the wheel down in such a way that the brake discs are not damaged.
– Pull the rear wheel back and take it out of the swingarm.
Info
Do not operate the foot brake when the rear wheel is removed.
B01393-10
13.4
Installing the rear wheel
x
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.
13 WHEELS, TIRES
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.
B01394-10
106
Main work
– Check the rear hub rubber dampers.
x
– Check the wheel bearing for damage and wear.
» If the wheel bearing is damaged or worn:
– Change the wheel bearing.
– Clean and grease the shaft seal rings x
1 and mating surfaces
A of the spacers.
– Clean the thread of the wheel spindle and nut
2
.
– Clean the fixing locations on the brake caliper support and swingarm.
– Install the rubber damper and rear sprocket carrier on the rear wheel.
– Position the rear wheel.
The brake linings are correctly positioned.
– Push the rear wheel as far forward as possible and place the chain on the rear sprocket.
13 WHEELS, TIRES
107
– Pull the rear wheel back and mount wheel spindle
3
.
Info
Mount the left and right chain adjusters
4 in the same position.
– Mount nut
2 and washer.
– Push the rear wheel forward so that the chain adjusters are on the screws, and tighten nut
2
.
Guideline
In order for the rear wheel to be correctly aligned, the markings on the left and right chain adjusters must be in the same position relative to the reference marks
B
.
Nut, rear wheel spindle M14x1.5
60 Nm
(44.3 lbf ft)
– Insert wheel speed sensor
5 into the hole. Mount and tighten screw
6
.
Guideline
Screw, wheel speed sensor M6 8 Nm (5.9 lbf ft)
B01393-11
Finishing work
– Take the motorcycle off of the rear wheel stand. ( p. 75)
13.5
Checking the rear hub rubber dampers
x
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. They eventually wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
13 WHEELS, TIRES
108
Preparatory work
– Raise the motorcycle with the rear wheel stand. ( p. 75)
– Remove the rear wheel.
Main work
– Check bearing
1
.
» If the bearing is damaged or worn:
– Change the bearing.
– Check the rubber dampers x
2 of the rear hub for damage and wear.
» If the rubber dampers of the rear hub are damaged or worn:
– Change all rubber dampers in the rear hub.
B00746-10
B00747-10
– Lay the read wheel on a workbench with the rear sprocket facing upwards and insert the wheel spindle in the hub.
– To check the play
A
, hold the rear wheel tight and try to rotate the rear sprocket.
Info
Measure the play on the outside of the rear sprocket.
Play in rubber dampers, rear wheel
≤ 5 mm (≤ 0.2 in)
» If play
A is larger than the specified value:
– Change all rubber dampers in the rear hub.
Finishing work
– Install the rear wheel.
– Take the motorcycle off of the rear wheel stand. ( p. 75)
13 WHEELS, TIRES
13.6
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 Uncontrollable handling characteristic due to non-approved and/or non-recommended tires/wheels.
– Only tires/wheels approved by KTM and with the corresponding speed index should be used.
109
Info
The type, condition and air pressure of the tires all have a major impact on the riding behavior of the motorcycle.
Worn tires have a negative effect on riding behavior, especially on wet surfaces.
400602-10
– Check the front and rear tires for cuts, run-in objects and other damage.
» If the tires exhibit cuts, run-in objects or other damage:
– Change the tires.
– Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth
≥ 2 mm (≥ 0.08 in)
13 WHEELS, TIRES
110
» If the tread depth is less than the minimum permissible depth:
– Change the tires.
– Check the age of the tires.
Info
The tire's date of the manufacture is usually part of the tire markings and is indicated by the last four digits of the DOT marking. The first two digits refer to the week of manufacture and last two digits refer to the year of manufacture.
KTM recommends that the tires are changed regardless of the actual wear, at the latest after 5 years.
» If a tire is more than 5 years old:
– Change the tires.
13.7
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 tire air pressure when the tires are cold.
Tire air pressure, solo
Front
Rear
2.0 bar (29 psi)
2.0 bar (29 psi)
Tire air pressure with passenger/full payload
Front
Rear
2.0 bar (29 psi)
2.2 bar (32 psi)
13 WHEELS, TIRES
» If the tire air pressure does not meet specifications:
– Correct the tire air pressure.
– Mount the dust cap.
111
14 ELECTRICAL SYSTEM
14.1
Removing the battery
x
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 the battery away from sparks or open flames. Charge only in well-ventilated areas.
– 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.
112
Preparatory work
– Remove the passenger seat. ( p. 78)
Main work
– Pull back the negative terminal cover
– Disconnect the negative cable
2
1
.
of the battery.
B00750-10
14 ELECTRICAL SYSTEM
– Pull back the positive terminal cover
3
.
– Disconnect the positive cable
4 of the battery.
– Detach rubber band
5
.
– Pull the battery up and out of the battery holder.
113
Info
Never operate the motorcycle with a discharged battery or without a battery. In both cases, electrical components and safety devices can be damaged. The vehicle is therefore no longer roadworthy.
B00751-10
14.2
Installing the battery
x
Main work
– Position the battery in the battery holder.
Info
The battery terminals must be at the top.
– Attach rubber band
1
.
– Reconnect the positive cable
2 of the battery.
– Position positive terminal cover
3
.
B00751-11
14 ELECTRICAL SYSTEM
– Connect the negative cable
4 of the battery.
– Position the negative terminal cover
5
.
B00750-11
Finishing work
– Mount the passenger seat. ( p. 79)
14.3
Recharging the battery
x
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 the battery away from sparks or open flames. Charge only in well-ventilated areas.
– 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.
114
14 ELECTRICAL SYSTEM
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
– Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
115
Info
Even when there is no load on the battery, it still loses power 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, which means that the acid level does not need to be checked.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the passenger seat. ( p. 78)
– Disconnect the negative cable of the battery to avoid damage to the motorcycle's electronics.
14 ELECTRICAL SYSTEM
116
Main work
– Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the battery, and to test the alternator. With this device, you cannot overcharge the battery.
Info
Never remove lid housing
2
.
