OWNER`S MANUAL 2016 RC 390 2016 CO

OWNER`S MANUAL 2016 RC 390 2016 CO
OWNER'S MANUAL 2016
RC 390 2016 CO
Art. no. 3213250en
DEAR KTM CUSTOMER
1
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.
DEAR KTM CUSTOMER
We wish you a lot of enjoyment in riding this vehicle.
Enter the serial numbers of your vehicle below.
Chassis number (
p. 20)
Engine number (
p. 21)
Key number (
Dealer's stamp
p. 21)
The Owner's Manual contained the latest information for this model series at the time of going to print. Minor differences due to developments in design cannot be ruled out completely.
All specifications are non-binding. KTM Motorrad 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, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to
the regular scope of supply.
© 2014 KTM Motorrad 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
KTM Motorrad AG
5230 Mattighofen, Austria
2
TABLE OF CONTENTS
TABLE OF CONTENTS
1
2
3
4
5
MEANS OF REPRESENTATION ........................................ 7
1.1
Symbols used ...................................................... 7
1.2
Formats used....................................................... 7
SAFETY ADVICE.............................................................. 8
2.1
Use definition...................................................... 8
2.2
Safety advice....................................................... 8
2.3
Degrees of risk and symbols .................................. 9
2.4
Tampering warning............................................... 9
2.5
Safe operation ................................................... 10
2.6
Protective clothing ............................................. 11
2.7
Work rules......................................................... 11
2.8
Environment...................................................... 11
2.9
Owner's Manual ................................................. 12
IMPORTANT NOTES...................................................... 13
3.1
Guarantee, warranty ........................................... 13
3.2
Operating and auxiliary substances ...................... 13
3.3
Spare parts, accessories ..................................... 13
3.4
Service ............................................................. 13
3.5
Figures ............................................................. 14
3.6
Customer service................................................ 14
VIEW OF VEHICLE ........................................................ 16
4.1
View of vehicle, front left (example) ..................... 16
4.2
View of vehicle, rear right (example) .................... 18
SERIAL NUMBERS ....................................................... 20
5.1
Chassis number ................................................. 20
5.2
Type label ......................................................... 20
5.3
Engine number .................................................. 21
5.4
Key number....................................................... 21
3
6
7
CONTROLS...................................................................
6.1
Clutch lever.......................................................
6.2
Hand brake lever................................................
6.3
Throttle grip ......................................................
6.4
Horn button.......................................................
6.5
Light switch ......................................................
6.6
High beam flasher button ...................................
6.7
Turn signal switch..............................................
6.8
Emergency OFF switch .......................................
6.9
Electric starter button.........................................
6.10 Ignition/steering lock ..........................................
6.11 Locking the steering ...........................................
6.12 Unlocking the steering........................................
6.13 Opening the filler cap.........................................
6.14 Closing the filler cap ..........................................
6.15 Seat lock...........................................................
6.16 Tool set.............................................................
6.17 Grab handles .....................................................
6.18 Passenger footrests ............................................
6.19 Shift lever .........................................................
6.20 Foot brake lever .................................................
6.21 Side stand.........................................................
COMBINATION INSTRUMENT .......................................
7.1
Overview ...........................................................
7.2
Activation and test .............................................
7.3
Warning notes....................................................
7.4
Function buttons................................................
7.5
Indicator lamps..................................................
7.6
Display .............................................................
22
22
22
23
23
24
24
25
25
26
26
27
27
28
29
29
30
30
31
31
32
33
34
34
35
36
39
40
41
TABLE OF CONTENTS
7.7
7.8
7.9
7.10
7.11
7.12
8
9
Filling level display in fuel tank ...........................
TRIP F display ...................................................
Coolant temperature indicator .............................
Info display .......................................................
Riding time/average speed menu .........................
Average speed/average fuel consumption 1
menu................................................................
7.13 Average fuel consumption 1/average fuel
consumption 2 menu .........................................
7.14 Average fuel consumption 2/service menu ............
7.15 Service/range menu............................................
7.16 Range/riding time menu .....................................
7.17 Total distance menu ODO ...................................
7.18 Distance menu 1 TRIP 1 ....................................
7.19 Distance menu 2 TRIP 2 ....................................
7.20 Setting kilometers or miles..................................
7.21 Setting the time.................................................
7.22 Adjusting the shift speed RPM 1 .........................
7.23 Adjusting the shift speed RPM 2 .........................
PREPARING FOR USE...................................................
8.1
Advice on first use .............................................
8.2
Running in the engine ........................................
8.3
Loading the vehicle ............................................
RIDING INSTRUCTIONS................................................
9.1
Checks and maintenance when preparing for
use ...................................................................
9.2
Starting.............................................................
9.3
Starting off........................................................
9.4
Shifting, riding ..................................................
9.5
Applying the brakes............................................
4
42
43
44
45
46
46
47
48
49
50
51
51
52
53
53
54
55
56
56
57
58
60
60
61
63
63
66
9.6
Stopping, parking...............................................
9.7
Transport ..........................................................
9.8
Refueling ..........................................................
10 SERVICE SCHEDULE ....................................................
10.1 Additional information ........................................
10.2 Required work ...................................................
10.3 Recommended work ...........................................
11 TUNING THE CHASSIS .................................................
11.1 Adjusting the spring preload of the shock
absorber ........................................................
11.2 Adjusting the shift lever......................................
12 SERVICE WORK ON THE CHASSIS.................................
12.1 Raising the motorcycle with the rear wheel
stand ................................................................
12.2 Taking the motorcycle off of the rear wheel
stand ................................................................
12.3 Raising the motorcycle with the front wheel
stand ................................................................
12.4 Taking the motorcycle off of the front wheel
stand ................................................................
12.5 Removing the front rider's seat ............................
12.6 Mounting the front rider's seat.............................
12.7 Removing the passenger seat ..............................
12.8 Mounting the passenger seat...............................
12.9 Checking for chain dirt accumulation...................
12.10 Cleaning the chain .............................................
12.11 Checking the chain tension .................................
12.12 Adjusting the chain tension.................................
12.13 Checking the chain, rear sprocket, and engine
sprocket............................................................
68
69
70
72
72
72
74
75
75
76
78
78
78
79
80
81
82
82
83
84
84
85
87
89
TABLE OF CONTENTS
12.14 Removing the battery cover ................................. 91
12.15 Mounting the battery cover.................................. 93
12.16 Removing the front spoiler .................................. 93
12.17 Fitting front spoiler ............................................ 95
12.18 Removing the left side cover ............................ 97
12.19 Installing the left side cover ............................ 98
12.20 Removing the right side cover ........................ 100
12.21 Installing the right side cover ......................... 101
13 BRAKE SYSTEM ......................................................... 102
13.1 ABS/antilock brake system................................ 102
13.2 Checking the brake discs .................................. 103
13.3 Checking the brake fluid level of the front
brake .............................................................. 104
13.4 Adding front brake fluid ................................ 105
13.5 Checking the front brake linings ........................ 106
13.6 Checking the rear brake fluid level..................... 107
13.7 Adding rear brake fluid ................................. 108
13.8 Checking the rear brake linings ......................... 109
13.9 Checking the free travel of foot brake lever ......... 110
13.10 Adjusting the free travel of the foot brake
lever ............................................................ 111
14 WHEELS, TIRES ......................................................... 113
14.1 Removing the front wheel .............................. 113
14.2 Installing the front wheel .............................. 114
14.3 Removing the rear wheel ............................... 116
14.4 Installing the rear wheel ................................ 117
14.5 Checking the rear hub rubber dampers ........... 118
14.6 Checking the tire condition ............................... 120
14.7 Checking the tire air pressure............................ 121
5
15 ELECTRICAL SYSTEM .................................................
15.1 Removing the battery ....................................
15.2 Installing the battery .....................................
15.3 Recharging the battery ..................................
15.4 Changing the ABS fuses ...................................
15.5 Changing the fuses of individual power
consumers.......................................................
15.6 Changing the low beam bulb .............................
15.7 Changing the high beam bulb............................
15.8 Checking the low beam headlight adjustment .....
15.9 Checking the high beam headlight adjustment....
15.10 Adjusting the headlight range of the low beam....
15.11 Adjusting the headlight range of the high
beam ..............................................................
16 COOLING SYSTEM ......................................................
16.1 Cooling system ................................................
16.2 Checking the coolant level in the compensating
tank................................................................
16.3 Checking the antifreeze and coolant level ...........
16.4 Correcting the coolant level in the
compensating tank...........................................
16.5 Draining the coolant .....................................
16.6 Filling/bleeding the cooling system .................
17 TUNING THE ENGINE.................................................
17.1 Checking the play in the throttle cable ...............
17.2 Adjusting the play in the throttle cable ...........
17.3 Checking the clutch lever play...........................
17.4 Adjusting the clutch cable play ......................
18 SERVICE WORK ON THE ENGINE ................................
18.1 Checking the engine oil level.............................
123
123
124
125
128
130
132
133
135
136
137
137
138
138
139
141
143
144
145
148
148
149
149
150
151
151
TABLE OF CONTENTS
Changing the engine oil and oil filter, cleaning
the oil screens .............................................
18.3 Adding engine oil .............................................
19 CLEANING, CARE .......................................................
19.1 Cleaning the motorcycle ...................................
19.2 Checks and maintenance steps for winter
operation.........................................................
20 STORAGE ...................................................................
20.1 Storage ...........................................................
20.2 Preparing for use after storage...........................
21 TROUBLESHOOTING ..................................................
22 BLINK CODE ..............................................................
23 TECHNICAL DATA.......................................................
23.1 Engine ............................................................
23.2 Engine tightening torques .................................
23.3 Capacities .......................................................
23.3.1
Engine oil ...................................................
23.3.2
Coolant .......................................................
23.3.3
Fuel ...........................................................
23.4 Chassis ...........................................................
23.5 Electrical system..............................................
23.6 Tires ...............................................................
23.7 Fork................................................................
23.8 Shock absorber ................................................
23.9 Chassis tightening torques ................................
24 SUBSTANCES ............................................................
25 AUXILIARY SUBSTANCES ...........................................
26 STANDARDS ..............................................................
INDEX ...............................................................................
6
18.2
151
154
156
156
158
160
160
161
162
165
171
171
172
175
175
175
175
175
177
177
178
178
178
184
186
188
189
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®
Identifies a protected name.
Brand™
Identifies a brand available on the open market.
7
2
SAFETY ADVICE
2.1
Use definition
8
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.
2
SAFETY ADVICE
2.3
Degrees of risk and symbols
9
Danger
Indicates a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Indicates a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Indicates a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Indicates a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.
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 parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
2.5
10
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
11
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.
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
12
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.
3
IMPORTANT NOTES
3.1
Guarantee, warranty
13
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service & Warranty Booklet 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 & Warranty Booklet.
3.2
Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to
advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4
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.
3
IMPORTANT NOTES
14
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of
components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace
parts before the next scheduled service.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
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
L02250-10
4
VIEW OF VEHICLE
1
Horn button (
p. 23)
1
Light switch (
p. 24)
1
High beam flasher button (
1
Turn signal switch (
2
Clutch lever (
3
Filler cap
4
Seat lock (
5
Side stand (
p. 33)
6
Shift lever (
p. 31)
p. 22)
p. 29)
p. 25)
17
p. 24)
4
VIEW OF VEHICLE
4.2
View of vehicle, rear right (example)
18
L02251-10
4
VIEW OF VEHICLE
1
Grab handles (
p. 30)
2
Tool set (
3
Ignition/steering lock (
4
Emergency OFF switch (
4
Electric starter button (
5
Throttle grip (
6
Hand brake lever (
7
Passenger footrests (
8
Foot brake lever (
p. 30)
p. 26)
p. 25)
p. 26)
p. 23)
p. 22)
p. 31)
p. 32)
19
5
SERIAL NUMBERS
5.1
Chassis number
20
The chassis number
 is stamped on the right side of the frame under the seat.
402175-10
5.2
Type label
The type label
1
0
402174-10
 is on the right of the frame behind the steering head.
5
SERIAL NUMBERS
5.3
Engine number
21
The engine number
 is stamped on the left side of the engine under the engine sprocket.
401949-10
5.4
Key number
The key number
 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
402245-10
6
CONTROLS
6.1
Clutch lever
22
The clutch lever
 is fitted on the left side of the handlebar.
L02111-10
6.2
Hand brake lever

The hand brake lever
is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
L02112-10
6
CONTROLS
6.3
Throttle grip
23
The throttle grip
 is fitted on the right side of the handlebar.
The horn button
 is fitted on the left side of the handlebar.
L02112-11
6.4
Horn button
Possible states
• Horn button
• Horn button
L02113-10
in neutral position
pressed – The horn is operated in this position.
6
CONTROLS
6.5
Light switch
24
The light switch
 is fitted on the left side of the handlebar.
Possible states
Low beam on – Light switch is turned downward. In this position, the low
beam and tail light are switched on.
High beam on – The light switch is turned upwards. In this position, the
low beam, the high beam and the tail light are switched on.
L02113-11
6.6
High beam flasher button
The high beam flasher button
 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.
L02113-12
6
CONTROLS
6.7
Turn signal switch
25
The turn signal switch
 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.
L02113-13
6.8
To switch off the turn signal, press the turn signal switch towards the switch case.
Emergency OFF switch
The emergency OFF switch
 is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch off – In this position, the ignition circuit is
interrupted, a running engine stops, and a non-running engine cannot be
started.
Emergency OFF switch on – This position is required for operation; the ignition circuit is closed.
L02114-10
6
CONTROLS
6.9
Electric starter button
26
The electric starter button
Possible states
• Electric starter button
• Electric starter button
 is fitted on the right side of the handlebar.
in basic position
pressed – In this position, the electric starter is actuated.
L02114-11
6.10
Ignition/steering lock
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.
L02115-01
Steering locked – In this position, the ignition circuit is interrupted and the
steering locked. The ignition key can be removed.
6
CONTROLS
6.11
Locking the steering
27
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Park the vehicle.
–
Turn the handlebar all the way to the left.
–
Insert the key into the ignition/handlebar lock, press in, and turn to the left. Remove
the key.
Steering is no longer possible.
400732-01
6.12
Unlocking the steering
–
Insert the key into the ignition/handlebar lock, press in, and turn to the right. Remove
the key.
You can now steer the bike again.
400731-01
6
CONTROLS
6.13
Opening the filler cap
28
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the
eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and
water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel. Store fuel properly
in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
–
Lift the cover
 of the filler cap and insert the ignition key in the lock.
Note
Danger of damage Ignition key breakage.
–
L02116-10
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.
6
CONTROLS
29
–
6.14
Remove the ignition key.
Closing the filler cap
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your health.
–
After closing the filler cap, ensure that it is locked properly. Change clothing that has been contaminated with fuel. Immediately clean contaminated
areas on the skin with soap and water.
–
Close the filler cap.
–
Push down the filler cap until the lock engages.
L02117-01
6.15
Seat lock

The seat lock
is located to the left of the seat.
It can be locked with the ignition key.
M00454-10
6
CONTROLS
6.16
Tool set
30
The tool set
 is in the storage compartment under the seat.
L02274-10
6.17
Grab handles

The grab handles
are used for moving the motorcycle around.
If you carry a passenger, the passenger can hold onto the grab handles during the trip.
L02256-10
6
CONTROLS
6.18
Passenger footrests
31
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.
L02273-01
6.19
Shift lever
Shift lever
401950-10
 is mounted on the left side of the engine.
6
CONTROLS
32
The gear positions can be seen in the photograph.
The neutral or idle position is between the first and second gears.
401950-11
6.20
Foot brake lever

Foot brake lever
is located in front of the right footrest.
The foot brake lever is used to activate the rear brake.
402177-10
6
CONTROLS
6.21
Side stand
33

The side stand
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.
402029-10
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.
7
COMBINATION INSTRUMENT
7.1
Overview
401685-10
34
1
Display (
2
Function buttons (
p. 41)
3
Info display (
4
Indicator lamps (
p. 39)
p. 45)
p. 40)
7
COMBINATION INSTRUMENT
7.2
Activation and test
35
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.
401686-01
7
COMBINATION INSTRUMENT
7.3
Warning notes
Low Oil Pressure appears on the info display if the oil pressure is too low.
401309-01
Low Fuel Level appears on the info display if the fuel level reaches the reserve mark.
401310-01
36
7
COMBINATION INSTRUMENT
37
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
401313-01
10.80 V
7
COMBINATION INSTRUMENT
38
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.
401461-01
7
COMBINATION INSTRUMENT
7.4
Function buttons
39

You can change the display mode with the MODE button
.
Possible display modes are total distance traveled (TRIP 1), distance 1 (ODO) and
distance 2 (TRIP 2).
Pressing and holding the SET button
resets the distance 1 (TRIP 1) and
distance 2 (TRIP 2) functions to 0.0 and briefly pressing the SET button
changes the
info display to the next display mode.
The ABS can be switched off using button
.