1
.
Charge the battery with a maximum of 10% of the capacity specified on battery
– Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the motorcycle is not in use
3 months
B01395-10
Finishing work
– Mount the passenger seat. ( p. 79)
14 ELECTRICAL SYSTEM
14.4
Changing the ABS fuses
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
Two fuses for the ABS are located under the passenger seat. These fuses protect the return pump and the hydraulic unit of the
ABS. The third fuse, which protects the ABS control unit, is located in the fuse box.
Preparatory work
– Switch off all power consumers and the engine.
– Remove the passenger seat. ( p. 78)
To change the fuse of the ABS hydraulic unit:
– Take off the protection cap and remove fuse
– Insert the new fuse.
1
.
– Mount the protection cap.
117
B01396-10
14 ELECTRICAL SYSTEM
To change the fuse of the ABS return pump:
– Take off the protection cap and remove fuse
– Insert the new fuse.
2
.
– Mount the protection cap.
B01396-11
Finishing work
– Mount the passenger seat. ( p. 79)
14.5
Changing the fuses of individual power consumers
Info
The fuse box with the main fuse and the fuses of the individual power consumers is located under the passenger seat.
Preparatory work
– Switch off all power consumers and switch off the engine.
– Remove the passenger seat. ( p. 78)
118
14 ELECTRICAL SYSTEM
B01397-01
119
Main work
– Open fuse box cover.
– Remove the defective fuse.
Guideline
Fuse 1 - 30 A - main fuse
Fuse 2 - 15 A - combination instrument
Fuse 3 - 10 A - control unit, main relay
Fuse
4 - 15 A - ignition coil, alarm system (OPTIONAL)
Fuse 5 - 15 A - radiator fan
Fuse 6 - 15 A - horn, brake light, turn signal, high beam, low beam, parking light, tail light, license plate lamp
Fuse 7 - 10 A - ABS
Fuse 8 - 10 A - for auxiliary equipment (permanent positive)
Fuse
9 - 10 A - for auxiliary equipment (accessories connected with ignition switch)
Fuse 10 - 10 A - control unit
Info
A defective fuse is indicated by a burned-out fuse wire
A
.
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
– Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
– Use spare fuses with the correct rating only.
14 ELECTRICAL SYSTEM
Tip
Replace the spare fuse in the fuse box so that it is available if needed.
– Check that the power consumer is functioning properly.
– Close the fuse box cover.
Finishing work
– Mount the passenger seat. ( p. 79)
14.6
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.
120
Preparatory work
– Switch off all power consumers and switch off the engine.
Main work
– Remove expanding rivets
1
.
601915-10
14 ELECTRICAL SYSTEM
– Remove screws
2
.
– Lift the headlight mask slightly and swing forward.
601914-10
– Take off protection cap
3
.
– Disconnect plug-in connector
4
.
B00760-10
– Detach retaining clamp
5
.
– Remove headlight bulb
6
.
– Position the new headlight bulb in the headlight housing.
Headlight (H4/socket P43t) ( p. 164)
Info
Insert the headlight bulb so that the catches latch into the recesses.
B00761-10
121
14 ELECTRICAL SYSTEM
– Attach retaining clamp
5
.
– Connect plug-in connection
4
.
– Mount protection cap
3
.
B00760-10
– Fold the headlight mask up.
– Mount and tighten screws
2
.
Guideline
Screw, headlight mask
601914-10
M6 11 Nm (8.1 lbf ft)
122
14 ELECTRICAL SYSTEM
– Mount expanding rivets
1 on both sides.
– Check that the lighting is functioning properly.
601915-10
14.7
Changing the parking light 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.
Preparatory work
– Switch off all power consumers and switch off the engine.
Main work
– Remove expanding rivets
1
.
123
601915-10
14 ELECTRICAL SYSTEM
– Remove screws
2
.
– Lift the headlight mask slightly and swing forward.
304865-10
– Remove screws
3
.
– Take off cover
4
.
B00762-10
124
14 ELECTRICAL SYSTEM
– Pull the socket with bulb
– Remove the bulb.
5 out of the housing.
– Position a new light bulb in the socket.
Parking light (W5W/socket W2.1x9.5d) ( p. 164)
– Position the socket with bulb
5 in the housing.
125
B00763-10
– Position cover
4
.
– Mount and tighten screws
3
.
B00762-10
14 ELECTRICAL SYSTEM
– Fold the headlight mask up.
– Mount and tighten screws
2
.
Guideline
Screw, headlight mask M6
304865-10
– Mount expanding rivets
1 on both sides.
– Check that the lighting is functioning properly.
126
11 Nm (8.1 lbf ft)
601915-10
14 ELECTRICAL SYSTEM
127
14.8
Checking the headlight setting
– Position the vehicle upright on a horizontal surface in front of a light wall and make a mark at the height of the center of the low beam headlight.
– Make another mark at a distance
B under the first mark.
Guideline
Distance
B
5 cm (2 in)
400726-10
– Position the vehicle vertically at a distance beam.
A in front of the wall and switch on the low
Guideline
Distance
A
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. 128)
14 ELECTRICAL SYSTEM
14.9
Adjusting the headlight range
Main work
– Remove expanding rivets
1
.
601915-10
– Remove screws
2
.
– Lift the headlight mask slightly and swing forward.
601914-10
128
14 ELECTRICAL SYSTEM
– Adjust the beam distance of the headlight by turning screw
3
.
Guideline
For a motorcycle with rider, and with luggage and a passenger if applicable, the light/dark boundary must be exactly on the lower mark (applied in: Checking headlight adjustment).
B00764-10
129
Info
Turn clockwise to increase the headlight range; turn counterclockwise to reduce the headlight range.
– Fold the headlight mask up.
– Mount and tighten screws
2
.
Guideline
Screw, headlight mask M6 11 Nm (8.1 lbf ft)
601914-10
– Mount expanding rivets
1 on both sides.
601915-10
14 ELECTRICAL SYSTEM
Finishing work
– Check the headlight setting. ( p. 127)
130
15 COOLING SYSTEM
15.1
Cooling system
131
Water pump
The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap
1
2 in the engine circulates the coolant.