401685-12
7
COMBINATION INSTRUMENT
7.5
Indicator lamps
40
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).
401686-01
7
COMBINATION INSTRUMENT
7.6
Display
The
The
The
The
The
The
The
41

speed
is shown in kilometers per hour km/h or in miles per hour mph.
tachometer
shows the engine speed in revolutions per minute.
gear display
shows the engaged gear.
coolant temperature appears in segment
.
time appears in segment
.
filling level in the fuel tank is displaced in segment
.
info display
shows additional information.






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.
401685-11
7
COMBINATION INSTRUMENT
7.7
Filling level display in fuel tank
42
The filling level display consists of 9 bars. The more bars are lit, the more fuel is in the fuel
tank.
401292-01
7
COMBINATION INSTRUMENT
7.8
TRIP F display
43
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
and the warning note Low Fuel Level appears on the info display.
401293-01
lights up
7
COMBINATION INSTRUMENT
7.9
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.
401292-01
44
7
COMBINATION INSTRUMENT
7.10
Info display
45

Various warning notes appear on info display
.
If the general warning lamp lights up, the corresponding warning note is shown on the
info display.
401291-10
7
COMBINATION INSTRUMENT
7.11
Riding time/average speed menu
46
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401334-01
•
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.
7.12
Next display mode on the info display
Average speed/average fuel consumption 1 menu
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401465-01
•
The motorcycle is moving.
–
Press the SET button briefly and repeatedly until the desired info display appears.
7
COMBINATION INSTRUMENT
47
In this menu, the average speed and the average fuel consumption 1 are displayed in
L/100 km (or L/100 miles).
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.
7.13
Next display mode on the info display
Average fuel consumption 1/average fuel consumption 2 menu
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401466-01
•
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 consumptions 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.
7
COMBINATION INSTRUMENT
Press the SET button
briefly.
7.14
48
Next display mode on the info display
Average fuel consumption 2/service menu
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401467-01
•
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.
Press the SET button
briefly.
Next display mode on the info display
7
COMBINATION INSTRUMENT
7.15
Service/range menu
49
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401468-01
•
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
7
COMBINATION INSTRUMENT
7.16
Range/riding time menu
50
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401469-01
•
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
7
COMBINATION INSTRUMENT
7.17
Total distance menu ODO
51
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401303-01
•
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.
7.18
Next display mode on the display
Distance menu 1 TRIP 1
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401304-01
•
The motorcycle is moving.
–
Press the MODE button briefly and repeatedly until TRIP 1 appears on the display.
7
COMBINATION INSTRUMENT
52
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.
7.19
Press the SET button
for 5 - 10 seconds.
Display of TRIP 1 is reset
Press the MODE button.
Next display mode on the display
Distance menu 2 TRIP 2
Condition
Alternative 1
• The ignition is on.
•
The motorcycle is stationary.
Alternative 2
• The ignition is on.
401305-01
•
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.
Press the SET button
for 5 - 10 seconds.
Display of TRIP 2 is reset
Press the MODE button.
Next display mode on the display
7
COMBINATION INSTRUMENT
7.20
Setting kilometers or miles
Info
Make the country-specific setting.
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 button for 5 - 10 seconds.
The display changes from km/h to mph or from mph to km/h.
401303-01
7.21
Setting the time
Condition
The ignition is on.
The motorcycle is stationary.
53
7
COMBINATION INSTRUMENT
–
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.
401303-01
7.22
Adjusting the shift speed RPM 1
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.
–
401307-01
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.
54
7
COMBINATION INSTRUMENT
The display RPM 1 goes out and the set speed is stored.
7.23
Adjusting the shift speed RPM 2
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 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.
401308-01
–
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.
55
8
PREPARING FOR USE
8.1
Advice on first use
56
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.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
8
PREPARING FOR USE
57
–
Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
–
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.
–
Run the engine in. (
You receive a delivery certificate and the service record at vehicle handover.
8.2
–
p. 57)
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. 54)
–
Adjust the shift speed RPM 2. (
p. 55)
–
Avoid fully opening the throttle!
8
PREPARING FOR USE
8.3
Loading the vehicle
58
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.
8
PREPARING FOR USE
59
–
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
125 kg (276 lb.)
Maximum permissible rear axle load
210 kg (463 lb.)
9
RIDING INSTRUCTIONS
9.1
Checks and maintenance when preparing for use
60
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. (
–
Check the brake fluid level of the front brake. (
–
Check the rear brake fluid level. (
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check the brake system function.
–
Check the coolant level in the compensating tank. (
–
Check for chain dirt accumulation. (
–
Check the chain tension. (
p. 85)
–
Check the tire condition. (
p. 120)
–
Check the tire air pressure. (
–
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.
p. 151)
p. 104)
p. 107)
p. 106)
p. 109)
p. 139)
p. 84)
p. 121)
9
RIDING INSTRUCTIONS
9.2
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 operate the vehicle without an air filter as dust and dirt will enter the engine and lead to 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.
61
9
RIDING INSTRUCTIONS
62
–
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.
B00782-10
–
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.
9
RIDING INSTRUCTIONS
63
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
 button for 3 – 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
401685-15
9.3
–
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.
9.4
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.
9
RIDING INSTRUCTIONS
64
Warning
Danger of accidents Malfunctions caused by incorrect ignition key position.
–
Do not change the ignition key position during a journey.
Warning
Danger of accidents Distraction from traffic activity by adjustments to the vehicle.
–
Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury Falling off of the passenger.
–
The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles. The feet must
be positioned on the passenger footrests. Note the regulations governing the minimum age of passengers.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
–
Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on.
Warning
Danger of accidents Reduced road grip with cold tires.
–
On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road
grip is ensured.
Warning
Danger of accidents Reduced road grip with new tires.
–
New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved
until the tires have been run in.
9
RIDING INSTRUCTIONS
65
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.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
–
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
401950-11
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.
9
RIDING INSTRUCTIONS
9.5
66
–
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.
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.
9
RIDING INSTRUCTIONS
67
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.
Warning
Danger of accidents Greater stopping distance due to ABS.
–
Braking should be appropriate to the driving situation and the road conditions.
Warning
Danger of accidents Very forceful braking can cause the wheels to block.
–
–
ABS must be switched on to be effective.
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.
9
RIDING INSTRUCTIONS
9.6
Stopping, parking
68
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 to or destruction of components due to excessive load.
–
The side stand is only designed for the weight of the motorcycle. Do no sit on the motorcycle when it is resting on the side stand. The
side stand or the frame may become damaged and the motorcycle may fall over.
–
Brake the motorcycle.
–
Shift gear to neutral.
9
–
RIDING INSTRUCTIONS
Switch off the ignition by turning the ignition key to the position
69
.
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.
9.7
.
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.
9
RIDING INSTRUCTIONS
70
–
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.
401448-01
9.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the
eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and
water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
Note
Material damage Premature clogging of the fuel filter.
–
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the
fuel system. (Your authorized KTM workshop will be glad to help.)
9
–
RIDING INSTRUCTIONS
71
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. (
–
Fill the fuel tank with fuel up to the lower edge
Total fuel tank
capacity, approx.
–
L02129-10
Close the filler cap. (
p. 28)
10 l (2.6 US gal)
p. 29)
 of the fuel filler.
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 185)
10
SERVICE SCHEDULE
10.1
Additional information
72
Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately.
10.2
Required work
Every two years
Every year
Every 15,000 km (9,300 mi)
Every 7,500 km (4,650 mi)
After 1,000 km (620 mi)
Read out the fault memory using the KTM diagnostics tool.
○
●
●
●
●
Check the functioning of the electrical equipment.
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
○
●
●
●
○
●
●
●
●
●
●
●
●
●
●
Change the engine oil and oil filter and clean the oil screens.
Check the brake discs. (
(
p. 151)
p. 103)
Check the front brake linings. (
Check the rear brake linings. (
Check the tire condition. (
Check the tire air pressure. (
p. 106)
p. 109)
p. 120)
p. 121)
Check the brake lines for damage and leakage.
Check the brake fluid level of the front brake. (
Check the rear brake fluid level. (
p. 104)
p. 107)
Check the shock absorber and fork for leaks. Perform a fork service and shock absorber service as needed
and depending on how the vehicle will be used.
Clean the dust boots of the fork legs.
Check the chain, rear sprocket, and engine sprocket. (
p. 89)
10
SERVICE SCHEDULE
73
Every two years
Every year
Every 15,000 km (9,300 mi)
Every 7,500 km (4,650 mi)
After 1,000 km (620 mi)
Check the chain tension. (
p. 85)
Check the coolant level in the compensating tank. (
p. 139)
Check that the radiator fan is functioning properly.
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
●
●
●
●
●
●
Change the air filter, clean the air filter box.
Check the cables for damage and routing without sharp bends.
○
Check the valve clearance.
○
●
Check the valve clearance, change the spark plugs.
●
Change the front brake fluid.
●
Change the rear brake fluid.
○
●
●
○
●
●
○
●
●
Check that the throttle cables are undamaged, routed without sharp bends, and set correctly.
○
●
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.
○
Reset the service interval display.
Make the service entry in KTM Dealer.net and in the service record.
Check the steering head bearing play.
Check the low beam headlight adjustment. (
Check the high beam headlight adjustment. (
○
One-time interval
●
Periodic interval
p. 135)
p. 136)
●
●
●
●
●
●
●
●
●
●
●
●
●
○
●
●
●
●
○
●
●
●
●
10
SERVICE SCHEDULE
10.3
Recommended work
74
Every four years
Every year
Every 7,500 km (4,650 mi)
After 1,000 km (620 mi)
Check the swingarm bearing.
●
Check the wheel bearings.
●
Grease all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.
○
●
●
●
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and correct routing.
○
●
●
●
Check the antifreeze.
○
●
●
Check the screws and nuts for tightness.
○
●
●
Change the coolant.
○
One-time interval
●
Periodic interval
●
●
11
TUNING THE CHASSIS
11.1
Adjusting the spring preload of the shock absorber
75
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.
–
Set the spring preload by turning adjusting ring
set.
 using the hook wrench from the tool
Guideline
Spring preload
Comfort
L02252-10
3 clicks
Standard
5 clicks
Sport
7 clicks
Full payload
8 clicks
Hook wrench, shock absorber (90529077000)
Info
The spring preload can be set to 10 different positions.
11
TUNING THE CHASSIS
11.2
Adjusting the shift lever
76
Info
The adjustment range of the shift lever is limited.
–
Loosen nut
, holding the threaded rod .
Info
 has a left-handed thread.
Loosen nut , holding the threaded rod .
Adjust the shift lever by turning shift rod .
Nut
–
–
Guideline
Shift rod adjustment range