. Heat expansion causes excess coolant to flow into compensating tank
3
.
When the temperature falls, this surplus coolant is sucked back into the cooling system.
This ensures that operating the vehicle at the specified coolant temperature will not result in a risk of malfunctions.
125 °C (257 °F)
B00765-10
15 COOLING SYSTEM
132
The coolant is cooled by the air stream and a radiator fan moswitch.
4
, which is controlled by a ther-
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.
401287-10
15.2
Checking the antifreeze and coolant level
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.
15 COOLING SYSTEM
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
133
B00766-10
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Remove the cap of the compensating tank
1
.
– Check the coolant antifreeze.
−25… −45 °C (−13… −49 °F)
» If the coolant antifreeze does not meet specifications:
– Correct the coolant antifreeze.
– Check the coolant level in the compensating tank.
The coolant level must be between MIN and MAX.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Alternative 2
Coolant (mixed ready to use) ( p. 170)
– Mount the cap of the compensating tank.
15 COOLING SYSTEM
B00767-10
– Screw off radiator cap
2
.
– Check the coolant antifreeze.
−25… −45 °C (−13… −49 °F)
» If the coolant antifreeze does not meet specifications:
– Correct the coolant antifreeze.
– Check the coolant level in the radiator.
The radiator must be completely filled.
» If the coolant level does not meet specifications:
– Correct the coolant level and find out the cause of the loss.
Alternative 1
Alternative 2
Coolant (mixed ready to use) ( p. 170)
» If you had to add more coolant than the specified amount:
> 0.20 l (> 0.21 qt.)
– Fill/bleed the cooling system.
– Mount the radiator cap.
15.3
Checking the coolant level
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.
134
15 COOLING SYSTEM
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
135
B00766-10
Condition
The engine is cold.
– Stand the motorcycle upright on a horizontal surface.
– Check the coolant level in the compensating tank
1
.
The coolant level must be between MIN and MAX.
» If the coolant level does not meet specifications:
– Correct the coolant level.
Alternative 1
Alternative 2
Coolant (mixed ready to use) ( p. 170)
– Screw off radiator cap
2 and check the coolant level in the radiator.
The radiator must be completely filled.
» If the coolant level does not meet specifications:
– Correct the coolant level and find out the cause of the loss.
Alternative 1
B00767-10
15 COOLING SYSTEM
Alternative 2
Coolant (mixed ready to use) ( p. 170)
» If you had to add more coolant than the specified amount:
> 0.20 l (> 0.21 qt.)
– Fill/bleed the cooling system.
– Mount the radiator cap.
15.4
Draining the coolant
x
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.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
136
Condition
The engine is cold.
Preparatory work
– Remove the front spoiler. ( p. 89)
15 COOLING SYSTEM
B00768-10
Main work
– Stand the motorcycle upright.
– Place a suitable container under the engine.
– Remove screw
1
.
– Remove the radiator cap.
– Completely drain the coolant.
– Mount screw
1 with a new seal ring and tighten it.
Guideline
Plug, water pump drain hole (125 Duke) M6
Plug, water pump drain hole
(200 Duke EU/MAL)
M6
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
15.5
Filling/bleeding the cooling system
x
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
– Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
137
15 COOLING SYSTEM
– Remove radiator cap
1
.
138
B00767-11
B00769-10
– Remove bleeder screw
2
.
– Tilt the vehicle slightly to the right.
– Pour in coolant until it emerges without bubbles at the vent hole, and then mount and tighten the bleeder screw immediately.
Alternative 1
Alternative 2
Coolant (mixed ready to use) ( p. 170)
– Fill the radiator completely with coolant. Mount the radiator cap.
– Rest the vehicle on the side stand.
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.
15 COOLING SYSTEM
139
– Start the engine and let it run warm.
– Stop the engine and allow it to cool down.
– When the engine is cool, check the coolant level in the radiator and, if necessary, add coolant.
– Remove the cap of the compensating tank up to the MAX mark.
3 and add coolant until the coolant level is
– Mount the cap of the compensating tank.
– Fit the front spoiler. ( p. 90)
B00766-11
16 TUNING THE ENGINE
140
16.1
Checking the play in the throttle cable
– Check the throttle grip for smooth operation.
– Move the handlebar to the straight-ahead position. Move the throttle grip backwards and forwards to ascertain the play in the throttle cable.
Throttle cable play 3… 5 mm (0.12… 0.2 in)
» If the throttle cable play does not meet specifications:
– Adjust the play in the throttle cable.
x
400192-10
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 let it run idle. Move the handlebar to and fro over the entire steering range.
The idle speed must not change.
» If the idle speed changes:
– Check the throttle cable routing.
16 TUNING THE ENGINE
16.2
Adjusting the play in the throttle cable
x
– Move the handlebar to the straight-ahead position.
– Push back sleeve
1
.
– Loosen lock nut
2
.
– Adjust the play in the throttle cable by turning adjusting screw
3
.
Guideline
Throttle cable play 3… 5 mm (0.12… 0.2 in)
– Tighten lock nut
– Slide on sleeve
2
1
.
.
B00728-10
16.3
Checking the clutch lever play
– Check the clutch lever for smooth operation.
– Move the handlebar to the straight-ahead position. Lightly pull the clutch lever and ascertain the clutch lever play
A
.
Clutch lever play 1… 3 mm (0.04… 0.12 in)
» If the clutch lever play does not meet specifications:
– Adjust the clutch cable play.
x
B00729-10
Note
Clutch damage If there is no play on the clutch lever, the clutch will begin to slip.
– When operating the motorcycle, always check the clutch lever play.
– Move the handlebar to and fro over the entire steering range.
The clutch lever play must not change.
141
16 TUNING THE ENGINE
» If the clutch lever play changes:
– Check the routing of the clutch cable.
16.4
Adjusting the clutch cable play
x
– Move the handlebar to the straight-ahead position.
– Push back sleeve
1
.