150… 162 mm (5.91… 6.38 in)
Info
Make the same adjustments on both sides.
At least five screw threads must be screwed into the seating.
–
Check adjusting angle
.
Guideline
Adjusting angle
shift lever
L02272-10
–
Tighten nut
 shift rod - linkage -
75°
, holding the threaded rod .
Guideline
Nut, shift rod
M6
10 Nm (7.4 lbf ft)
11
TUNING THE CHASSIS
–
Tighten nut
77
, holding the threaded rod .
Guideline
Nut, shift rod
–
M6LH
10 Nm (7.4 lbf ft)
Check the shift lever to ensure it is functioning properly and can move freely.
12
SERVICE WORK ON THE CHASSIS
12.1
Raising the motorcycle with the rear wheel stand
78
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Mount the supports of the wheel stand.
–
Insert the adapter in the rear wheel stand.
Bushing kit for lifting gear (90229955044)
Universal V adapter (61029955244)
Rear wheel stand (61029055400)
–
Stand the motorcycle upright, align the lifting gear with the swingarm and the adapters,
and lift the motorcycle.
L02255-01
12.2
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.
12
SERVICE WORK ON THE CHASSIS
79
–
Secure the motorcycle against falling over.
–
Remove the rear wheel stand and lean the vehicle on the side stand
402029-10
12.3
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. (
Condition
– Remove protection cap
M00453-10
.
p. 78)
.
12
SERVICE WORK ON THE CHASSIS
–
Move the handlebar to the straight-ahead position. Position the wheel stand.
Adapter (61029955620)
Front wheel stand (61029055500)
Info
Always raise the rear of the motorcycle first.
–
Raise the front of the motorcycle.
L02253-01
12.4
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.
Main work
– Secure the motorcycle against falling over.
–
L02254-01
Remove the front wheel stand.
80
12
SERVICE WORK ON THE CHASSIS
–
Mount protection cap
81
.
M00453-10
Finishing work
– Take the motorcycle off of the rear wheel stand. (
12.5
p. 78)
Removing the front rider's seat
M00454-10
–
Insert the ignition key in seat lock
–
Raise the rear of the front rider's seat, pull it toward the rear, and remove it upward.
–
Remove the ignition key from the seat lock.
 and turn it clockwise.
12
SERVICE WORK ON THE CHASSIS
12.6
Mounting the front rider's seat
82
–
Attach recesses
on the front rider's seat to the fuel tank, push the front rider's seat
forward, and lower at the rear.
–
Check that the front rider's seat is correctly mounted.

Catch
 engages in the recess.
401921-10
12.7
Removing the passenger seat
Preparatory work
– Remove the front rider's seat. (
Main work
– Remove screw
–
L02191-10
p. 81)
 with the washer.
Lift and take off the passenger seat.
12
SERVICE WORK ON THE CHASSIS
12.8
Mounting the passenger seat
Main work
– Attach hook
83
 into bracket .
–
Lower the passenger seat and push back.
–
Mount and tighten screw
M00449-10
 with the washer.
Guideline
Screw, passenger seat
M6
7 Nm (5.2 lbf ft)
Warning
Danger of accidents The passenger seat can come loose from the anchoring if it
is not mounted correctly.
–
L02191-11
–
After mounting the passenger seat, check that it is locked correctly by
pulling up.
Check that the passenger seat is correctly mounted.
Finishing work
– Mount the front rider's seat. (
p. 82)
12
SERVICE WORK ON THE CHASSIS
12.9
Checking for chain dirt accumulation
–
84
Check the chain for coarse dirt accumulation.
»
If the chain is very dirty:
–
Clean the chain. (
p. 84)
400678-01
12.10
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.
12
SERVICE WORK ON THE CHASSIS
85
Info
The service life of the chain depends largely on its maintenance.
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
p. 78)
Main work
– Clean the chain regularly.
–
Rinse off loose dirt with a soft jet of water.
–
Remove old grease remains with chain cleaner.
Chain cleaner (
–
p. 186)
After drying, apply chain spray.
Chain lube for road use (
p. 186)
400725-01
Finishing work
– Take the motorcycle off of the rear wheel stand. (
12.11
p. 78)
Checking the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in
the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain
or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine
sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it
if necessary.
12
SERVICE WORK ON THE CHASSIS
86
–
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
.

Info

The upper chain section
must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Chain tension
»
If the chain tension does not meet specifications:
–
L02261-10
5… 7 mm (0.2… 0.28 in)
Adjust the chain tension. (
p. 87)
12
SERVICE WORK ON THE CHASSIS
12.12
Adjusting the chain tension
87
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in
the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain
or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine
sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it
if necessary.
Preparatory work
– Check the chain tension. (
–
p. 85)
Raise the motorcycle with the rear wheel stand. (
p. 78)
12
SERVICE WORK ON THE CHASSIS
Main work
– Loosen nut
88
.
.
–
Loosen nuts
–
Adjust the chain tension by turning adjusting screws
 on the left and right.
Guideline
Chain tension
5… 7 mm (0.2… 0.28 in)


Turn adjusting screws
on the left and right so that the markings on the left and
right chain adjusters
are in the same position in relation to reference marks
.
The rear wheel is then correctly aligned.