– Loosen lock nut
2
.
– Adjust the play in the clutch level
A by turning adjusting screw
3
.
Guideline
Clutch lever play 1… 3 mm (0.04… 0.12 in)
– Tighten lock nut
2
.
– Slide on sleeve
1
.
142
B00730-10
17 SERVICE WORK ON THE ENGINE
17.1
Checking the engine oil level
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Check the engine oil level.
Info
After switching off the engine, wait one minute before checking the level.
The engine oil must be between the lower and upper edge of the oil level viewer.
» If the engine oil level is not at the specified level:
– Add the engine oil. ( p. 146)
B00772-01
143
17.2
Changing the engine oil and oil filter, cleaning the oil screen
x
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.
17 SERVICE WORK ON THE ENGINE
Info
Drain the engine oil only when the engine is warm.
B00774-10
Preparatory work
– Remove the front spoiler. ( p. 89)
– Stand the motorcycle on its side stand on a horizontal surface.
Main work
– Place a suitable container under the engine.
– Remove the oil drain plug
– Remove oil screen
2
1 with the O-ring.
with the O-ring.
– Completely drain the engine oil.
– Clean the oil drain plug and oil screen thoroughly.
– Position oil screen
2 and mount and tighten oil drain plug
1 with the O-ring.
Guideline
Oil drain plug (125 Duke)
Oil drain plug (200 Duke EU/MAL)
M24
M24
20 Nm
(14.8 lbf ft)
20 Nm
(14.8 lbf ft)
144
17 SERVICE WORK ON THE ENGINE
– Remove screws
3
. Remove the oil filter cover
4 with the O-ring.
– Pull oil filter
5 out of the oil filter housing.
Circlip pliers reverse (51012011000)
– Completely drain the engine oil.
– Thoroughly clean the parts and sealing area.
B00775-10
B00776-10
– Insert oil filter
5
.
– Oil the O-ring of the oil filter cover. Mount oil filter cover
6
.
– Mount and tighten the screws.
Guideline
Screw, oil filter cover (125
Duke)
M5 8 Nm
(5.9 lbf ft)
Screw, oil filter cover
(200 Duke EU/MAL)
M5 8 Nm
(5.9 lbf ft)
Loctite ® 243™
Loctite ® 243™
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
145
17 SERVICE WORK ON THE ENGINE
B00773-11
– Remove the oil filler plug engine oil.
7 with the O-ring from the clutch cover and fill up with
Engine oil
After oil change approx.
1.2 l (1.3 qt.) External temperature: 0… 50 °C
(32… 122 °F)
External temperature: −10… 40 °C
(14… 104 °F)
– Install and tighten the oil filler plug with the O-ring.
Engine oil
(SAE 15W/50)
Engine oil
(SAE 10W/40)
146
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
– Fit the front spoiler. ( p. 90)
– Check the engine oil level. ( p. 143)
17.3
Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
17 SERVICE WORK ON THE ENGINE
Main work
– Remove the oil filler plug engine oil.
1 with the O-ring from the clutch cover and fill up with
Engine oil (SAE 15W/50) ( p. 171)
Engine oil (SAE 10W/40) ( p. 171)
147
B00773-10
Info
For optimal performance of the engine oil, do not mix different types of engine oil.
If appropriate, change the engine oil.
– Install and tighten the oil filler plug with O-ring.
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. 143)
18 CLEANING, CARE
148
18.1
Cleaning the 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.
– Seal the exhaust system to keep water out.
– 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 paintbrush.
401061-01
18 CLEANING, CARE
149
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.
– 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 sleeves 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 anti-corrosion materials.
Cleaning and preserving materials for metal, rubber and plastic ( p. 173)
– Treat all painted parts with a mild paint polish.
18 CLEANING, CARE
150
High-luster polish for paint ( p. 174)
– Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
– Oil the ignition/steering lock.
18.2
Checks and maintenance steps for winter operation
Info
If the motorcycle is used in the winter, salt can be expected on the roads. Precautions need to be taken against road salt corrosion.
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. 148)
– 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, swingarm, and all other bright and zinc-plated parts (except for the brake discs) with a wax-based corrosion inhibitor.
18 CLEANING, CARE
Info
Corrosion inhibitor is not permitted to come in contact with the brake discs as this would greatly reduce the braking force.
151
19 STORAGE
152
19.1
Storage
Info
If you want to garage the motorcycle for a longer period, take the following steps.
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.
– Make sure the tank is empty to the point where the Low Fuel Level message lights up so that you can fill up with fresh fuel when you put the motorcycle back into operation.
– Clean the motorcycle. ( p. 148)
– Change the engine oil and oil filter, clean the oil screen.
x
– Check the antifreeze and coolant level. ( p. 132)
– Check the tire air pressure. ( p. 110)
– Remove the battery.
– Recharge the battery.
Guideline
Storage temperature of battery without direct sunlight
0… 35 °C (32… 95 °F)
– Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
Info
KTM recommends jacking up the motorcycle.
19 STORAGE
153
– Raise the motorcycle with the rear wheel stand. ( p. 75)
– Raise the motorcycle with the front wheel stand. ( p. 76)
– Cover the motorcycle 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 exhaust system to rust.
19.2
Preparing for use after storage
– Take the motorcycle off of the front wheel stand. ( p. 77)
– Take the motorcycle off of the rear wheel stand. ( p. 75)
– Recharge the battery.
– Install the battery.
– Perform checks and maintenance steps when preparing for use. ( p. 59)
– Take a test ride.
401059-01
20 TROUBLESHOOTING
Faults
Engine does not crank when the electric starter button is pressed
Possible cause
Operating error
Battery discharged
Fuse 1, 2, 3, or 4 is blown
Engine turns only if the clutch lever is drawn
Engine turns but does not start
No ground connection present
The vehicle is in gear
The vehicle is in gear and the side stand is folded out
Operating error
Engine has too little power
Engine overheats
Defect in fuel injection system
Air filter is very dirty
Fuel filter is very dirty
Defect in fuel injection system
Too little coolant in cooling system
Radiator fins very dirty
Foam formation in cooling system
Thermostat defective
Fuse 5 blown
154
Action
– Go through the steps of starting the engine.
– Recharge the battery.
x
– Change the fuses of individual power consumers.
– Check the ground connection.
– Shift gear to neutral.
– Shift gear to neutral.
– Go through the steps of starting the engine.
– Read out the fault memory using the KTM diagnostics tool.
x
– Change the air filter.
– Check the fuel pressure.
x
– Read out the fault memory using the KTM diagnostics tool.
x
– Check the cooling system for leakage.
– Check the coolant level. ( p. 134)
– Clean the radiator fins.
– Drain the coolant.
x
– Fill/bleed the cooling system.
x
– Check the thermostat.
x
– Change the fuses of individual power consumers.
20 TROUBLESHOOTING
Faults
Engine overheats
The engine diagnosis warning lamp ( MIL) lights up red
Engine dies during the trip
The ABS warning lamp lights up
High oil consumption
Headlight and parking light are not functioning
Turn signal, brake light, and horn are not functional
Time is not (correctly) displayed
Battery discharged
155
Possible cause
Defect in radiator fan system
Defect in fuel injection system
Lack of fuel
Fuse 1, 2, 3, or 4 is blown
ABS fuse is blown
Large difference in wheel speeds of the front and rear wheels
Malfunction in ABS
Engine vent hose bent
Engine oil level too high
Engine oil too thin (low viscosity)
Fuse
6 blown
Fuse 6 blown
Fuse 2 blown
Ignition not switched off when vehicle was parked
Action
– Check the radiator fan system.
x
– Read out the fault memory using the KTM diagnostics tool.
x
– Change the fuses of individual power consumers.
– Change the ABS fuses. ( p. 117)
– Stop the vehicle, switch off the ignition, and start it again.
– Read out the ABS fault memory using the KTM diagnostics tool.
x
– Route the vent hose without bends or change it if necessary.
– Check the engine oil level. ( p. 143)
– Change the engine oil and oil filter, clean the oil screen.
x
– Change the fuses of individual power consumers.
– Change the fuses of individual power consumers.
– Change the fuses of individual power consumers.
– Recharge the battery.
x
20 TROUBLESHOOTING
Faults
Battery discharged
Combination instrument shows nothing on the display
Possible cause
Battery is not being charged by alternator
Fuse 2 blown
Speedometer in combination instrument not functioning
Speedometer wiring harness is damaged or plug-in connection is oxidized
156
Action
– Check the charging voltage.
x
– Check the open-circuit current.
x
– Change the fuses of individual power consumers.
– Check the wiring harness and plug-in connection.
21 TECHNICAL DATA
21.1
Engine
21.1.1
125 Duke
Design
Displacement
Stroke
Bore
Compression ratio
Control
Valve diameter, intake
Valve diameter, exhaust
Valve clearance, intake, cold
Valve clearance, exhaust, cold
Crankshaft bearing
Conrod bearing
Pistons
Piston rings
Engine lubrication
Primary transmission
Clutch
Transmission
Transmission ratio
1st gear
2nd gear
3rd gear
1-cylinder 4-stroke engine, water-cooled
125 cm³ (7.63 cu in)
47.2 mm (1.858 in)
58 mm (2.28 in)
12.8:1
DOHC, 4 valves controlled via cam lever, chain drive
22.5 mm (0.886 in)
19 mm (0.75 in)
0.08… 0.12 mm (0.0031… 0.0047 in)
0.13… 0.17 mm (0.0051… 0.0067 in)
Two ball bearings
Sleeve bearing
Cast light alloy
1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Pressure circulation lubrication with one rotary pump
22:72
Clutch in oil bath/mechanically activated
6-gear, claw shifted
12:34
15:31
18:28
157
21 TECHNICAL DATA
4th gear
5th gear
6th gear
Mixture preparation
Ignition
Alternator
Spark plug
Spark plug electrode gap
Cooling
Idle speed
Starting aid
21.1.2
200 Duke EU/MAL
Design
Displacement
Stroke
Bore
Compression ratio
Control
Valve diameter, intake
Valve diameter, exhaust
Valve clearance, intake, cold
Valve clearance, exhaust, cold
158
21:26
22:23
24:22
Electronically controlled fuel injection
Contactless controlled fully electronic ignition with digital ignition adjustment
12 V, 238 W
BOSCH VR 5 NE
0.8 mm (0.031 in)
Water cooling, permanent circulation of coolant by water pump
1,450… 1,550 rpm
Electric starter
1-cylinder 4-stroke engine, water-cooled
200 cm³ (12.2 cu in)
49 mm (1.93 in)
72 mm (2.83 in)
11,5:1
DOHC, 4 valves controlled via cam lever, chain drive
28.5 mm (1.122 in)
24 mm (0.94 in)
0.08… 0.12 mm (0.0031… 0.0047 in)
0.13… 0.17 mm (0.0051… 0.0067 in)
21 TECHNICAL DATA
Crankshaft bearing
Conrod bearing
Pistons
Piston rings
Engine lubrication
Primary transmission
Clutch
Transmission
Transmission ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Mixture preparation
Ignition
Alternator
Spark plug
Spark plug electrode gap
Cooling
Idle speed
Starting aid
159
Two ball bearings
Sleeve bearing
Cast light alloy
1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Pressure circulation lubrication with one rotary pump