Info
The upper chain section must be taut.
Chain wear is not always even, so you should check the setting at different chain
positions.
L02150-10
–
Tighten nuts
–
Make sure that chain adjusters
–
Tighten nut
.
 are fitted correctly on adjusting screws .
.
Guideline
Nut, rear wheel spindle
M14x1.5
90 Nm
(66.4 lbf ft)
12
SERVICE WORK ON THE CHASSIS
12.13
Checking the chain, rear sprocket, and engine sprocket
–
89
Check the rear sprocket and engine sprocket for wear.
»
If the rear sprocket and engine sprocket are worn:
–
Change the power set.
Info
The engine sprocket, rear sprocket, and chain should always be replaced
together.
100132-10
12
SERVICE WORK ON THE CHASSIS
90
–
Shift gear to neutral.
–
Pull the lower chain section with specified weight
.
Guideline
Weight, chain wear measurement
–
Measure the distance
15 kg (33 lb.)
 of 20 chain links in the lower chain section.
Info
A
0
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Maximum distance
chain section
»
B
0
If distance
–
 at the longest
301.6 mm (11.874 in)
 is greater than the specified measurement:
Change the power set.
Info
1 2 3
18 19 20
401288-10
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
12
SERVICE WORK ON THE CHASSIS
91
–
Push the chain up in the area behind the chain guide.
–
Check the chain sliding guard for wear.
»
If the chain sliding guard has lost material due to wear to the extent that, in
area
, the drilled hole of screw
is visible from above:

–
–

Change the chain sliding guard.
Check that the chain sliding guard is firmly seated.
»
If the chain sliding guard is loose:
–
Tighten the chain sliding guard.
L02167-10
12.14
Removing the battery cover
Preparatory work
– Remove the front rider's seat. (
p. 81)
12
SERVICE WORK ON THE CHASSIS
Main work
– Pull loop
–
M00450-10
 toward the rear.
 forward and remove toward the top.
Pull battery cover
92
12
SERVICE WORK ON THE CHASSIS
12.15
Mounting the battery cover
Main work
– Position battery cover
93
 and pull toward the rear.
The battery cover engages with an audible click.
–
Check the battery cover is seated correctly.
M00451-10
Finishing work
– Mount the front rider's seat. (
12.16
p. 82)
Removing the front spoiler
Preparatory work
– Remove the right side cover.
–
Remove the left side cover.
Main work
– Remove screws
L02258-10
.
(
(
p. 100)
p. 97)
12
SERVICE WORK ON THE CHASSIS
–
Remove screw
–
Remove screws
–
Remove screw
.
L02257-11
.
L02263-12
G01721-13
–
.
Remove screw .
–
Take off the front spoiler.
94
12
SERVICE WORK ON THE CHASSIS
12.17
Fitting front spoiler
95
Main work
– Position the front spoiler.
–
Mount and tighten screw
.
Guideline
Screw, front spoiler retaining bracket,
rear, on engine
–
Mount and tighten screw
M6
9 Nm (6.6 lbf ft)
M6
9 Nm (6.6 lbf ft)
M6
6 Nm (4.4 lbf ft)
.
Guideline
G01721-14
Screw, front spoiler retaining bracket,
rear, on engine
–
Mount and tighten screws
.
Guideline
Screw, front spoiler retaining bracket,
rear
L02263-13
12
SERVICE WORK ON THE CHASSIS
–
Mount and tighten screw
96
.
Guideline
Screw, front spoiler, right, on footrest
bracket
M6
7 Nm (5.2 lbf ft)
M6
7 Nm (5.2 lbf ft)
L02257-12
–
Mount and tighten screws
.
Guideline
Screw, front spoiler
L02258-12
Finishing work
– Install the left side cover.
–
Install the right side cover.
(
p. 98)
(
p. 101)
12
SERVICE WORK ON THE CHASSIS
12.18
Removing the left side cover
–
97
–
.
Remove screws .
–
Pull off holding lug in area
–
Remove expanding rivet
Remove screws
.
L02268-10
M00456-10
.
12
SERVICE WORK ON THE CHASSIS
–
Swing the side cover outward.
–
Pull hose
–
Take off the side cover.
–
Position hose
 out of hose guide .
L02260-10
12.19
Installing the left side cover
L02260-11
 in hose guide .
98
12
SERVICE WORK ON THE CHASSIS
99
–
Position the side cover.
–
Mount and tighten screws
.
Guideline
Screw, side cover
M6
–
Push on the side cover in area
–
Mount and tighten screws
7 Nm (5.2 lbf ft)
.
The holding lug engages in the drilled hole on the front spoiler.
.
Guideline
L02268-11
Screw, side cover on front mask
–
M00456-11
Mount expanding rivet
.
M6
6 Nm (4.4 lbf ft)
12
SERVICE WORK ON THE CHASSIS
12.20
Removing the right side cover
–
100
–
.
Remove screws .
–
Pull off holding lug in area
–
Remove expanding rivet
–
Take off the side cover.
Remove screws
.
L02267-10
M00455-10
.
12
SERVICE WORK ON THE CHASSIS
12.21
Installing the right side cover
101
–
Position the side cover.
–
Mount and tighten screws
.
Guideline
Screw, side cover
–
M6
Push on the side cover in area
7 Nm (5.2 lbf ft)
.
The holding lug engages in the drilled hole on the front spoiler.
–
Mount and tighten screws
.
Guideline
L02267-10
Screw, side cover on front mask
–
M00455-10
Mount expanding rivet
.
M6
6 Nm (4.4 lbf ft)
13
BRAKE SYSTEM
13.1
ABS/antilock brake system
102

The ABS unit
, which consists of a hydraulic unit, ABS control unit, and return pump, is
installed under the seat. A wheel speed sensor
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 Vehicle rollover
–
402052-10
It is not always possible to prevent vehicle rollover in extreme riding situations
(e. g. luggage loaded with a high center of gravity, varying road surfaces, steep
descents, full braking without disengaging the gear). Adapt your riding style to
the road conditions and your 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.
13
BRAKE SYSTEM
103

The ABS warning lamp
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
can be used to switch ABS off manually (see Starting).

13.2
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.)
–
Check the thickness of the front and rear brake discs at several places on the disk to
see if it conforms to measurement
.

Info
Wear reduces the thickness of the brake disc in area
 of the brake disc.
Brake discs - wear limit
400480-10
»
Front
4.5 mm (0.177 in)
Rear
3.6 mm (0.142 in)
If the brake disc thickness is less than the specified value:
13
BRAKE SYSTEM
104
–
–
Check the front and rear brake discs for damage, cracking, and deformation.
»
If the brake disc shows signs of damage, cracking, or deformation:
–
13.3
Change the brake discs.
Change the brake discs.
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.)
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Check the brake fluid level in viewer
»
If the brake fluid is below the MIN marking:
–
L02132-10
.
Add front brake fluid.
(
p. 105)
13
BRAKE SYSTEM
13.4
Adding front brake fluid
105
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.
Info
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. (
p. 106)
13
BRAKE SYSTEM
106
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
–
–
.
Remove cover  with membrane .
Add brake fluid to level .
Remove screws
Guideline
Level
L02133-10
Brake fluid DOT 4 / DOT 5.1 (
–
5 mm (0.2 in)

p. 184)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
13.5
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.
13
BRAKE SYSTEM
107
–
Check the brake linings for minimum thickness
Minimum thickness
»
≥ 1 mm (≥ 0.04 in)
If the minimum thickness is less than specified:
–
–

.
Change the front brake linings.
Check the brake linings for damage and cracking.
»
If there is wear or tearing:
–
Change the front brake linings.
M00457-10
13.6
Checking the rear brake fluid level
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–
Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
glad to help.)
13
BRAKE SYSTEM
108
–
Stand the vehicle upright.
–
Check the brake fluid level in the brake fluid reservoir.
»
If the fluid level reaches the MIN marking
–
Add rear brake fluid.
(
:
p. 108)
M00458-10
13.7
Adding rear brake fluid
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
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.)
13
BRAKE SYSTEM
109
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.
Preparatory work
– Check the rear brake linings. (
p. 109)
Main work
– Stand the vehicle upright.
–
–
 with membrane .
Add brake fluid to level .
Remove screw cap
Brake fluid DOT 4 / DOT 5.1 (
–
M00459-10
13.8
p. 184)
Refit screw cap with membrane.
Info
Clean up overflowed or spilt brake fluid immediately with water.
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.)
13
BRAKE SYSTEM
110
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
–
Check the brake linings for minimum thickness
Minimum thickness
»
≥ 1 mm (≥ 0.04 in)
If the minimum thickness is less than specified:
–
–

.
Change the rear brake linings.
Check the brake linings for damage and cracking.
»
If there is wear or tearing:
–
Change the rear brake linings.
M00460-10
13.9
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.
13
BRAKE SYSTEM
111
–
Disconnect spring
–
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
.
.