22:72
Clutch in oil bath/mechanically activated
6-gear, claw shifted
12:34
15:31
18:28
21:26
22:23
24:22
Electronically controlled fuel injection
Contactless controlled fully electronic ignition with digital ignition adjustment
12 V, 238 W
BOSCH VR 5 NE
0.8 mm (0.031 in)
Water cooling, permanent circulation of coolant by water pump
1,450… 1,550 rpm
Electric starter
21 TECHNICAL DATA
21.2
Engine tightening torques
Oil jet
Screw, engine vent plate
Screw, oil filter cover
Screw, retaining bracket
Screw, retaining bracket, stator cable
Screw, stator
Cylinder head screw
Nut, water pump impeller
Plug, water pump drain hole
Screw, alternator cover
Screw, bearing retainer
Screw, camshaft bearing bridge
Screw, chain securing guide
M6
M6
Screw, clutch cover
Screw, engine case
M6
M6x40
Screw, engine case M6x60
Screw, freewheel gear retaining bracket M6
Screw, locking lever
Screw, oil pump
Screw, retaining bracket, shaft seal ring, clutch cover
Screw, shift drum locating
Screw, starter motor
M6
M6
M6
M6
M6
M5
M5
M5
M5
M5
M5
M6
M6
M6
M6
M6
6 Nm (4.4 lbf ft)
7 Nm (5.2 lbf ft)
8 Nm (5.9 lbf ft)
6 Nm (4.4 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
12 Nm (8.9 lbf ft)
8 Nm (5.9 lbf ft)
8 Nm (5.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
11 Nm (8.1 lbf ft)
11 Nm (8.1 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
11 Nm (8.1 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
–
–
–
–
Loctite
®
–
243™
Loctite
®
–
243™
–
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
–
243™
160
21 TECHNICAL DATA
Screw, timing chain tensioner
Screw, timing chain tensioning rail
Screw, valve cover
Screw, water pump cover
Nut, conrod bearing (125 Duke)
Screw, conrod bearing
(200 Duke EU/MAL)
Nut, exhaust flange
Screw, balancer shaft gear
Screw, camshaft drive sprocket
Screw, return spring, quick shifter
Stud, exhaust flange
Cylinder head screw
M6
M6
M6
M6
M7
M7
M8
M8
M8
M8
M8
M10
Oil pressure sensor
Rotor screw
Water temperature sensor
Spark plug
Nut, inner clutch hub
Nut, primary gear
Nut, timing chain sprocket
Oil drain plug
M10
M10
M10
M12
M14LH
M14
M14
M24
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
12 Nm (8.9 lbf ft)
24 Nm (17.7 lbf ft)
24 Nm (17.7 lbf ft)
22 Nm (16.2 lbf ft)
20 Nm (14.8 lbf ft)
20 Nm (14.8 lbf ft)
12 Nm (8.9 lbf ft)
22 Nm (16.2 lbf ft)
Step 1
20 Nm (14.8 lbf ft)
Step 2
40 Nm (29.5 lbf ft)
14 Nm (10.3 lbf ft)
46 Nm (33.9 lbf ft)
14 Nm (10.3 lbf ft)
15 Nm (11.1 lbf ft)
60 Nm (44.3 lbf ft)
55 Nm (40.6 lbf ft)
55 Nm (40.6 lbf ft)
20 Nm (14.8 lbf ft)
–
–
–
–
–
Loctite
®
243™
–
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
–
Thread is oiled, head flat is greased
161
–
Loctite
®
243™
–
–
Loctite
®
–
243™
Loctite
®
–
243™
21 TECHNICAL DATA
21.3
Capacities
21.3.1
Engine oil
Engine oil
First filling 1.5 l (1.6 qt.)
After oil change approx.
1.2 l (1.3 qt.)
21.3.2
Coolant
Coolant 1 l (1 qt.)
21.3.3
Fuel
Total fuel tank capacity, approx. 11 l (2.9 US gal)
Fuel reserve, approx.
External temperature: 0…
50 °C (32… 122 °F)
External temperature: −10…
40 °C (14… 104 °F)
External temperature: 0…
50 °C (32… 122 °F)
External temperature: −10…
40 °C (14… 104 °F)
Engine oil (SAE 15W/50)
Engine oil (SAE 10W/40)
Engine oil (SAE 15W/50)
Engine oil (SAE 10W/40)
Coolant (mixed ready to use) ( p. 170)
Super unleaded (ROZ 95/RON 95/PON 91) ( p. 172)
1.5 l (1.6 qt.)
162
21 TECHNICAL DATA
21.4
Chassis
Frame
Fork
Shock absorber
Brake system
Front
Rear
Suspension travel
Front
Rear
Brake discs - diameter
Front
Rear
Brake discs - wear limit
Front
Rear
Tire air pressure, solo
Front
Rear
Tire air pressure with passenger/full payload
Front
Rear
Secondary ratio (125 Duke)
Secondary ratio (200 Duke EU/MAL)
Lattice frame of steel tubes, powder-coated
WP Suspension
WP Suspension
Disc brake with four-pot brake caliper
Disc brake with single-piston brake caliper, floating
150 mm (5.91 in)
150 mm (5.91 in)
300 mm (11.81 in)
230 mm (9.06 in)
3.6 mm (0.142 in)
3.6 mm (0.142 in)
2.0 bar (29 psi)
2.0 bar (29 psi)
2.0 bar (29 psi)
2.2 bar (32 psi)
14:45
14:42
163
21 TECHNICAL DATA
Chain
Steering head angle
Wheelbase
Seat height, unloaded
Ground clearance, unloaded
Weight without fuel, approx. (125 Duke)
Weight without fuel, approx. (200 Duke EU/MAL)
21.5
Electrical system
Battery (125 Duke) FTZ-7
Battery (200 Duke EU/MAL)
Fuse
Fuse
Fuse
Fuse
Fuse
Headlight
Parking light
Instrument lights and indicator lamps
Turn signal
FTZ-9
75011088010
75011088015
75011088030
58011109115
58011109125
H4/socket P43t
W5W/socket W2.1x9.5d
LED
LED
5/8 x 1/4” (520) O‑ring
65°
1,361±15 mm (53.58±0.59 in)
800 mm (31.5 in)
170 mm (6.69 in)
127 kg (280 lb.)
129.5 kg (285.5 lb.)
Battery voltage: 12 V
Nominal capacity: 6 Ah
Maintenance-free
Battery voltage: 12 V
Nominal capacity: 8 Ah
Maintenance-free
10 A
15 A
30 A
15 A
25 A
12 V
60/55 W
12 V
5 W
164
21 TECHNICAL DATA
Brake/tail light
License plate lamp
LED
LED
21.6
Tires
Front tires
110/70 R 17 M/C 54S TL
MRF revz FC
Additional information is available in the Service section under: http://www.ktm.com
21.7
Fork
Fork part number
Fork
Fork length
Fork oil
21.8
Shock absorber
Shock absorber part number
Shock absorber
Spring preload
Standard
Full payload
Static sag
Riding sag
450 ml (15.21 fl. oz.)
Rear tires
150/60 R 17 M/C 66S TL
MRF revz C
90101000044
WP Suspension
736 mm (28.98 in)
90604010000
WP Suspension
3 clicks
6 clicks
25 mm (0.98 in)
45… 50 mm (1.77… 1.97 in)
165
21 TECHNICAL DATA
Fitted length
21.9
Chassis tightening torques
Screw, chain guard
Screw, headlight
Remaining screws, chassis
Screw, EFI control unit
Screw, trim, subframe, bottom
Remaining screws, chassis M5
Screw, brake fluid reservoir of rear brake M5
EJOT PT ®
EJOT PT ®
M4
M4
M4
Screw, brake line holder, rear
Screw, fuel pump
Screw, fuel tank closure flange
Screw, fuel tank cover
Screw, fuel tank trim
Screw, license plate holder
Screw, rollover sensor
Screw, side stand switch
M5
M5
M5
M5
M5
M5
M5
M5
Screw, spoiler
Screw, subframe cover, bottom
Screw, windshield
Nut, foot brake lever adjustment
Nut, radiator
Remaining nuts, chassis
M5
M5
M5
M6
M6
M6
300 mm (11.81 in)
4 Nm (3 lbf ft)
4 Nm (3 lbf ft)
4 Nm (3 lbf ft)
4 Nm (3 lbf ft)
2 Nm (1.5 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
8 Nm (5.9 lbf ft)
5 Nm (3.7 lbf ft)
3 Nm (2.2 lbf ft)
4 Nm (3 lbf ft)
5 Nm (3.7 lbf ft)
11 Nm (8.1 lbf ft)
6 Nm (4.4 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
5 Nm (3.7 lbf ft)
3 Nm (2.2 lbf ft)
10 Nm (7.4 lbf ft)
5 Nm (3.7 lbf ft)
15 Nm (11.1 lbf ft)
–
–
–
–
–
–
–
–
–
–
–
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
–
243™
–
–
–
Loctite
®
–
243™
166
21 TECHNICAL DATA
Remaining screws, chassis
Screw, ABS hose clamp
Screw, air filter box
M6
M6
M6
Screw, bottom of rear part M6
Screw, brake fluid reservoir of rear brake M6
Screw, cable holder, side stand switch
Screw, chain sliding guard
M6
M6
Screw, compensating tank
Screw, foot brake cylinder
Screw, front fender
Screw, front seat fixing
Screw, fuel tank
Screw, headlight holder
Screw, headlight mask
Screw, ignition coil
Screw, license plate holder
Screw, magnetic holder on side stand
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
Screw, radiator bracket
Screw, radiator holder
Screw, rear splash protector
Screw, rollover sensor holder
Screw, seat
Screw, shift activation
Screw, voltage regulator
M6
M6
M6
M6
M6
M6
M6
10 Nm (7.4 lbf ft)
8 Nm (5.9 lbf ft)
6 Nm (4.4 lbf ft)
11 Nm (8.1 lbf ft)
9 Nm (6.6 lbf ft)
9 Nm (6.6 lbf ft)
9 Nm (6.6 lbf ft)
11 Nm (8.1 lbf ft)
9 Nm (6.6 lbf ft)
11 Nm (8.1 lbf ft)
5 Nm (3.7 lbf ft)
11 Nm (8.1 lbf ft)
11 Nm (8.1 lbf ft)
11 Nm (8.1 lbf ft)
9 Nm (6.6 lbf ft)
14 Nm (10.3 lbf ft)
5 Nm (3.7 lbf ft)
6 Nm (4.4 lbf ft)
9 Nm (6.6 lbf ft)
9 Nm (6.6 lbf ft)
11 Nm (8.1 lbf ft)
11 Nm (8.1 lbf ft)
11 Nm (8.1 lbf ft)
10 Nm (7.4 lbf ft)
–
–
–
–
–
Loctite
®
243™
Loctite
®
–
243™
–
–
–
Loctite
®
–
243™
–
–
–
Loctite
®
243™
–
–
–
–
–
Loctite
®
243™
–
167
21 TECHNICAL DATA
Screw, voltage regulator holder
Screw, wheel speed sensor
Remaining nuts, chassis
Remaining screws, chassis
Screw, bottom triple clamp
Screw, engine bearer on frame
Screw, foot brake lever
Screw, fork stub
Screw, front brake disc
Screw, front wheel spindle
Screw, handlebar clamp
Screw, handrail
Screw, horn
Screw, rear brake disc
Screw, rear footrest bracket
Screw, shift lever
Screw, top triple clamp
Screw, front brake caliper
Fitting side stand
Fitting, engine mounting bracket
Nut, mirror
Nut, turn signal
Remaining nuts, chassis
Remaining screws, chassis
M8
M8
M8x1
M10
M10
M10
M10
M10
M10
M8
M8
M8
M8
M8
M8
M6
M6
M8
M8
M8
M8
M8
M8
M8
15 Nm (11.1 lbf ft)
8 Nm (5.9 lbf ft)
30 Nm (22.1 lbf ft)
25 Nm (18.4 lbf ft)
15 Nm (11.1 lbf ft)
26 Nm (19.2 lbf ft)
15 Nm (11.1 lbf ft)
15 Nm (11.1 lbf ft)
30 Nm (22.1 lbf ft)
25 Nm (18.4 lbf ft)
21 Nm (15.5 lbf ft)
31 Nm (22.9 lbf ft)
6 Nm (4.4 lbf ft)
30 Nm (22.1 lbf ft)
26 Nm (19.2 lbf ft)
15 Nm (11.1 lbf ft)
11 Nm (8.1 lbf ft)
27 Nm (19.9 lbf ft)
34 Nm (25.1 lbf ft)
46 Nm (33.9 lbf ft)
16 Nm (11.8 lbf ft)
6 Nm (4.4 lbf ft)
50 Nm (36.9 lbf ft)
45 Nm (33.2 lbf ft)
–
–
–
–
–
–
Loctite
®
–
243™
–
–
–
Loctite
®
–
243™
Loctite
®
243™
Loctite
®
243™
Loctite
®
243™
–
–
–
–
Loctite
®
243™
–
–
–
168
21 TECHNICAL DATA
Fitting, handlebar support
Nut, rear sprocket screw
Screw, front footrest bracket
Screw, side stand bracket
Screw, top shock absorber
Stud, rear sprocket
Nut, rear wheel spindle
Nut, swingarm pivot
Screw, top steering head
Swingarm bearing adjusting ring
M10x1.25
M10x1.25
M10x1.25
M10x1.25
M10x1.25
M10x1.25
M14x1.5
M14x1.5
M16x1.5
M22x1
Nut, steering head M30x1
21 Nm (15.5 lbf ft)
32 Nm (23.6 lbf ft)
46 Nm (33.9 lbf ft)
25 Nm (18.4 lbf ft)
50 Nm (36.9 lbf ft)
50 Nm (36.9 lbf ft)
60 Nm (44.3 lbf ft)
98 Nm (72.3 lbf ft)
52 Nm (38.4 lbf ft)
Tighten and ensure that there is no play
–
–
–
–
–
–
–
–
–
Loctite
®
243™
–
Step 1
50 Nm (36.9 lbf ft)
2nd stage (loosen, counterclockwise)
2 turns
Step 3
5 Nm (3.7 lbf ft)
169
22 SUBSTANCES
170
Brake fluid DOT 4 / DOT 5.1
According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex
®
products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex ®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming.
KTM recommends
Motorex ®
products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13…
−49 °F)
50 % corrosion inhibitor/antifreeze
50 % distilled water
Coolant (mixed ready to use)
Antifreeze
Supplier
Motorex ®
– COOLANT G48
−40 °C (−40 °F)
22 SUBSTANCES
171
Engine oil (SAE 15W/50)
According to
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends
Motorex ®
products.
Partially synthetic engine oil
Supplier
Motorex ®
– Formula 4T
Engine oil (SAE 10W/40)
According to
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends
Motorex ®
products.
Partially synthetic engine oil
Supplier
Motorex ®
– Formula 4T
22 SUBSTANCES
172
Fork oil (SAE 5)
According to
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties. KTM recommends
Motorex ®
products.