Guideline
Free travel at foot brake lever
»
If the free travel does not meet specifications:
–
–
3… 5 mm (0.12… 0.2 in)
Adjust the free travel of the foot brake lever.
Reconnect spring
(
p. 111)
.
M00461-10
13.10
Adjusting the free travel of the 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.
13
BRAKE SYSTEM
112
–
Disconnect spring
–
Release nut
.
 and use screw  to adjust the specified free travel .
Guideline
Free travel at foot brake lever
Info
The range of adjustment is limited.
M00461-11
–
Hold screw
–
Attach spring
 and tighten nut .
.
3… 5 mm (0.12… 0.2 in)
14
WHEELS, TIRES
14.1
Removing the front wheel
113
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
–
Raise the motorcycle with the front wheel stand. (
p. 78)
p. 79)
Main work
– Remove screws
–
–
–
 and push the fender to the side.
Remove screw  and pull wheel speed sensor  out of the hole.
Loosen screw  and screws .
Unscrew screw  about 6 turns and press your hand on the screw to push the wheel
spindle out of the axle clamp. Remove screw .
Warning
Danger of accidents Reduced braking 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.
L02277-10
14
WHEELS, TIRES
14.2
Installing the front wheel
114
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
– Remove spacers
–
»
If the wheel bearing is damaged or worn:
–
–
.
Check the wheel bearing for damage and wear.
Change the front wheel bearing.
Clean and grease the shaft seal rings
Long-life grease (
L02183-11
–
Insert the spacers.
p. 186)
 and mating surfaces  of the spacers.
14
WHEELS, TIRES
115
–
Clean the thread of the wheel spindle and screw
–
Position the front wheel and insert the wheel spindle.
.
The brake linings are correctly positioned.
–
Mount and tighten screw
.
Guideline
Screw, front wheel spindle
–
Position wheel speed sensor
M8
20 Nm
(14.8 lbf ft)
 in the drill hole. Mount and tighten screw .
Guideline
Screw, wheel speed sensor
holder
M6
9 Nm
(6.6 lbf ft)
Loctite® 243™
–
Mount and tighten screws
–
Operate the hand brake lever repeatedly until the brake linings are in contact with the
brake disc and there is a pressure point.
–
Take the motorcycle off of the front wheel stand. (
–
Pull the front brake and compress the fork forcefully a few times.
.
p. 80)
The fork legs straighten.
M00463-10
–
Tighten screws
.
Guideline
Screw, fork stub
M8
Finishing work
– Take the motorcycle off of the front wheel stand. (
–
Take the motorcycle off of the rear wheel stand. (
15 Nm
(11.1 lbf ft)
p. 80)
p. 78)
14
WHEELS, TIRES
14.3
Removing the rear wheel
116
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
p. 78)
Main work
– Remove screw
–
–
 and pull wheel speed sensor  out of the hole.
Remove nut  and the washer. Remove chain adjuster .
Holding the rear wheel, withdraw wheel spindle  with the washer and chain
adjuster.
–
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.
L02150-11
14
WHEELS, TIRES
14.4
Installing the rear wheel
117
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
Warning
Danger of accidents No braking effect when operating the rear brake.
–
After installing the rear wheel, always operate the foot brake until the pressure point is reached.
Main work
– Check the rear hub rubber dampers.
p. 118)
Remove spacers
–
Check the wheel bearing for damage and wear.
»
–

.
If the wheel bearing is damaged or worn:
–
Change the rear wheel bearing.
Clean and grease the shaft seal rings
Long-life grease (
L02151-10
(
–
 and mating surfaces  of the spacers.
p. 186)
–
Insert the spacers.
–
Clean the thread of the wheel spindle and nut
–
Clean the fixing locations on the brake caliper support and swingarm.
–
Position the rear wheel.
–
Push the rear wheel as far forward as possible and place the chain on the rear sprocket.
.
The brake linings are correctly positioned.
14
WHEELS, TIRES
118
–
Pull the rear wheel back and mount wheel spindle
adjuster
.
 with the washer and chain

Info
Mount the left and right chain adjusters
 in the same position.
–
Mount nut
–
Push the rear wheel forward so that the chain adjusters are in contact with the screws,
and tighten nut
.
 and washer.

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
.

Nut, rear wheel spindle
–
Position wheel speed sensor
M14x1.5
90 Nm
(66.4 lbf ft)
 in the drill hole. Mount and tighten screw .
Guideline
L02150-13
Screw, wheel speed sensor
holder
M6
Finishing work
– Take the motorcycle off of the rear wheel stand. (
14.5
9 Nm
(6.6 lbf ft)
Loctite® 243™
p. 78)
Checking the rear hub rubber dampers
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.
14
WHEELS, TIRES
119
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
–
Remove the rear wheel.
Main work
– Check bearing
»
.
Change the rear wheel bearing.
Check the rubber dampers
»
p. 116)
If the bearing is damaged or worn:
–
–
(
p. 78)
 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.
L02153-10
–
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
, 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
»
L02152-10
If play
–
 is larger than the specified value:
Change all rubber dampers in the rear hub.
Finishing work
– Install the rear wheel.
–
≤ 5 mm (≤ 0.2 in)
(
p. 117)
Take the motorcycle off of the rear wheel stand. (
p. 78)
14
WHEELS, TIRES
14.6
Checking the tire condition
120
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.
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.
–
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.
400602-10
Minimum tread depth
≥ 2 mm (≥ 0.08 in)
14
WHEELS, TIRES
121
»
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:
–
14.7
Change the tires.
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.
–
Remove the dust cap.
–
Check tire air pressure when the tires are cold.
Tire air pressure, solo
Front
2.0 bar (29 psi)
Rear
2.0 bar (29 psi)
Tire air pressure with passenger/full payload
400695-01
Front
2.0 bar (29 psi)
Rear
2.2 bar (32 psi)
14
WHEELS, TIRES
122
»
If the tire air pressure does not meet specifications:
–
–
Correct the tire air pressure.
Mount the dust cap.
15
ELECTRICAL SYSTEM
15.1
Removing the battery
123
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
Preparatory work
– Remove the front rider's seat. (
–
Remove the battery cover. (
p. 81)
p. 91)
Main work
– Pull back the negative terminal cover
–
L02156-10
Disconnect the negative cable
.
 of the battery.
15
ELECTRICAL SYSTEM
124
–
Pull back the positive terminal cover
–
Disconnect the positive cable
–
Detach rubber band
–
Pull the battery up and out of the battery holder.
.
 of the battery.
.
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.
L02157-11
15.2
Installing the battery
Main work
– Position the battery in the battery holder.
Info
The battery terminals must be at the top.
L02157-10
–
Attach rubber band
–
Reconnect the positive cable
–
.
 of the battery.
Position positive terminal cover .
15
ELECTRICAL SYSTEM
–
–
125
 of the battery.
Position the negative terminal cover .
Connect the negative cable
L02156-11
Finishing work
– Mount the battery cover. (
15.3
p. 93)
–
Mount the front rider's seat. (
–
Set the clock. (
p. 82)
p. 53)
Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
15
ELECTRICAL SYSTEM
126
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–
Do not dispose of batteries with the household waste. Dispose of a defective battery in an environmentally friendly manner. Give
the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
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 front rider's seat. (
–
Remove the battery cover. (
–
Disconnect the negative cable of the battery to avoid damage to the motorcycle's electronics.
p. 81)
p. 91)
15
ELECTRICAL SYSTEM
127
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
–
.
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
L02139-10
Finishing work
– Mount the battery cover. (
p. 93)
–
Mount the front rider's seat. (
–
Set the clock. (
p. 53)
p. 82)
3 months
15
ELECTRICAL SYSTEM
15.4
Changing the ABS fuses
128
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
–
Use only fuses with the prescribed amperage. Never bypass or repair fuses.
Info
Two fuses for the ABS are located under the protective cap next to the negative terminal of the battery. 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 front rider's seat. (
–
Remove the battery cover. (
p. 81)
p. 91)
To change the fuse of the ABS hydraulic unit:
– Take off the protection cap and remove fuse
.
Info
A defective fuse is indicated by a burned-out fuse wire
.
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are
used.
L02158-10
–
–
Use only fuses with the prescribed amperage. Never bypass or repair
fuses.
Use spare fuses with the correct rating only.
15
ELECTRICAL SYSTEM
129
Fuse (75011088015) (
p. 177)
Tip
Replace spare fuse
–
 in the fuse box so that it is available if needed.
Mount the protection cap.
To change the fuse of the ABS return pump:
– Take off the protection cap and remove fuse
.
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are
used.
–
–
L02158-11
Use only fuses with the prescribed amperage. Never bypass or repair
fuses.
Use spare fuses with the correct rating only.
Fuse (90111088025) (
p. 177)
Tip
Replace spare fuse
–
Mount the protection cap.
Finishing work
– Mount the battery cover. (
–
 in the fuse box so that it is available if needed.
p. 93)
Mount the front rider's seat. (
p. 82)
15
ELECTRICAL SYSTEM
15.5
Changing the fuses of individual power consumers
130
Info
The fuse box with the main fuse and fuses of the individual power consumers is located next to the positive terminal of the battery.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the front rider's seat. (
–
Remove the battery cover. (
p. 81)
p. 91)
Main work
– Open fuse box cover.
–
Remove the defective fuse.
Guideline
Fuse 1 - 30 A - main fuse
Fuse 2 - 15 A - start auxiliary relay, alarm system (OPTIONAL)
Fuse 3 - 15 A - control unit, power relay
L02275-10
Fuse 4 - 15 A - ignition coil
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 - combination instrument, control unit
Fuse 8 - 5 A - ABS control unit
Fuse 9 - 10 A - auxiliary equipment
Fuse 10 - 10 A - auxiliary equipment
15
ELECTRICAL SYSTEM
131
Info
A defective fuse is indicated by a burned-out fuse wire
.
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are
used.
–
–
Use only fuses with the prescribed amperage. Never bypass or repair fuses.
Use spare fuses with the correct rating only.
Fuse (75011088005) (
p. 177)
Fuse (75011088010) (
p. 177)
Fuse (75011088015) (
p. 177)
Fuse (75011088030) (
p. 177)
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 battery cover. (
–
p. 93)
Mount the front rider's seat. (
p. 82)
15
ELECTRICAL SYSTEM
15.6
Changing the low beam bulb
132
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
– Turn socket
–
 counterclockwise.
–
 out of the headlight housing.
Disconnect the socket with the low beam bulb from connector  and remove.
–
Connect the new socket with the low beam bulb to the connector.
Pull the socket with low beam bulb
Low beam (H11 / Sockel PGJ19-2) (
L02161-10
p. 177)
15
ELECTRICAL SYSTEM
133
–
Position the socket with the low beam bulb in the headlight housing.
–
Turn the socket clockwise.
–
Check that the lighting is functioning properly.
L02166-10
15.7
Changing the high beam 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.
15
ELECTRICAL SYSTEM
134
Main work
– Turn socket
–
 counterclockwise.
–
 out of the headlight housing.
Disconnect the socket with the high beam bulb from connector  and remove.
–
Connect the new socket with the high beam bulb to the connector.
Pull the socket with high beam bulb
High beam (H11 / Sockel PGJ19-2) (
p. 177)
L02162-10
L02165-10
–
Position the socket with the high beam bulb in the headlight housing.
–
Turn the socket clockwise.
–
Check that the lighting is functioning properly.
15
ELECTRICAL SYSTEM
15.8
Checking the low beam headlight adjustment
A
0
135
–
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
 under the first mark.
Guideline
0
B
Distance
–