Supplier
Motorex ®
– Racing Fork Oil
Super unleaded (ROZ 95/RON 95/PON 91)
According to
– 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).
23 AUXILIARY SUBSTANCES
Chain cleaner
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex
®
– Chain Clean
Chain lube for road use
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex ®
– Chainlube Road
Cleaning and preserving materials for metal, rubber and plastic
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex ®
– Protect & Shine
Fuel additive
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex ®
– Fuel Stabilizer
173
23 AUXILIARY SUBSTANCES
High-luster polish for paint
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex
®
– Moto Polish
Long-life grease
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex ®
– Bike Grease 2000
Motorcycle cleaner
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex ®
– Moto Clean 900
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex ®
– Clean & Polish
174
23 AUXILIARY SUBSTANCES
Universal oil spray
Guideline
– KTM recommends Motorex
®
products.
Supplier
Motorex
®
– Joker 440 Synthetic
175
24 STANDARDS
176
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.
INDEX
INDEX
A
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Antilock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
B
Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 93
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Brake linings
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 95
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
177
Brakes, applying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
C
Capacity
Chain
chain dirt accumulation, checking . . . . . . . . . . . . . . . . . 81
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Clutch lever play
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Combination instrument
activation and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
average fuel consumption 1/average fuel consumption 2
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
average fuel consumption 2/service menu . . . . . . . . . . . . 41
average speed/average fuel consumption 1 menu . . . . . . . 39
coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . 37
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INDEX
display
TRIP F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
distance menu 1
TRIP 1 . . . . . . . . . . . . . . . . . . . . . . . . . 44
distance menu 2
TRIP 2 . . . . . . . . . . . . . . . . . . . . . . . . . 45
filling level display in fuel tank . . . . . . . . . . . . . . . . . . . . 35
function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
info display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
range/riding time menu . . . . . . . . . . . . . . . . . . . . . . . . . 43
riding time/average speed menu . . . . . . . . . . . . . . . . . . . 39
service/range menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
total distance menu
ODO . . . . . . . . . . . . . . . . . . . . . . . . 44
warning notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Coolant
draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 134
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
178
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Filling up
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Front spoiler
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Fuse
individual power consumers, changing . . . . . . . . . . . . . . 118
Fuses, ABS
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
INDEX
G
Grab handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Headlight adjustment
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Headlight bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
High beam flasher button . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
I
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
K
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Kilometers or miles
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
L
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
M
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
raising with the front wheel stand . . . . . . . . . . . . . . . . . . 76
179
raising with the rear wheel stand . . . . . . . . . . . . . . . . . . . 75
taking off of the front wheel stand . . . . . . . . . . . . . . . . . . 77
taking off of the rear wheel stand . . . . . . . . . . . . . . . . . . 75
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Oil screen
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
P
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Parking light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Passenger seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Play in throttle cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Preparing for use
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
checks and maintenance when preparing for use . . . . . . . . 59
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INDEX
R
Rear hub rubber dampers
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
S
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-72
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Shift speed RPM 1
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Shift speed RPM 2
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
180
Shock absorber
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 73
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
T
Technical data
capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
chassis tightening torques . . . . . . . . . . . . . . . . . . . . . . 166
electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
engine tightening torques . . . . . . . . . . . . . . . . . . . . . . 160
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Time
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INDEX
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154-156
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
U
Use definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . . . 150
Work rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
181
*3211963en*
3211963en
12/2012
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM
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