5 cm (2 in)
Position the vehicle perpendicular to the wall at a distance
on the low beam.
 from the wall and switch
Guideline
400726-10
Distance

5 m (16 ft)
–
The rider, with luggage and passenger if applicable, now mounts the motorcycle.
–
Check the low beam headlight adjustment.
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 light-dark border does not meet specifications:
–
Adjust the headlight range of the low beam. (
p. 137)
15
ELECTRICAL SYSTEM
15.9
Checking the high beam headlight adjustment
0
A
136
–
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
 under the first mark.
Guideline
0
B
Distance
–
5 cm (2 in)

Position the vehicle vertically at a distance
high beam.
 in front of the wall and switch on the
Guideline
Distance
5 m (16 ft)
–
The rider, with luggage and passenger if applicable, now mounts the motorcycle.
–
Check the high beam headlight adjustment.
The center of the light cone 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.
B
0
»
If the center of the light cone is not located where specified:
–
400575-10

Adjust the headlight range of the high beam. (
p. 137)
15
ELECTRICAL SYSTEM
15.10
Adjusting the headlight range of the low beam
137
Main work
– Adjust the beam range of the low beam by turning screw
.
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 the low
beam headlight setting).
Info
L02164-10
Turn clockwise to increase the headlight range; turn counterclockwise to reduce
the headlight range.
Finishing work
– Check the low beam headlight adjustment. (
15.11
p. 135)
Adjusting the headlight range of the high beam
Main work
– Adjust the beam distance of the high beam by turning screw
.
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 the high
beam headlight setting).
Info
L02163-10
Turn clockwise to increase the headlight range; turn counterclockwise to reduce
the headlight range.
Finishing work
– Check the high beam headlight adjustment. (
p. 136)
16
COOLING SYSTEM
16.1
Cooling system
138


Water pump
in the engine circulates the coolant.
The pressure resulting from the warming of the cooling system is regulated by a valve in
radiator cap
. Heat expansion causes excess coolant to flow into compensating tank
.
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)
L02259-10

16
COOLING SYSTEM
139

The coolant is cooled by the air stream and a radiator fan
, which is controlled by a thermoswitch.
The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling
effect.
402242-10
16.2
Checking the coolant level in the compensating tank
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
16
COOLING SYSTEM
140
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
The radiator is completely full.
–
Stand the motorcycle upright on a horizontal surface.
–
Check the coolant level in the compensating tank
.
The coolant level must be between MIN and MAX.
»
If there is no coolant in the compensating tank:
–
Check the cooling system for leaks.
Info
Do not start up the motorcycle!
M00464-10
–
»
Fill/bleed the cooling system.
(
p. 145)
If the coolant in the compensating tank is not at the required level, but the tank is
not empty:
–
Correct the coolant level in the compensating tank. (
p. 143)
16
COOLING SYSTEM
16.3
Checking the antifreeze and coolant level
141
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
Preparatory work
– Remove the right side cover.
(
p. 100)
Main work
– Stand the motorcycle upright on a horizontal surface.
–
Remove the cap of the compensating tank
–
Check the coolant antifreeze.
.
−25… −45 °C (−13… −49 °F)
»
If the coolant antifreeze does not meet specifications:
–
M00464-10
–
Correct the coolant antifreeze.
Check the coolant level in the compensating tank.
The coolant level must be between MIN and MAX.
16
COOLING SYSTEM
142
»
If the coolant level does not meet specifications:
–
Correct the coolant level.
Coolant (
p. 184)
–
Mount the cap of the compensating tank.
–
Remove radiator cap
–
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.
L02266-11
»
If the coolant level does not meet specifications:
–
Correct the coolant level and find out the cause of the loss.
Coolant (
»
If you had to add more coolant than the specified amount:
> 0.20 l (> 0.21 qt.)
–
–
p. 184)
Fill/bleed the cooling system.
(
Mount the radiator cap.
Finishing work
– Install the right side cover.
(
p. 101)
p. 145)
16
COOLING SYSTEM
16.4
Correcting the coolant level in the compensating tank
143
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
The radiator is completely full.
Preparatory work
– Check the coolant level in the compensating tank. (
Main work
– Remove cover
–
Add coolant to the MAX marking.
Coolant (
–
M00464-12
 of the compensating tank.
p. 184)
Mount the cover of the compensating tank.
p. 139)
16
COOLING SYSTEM
16.5
Draining the coolant
144
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
Preparatory work
– Remove the right side cover.
(
p. 100)
–
Remove the left side cover.
(
–
Remove the front spoiler. (
p. 93)
p. 97)
Main work
– Stand the motorcycle upright.
L02269-10
–
Place a suitable container under the engine.
–
Remove screw
–
Remove the radiator cap.
–
Completely drain the coolant.
–
Mount screw
.
 with a new seal ring and tighten it.
16
COOLING SYSTEM
145
Guideline
Plug, water pump drain hole
16.6
M6
8 Nm (5.9 lbf ft)
Filling/bleeding the cooling system
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Main work
– Remove radiator cap
L02266-10
.
16
COOLING SYSTEM
146
–
Release bleeder screw
–
Tilt the vehicle slightly to the right.
–
Pour in coolant until it emerges without bubbles at the bleeder screw, and then mount
and tighten the bleeder screw immediately.
Coolant (
 by three turns.
p. 184)
–
Fill the radiator completely with coolant. Mount the radiator cap.
–
Rest the vehicle on the side stand.
L02265-10
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 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.
–
Mount the cap of the compensating tank.
M00464-11
Finishing work
– Fit the front spoiler. (
–
p. 95)
Install the left side cover.
(
p. 98)
 and add coolant until the coolant level is
16
COOLING SYSTEM
147
–
Install the right side cover.
(
p. 101)
17
TUNING THE ENGINE
17.1
Checking the play in the throttle cable
148
–
Check the throttle grip for smooth operation.
–
Move the handlebar to the straight-ahead position. Move the throttle grip back and forth
to ascertain 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.
(
p. 149)
Danger
400192-11
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.
17
TUNING THE ENGINE
17.2
Adjusting the play in the throttle cable
149
–
Move the handlebar to the straight-ahead position.
–
Push back sleeve
–
.
Loosen lock nut .
–
Adjust the play in the throttle cable by turning adjusting screw
.
Guideline
Throttle cable play
–
M00452-10
17.3
3… 5 mm (0.12… 0.2 in)
–
.
Slide on sleeve .
–
Check the clutch lever for smooth operation.
–
Move the handlebar to the straight-ahead position. Pull the clutch lever until resistance
is perceptible, and determine the play in the clutch lever
.
Tighten lock nut
Checking the clutch lever play

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.
(
p. 150)
Note
L02111-11
Clutch damage If there is no play on the clutch lever, the clutch will begin to slip.
–
–
Before 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.
17
TUNING THE ENGINE
150
»
If the clutch lever play changes:
–
17.4
Check the routing of the clutch cable.
Adjusting the clutch cable play
–
Move the handlebar to the straight-ahead position.
–
Push back sleeve
–
.
Loosen lock nut .
–
Adjust the play in the clutch level
 by turning adjusting screw .
Guideline
Clutch lever play
L02155-10
–
Tighten lock nut
–
Slide on sleeve
.
.
1… 3 mm (0.04… 0.12 in)
18
SERVICE WORK ON THE ENGINE
18.1
Checking the engine oil level
151
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.
»
L02257-10
18.2
If the engine oil level is not at the specified level:
–
Add the engine oil. (
p. 154)
Changing the engine oil and oil filter, cleaning the oil screens
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
–
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
18
SERVICE WORK ON THE ENGINE
152
Info
Drain the engine oil only when the engine is warm.
Preparatory work
– Remove the right side cover.
(
p. 100)
–
Remove the left side cover.
(
–
Remove the front spoiler. (
p. 93)
–
Stand the motorcycle on its side stand on a horizontal surface.
p. 97)
Main work
– Place a suitable container under the engine.
–
Remove the oil drain plug
–
Remove oil screen
 with the O-ring.
–
 with the O-ring.
Remove screw plug  with oil screen .
–
Completely drain the engine oil.
–
Thoroughly clean the oil drain plugs and oil screens.
–
Position oil screen
 and mount and tighten oil drain plug  with the O-ring.
Guideline
Oil drain plug
–
Mount and tighten screw plug
M24x1.5
15 Nm
(11.1 lbf ft)
 with oil screen  and the O-ring.
Guideline
Oil screen screw plug, small
L02270-10
M17x1.5
12 Nm (8.9 lbf ft)
18
SERVICE WORK ON THE ENGINE
–
–
153
. Remove the oil filter cover  with the O-ring.
Pull oil filter  out of the oil filter housing.
Remove screws
Circlip pliers reverse (51012011000)
–
Completely drain the engine oil.
–
Thoroughly clean the parts and sealing area.
–
Insert oil filter
–
Lubricate the O-ring of the oil filter cover. Mount the oil filter cover
–
Mount and tighten the screws.
101918-10
.
.
Guideline
Screw, oil filter cover
M5
8 Nm (5.9 lbf ft)
Info
L02271-10
Too little engine oil or poor-quality engine oil results in premature wear to the
engine.
18
SERVICE WORK ON THE ENGINE
–
Remove the oil filler plug
engine oil.
Engine oil
–
154
 with the O-ring from the clutch cover and fill up with
1.6 l (1.7 qt.)
Engine oil (SAE 15W/50) (
p. 184)
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.
–
401955-12
–
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. (
18.3
p. 95)
–
Install the left side cover.
–
Install the right side cover.
–
Check the engine oil level. (
(
p. 98)
(
p. 101)
p. 151)
Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
18
SERVICE WORK ON THE ENGINE
Main work
– Remove the oil filler plug
engine oil.
1
0
155
 with the O-ring from the clutch cover and fill up with
Engine oil (SAE 15W/50) (
p. 184)
Info
For optimal performance of the engine oil, do not mix different types of engine
oil.
If appropriate, change the engine oil.
401955-10
–
Install and tighten the oil filler plug with the 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. 151)
19
CLEANING, CARE
19.1
Cleaning the motorcycle
156
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.
Motorcycle cleaner (
401061-01
p. 186)
19
CLEANING, CARE
157
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.
–
Clean the chain. (
–
Treat bare metal parts (except for brake discs and exhaust system) with anti-corrosion
materials.
p. 84)
Preserving materials for paints, metal and rubber (
–
Treat all painted parts with a mild paint polish.
p. 187)
19
CLEANING, CARE
158
Perfect Finish and high gloss polish for paints (
p. 187)
Info
Do not polish parts that were matte when delivered as this would strongly impair
the material quality.
–
Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
( p. 187)
–
Oil the ignition/steering lock.
Universal oil spray (
19.2
p. 187)
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.
–
Clean the motorcycle. (
–
Clean the brakes.
p. 156)
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.
401060-01
19
CLEANING, CARE
159
–
Treat the engine, swingarm, and all other bright and zinc-plated parts (except for the
brake discs) with a wax-based corrosion inhibitor.
Info
Corrosion inhibitor is not permitted to come in contact with the brake discs as
this would greatly reduce the braking force.
–
Clean the chain. (
p. 84)
20
STORAGE
20.1
Storage
160
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.
–
When refueling for the last time before taking the motorcycle out of service, add fuel
additive.
Fuel additive (
401058-01
p. 186)
–
Refuel. (
–
Clean the motorcycle. (
–
Change the engine oil and oil filter and clean the oil screens.
–
Check the antifreeze and coolant level. (
–
Check the tire air pressure. (
–
Remove the battery.
–
Recharge the battery.
p. 70)
p. 156)
(
(
p. 151)
p. 141)
p. 121)
p. 123)
(
p. 125)
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.
–
Raise the motorcycle with the rear wheel stand. (
p. 78)
20
STORAGE
161
–
Raise the motorcycle with the front wheel stand. (
–
Cover the motorcycle with a tarp or similar cover that is permeable to air.
p. 79)
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.
20.2
Preparing for use after storage
401059-01
–
Take the motorcycle off of the front wheel stand. (
–
Take the motorcycle off of the rear wheel stand. (
–
Recharge the battery.
–
Install the battery.
–
Set the clock. (
–
Perform checks and maintenance steps when preparing for use. (
–
Take a test ride.
(
(
p. 80)
p. 78)
p. 125)
p. 124)
p. 53)
p. 60)
21
TROUBLESHOOTING
162
Faults
Possible cause
Action
Engine does not crank when the electric starter button is pressed
Operating error
–
Go through the steps of starting the engine.
( p. 61)
Battery discharged
–
Recharge the battery.
Fuse 1, 3, 4, or 7 is blown
–
Change the fuses of individual power consumers.
( p. 130)
No ground connection present
–
Check the ground connection.
Engine turns only if the clutch lever is
drawn
The vehicle is in gear
–
Shift gear to neutral.
The vehicle is in gear and the side
stand is folded out
–
Shift gear to neutral.
Engine turns but does not start
Operating error
–
Go through the steps of starting the engine.
( p. 61)
Defect in fuel injection system
–
Read out the fault memory using the KTM diagnostics tool.
Air filter is very dirty
–
Change the air filter.
Fuel filter is very dirty
–
Check the fuel pressure.
Defect in fuel injection system
–
Read out the fault memory using the KTM diagnostics tool.
Too little coolant in cooling system
–
Check the cooling system for leakage.
–
Check the coolant level in the compensating
tank. ( p. 139)
Radiator fins very dirty
–
Clean the radiator fins.
Foam formation in cooling system
–
Drain the coolant.
Engine has too little power
Engine overheats
(
(
p. 125)
p. 144)
–
Fill/bleed the cooling system.
Thermostat defective
–
Check the thermostat.
Fuse 5 blown
–
Change the fuses of individual power consumers.
( p. 130)
(
p. 145)
21
TROUBLESHOOTING
163
Faults
Possible cause
Action
Engine overheats
Defect in radiator fan system
–
Check the radiator fan system.
The engine diagnosis warning
lamp (MIL) lights up red
Defect in fuel injection system
–
Read out the fault memory using the KTM diagnostics tool.
Engine dies during the trip
Lack of fuel
–
Refuel. (
Fuse 1, 3, 4, or 7 is blown
–
Change the fuses of individual power consumers.
( p. 130)
p. 70)
ABS fuse is blown
–
Change the ABS fuses. (
Large difference in wheel speeds of the
front and rear wheels
–
Stop the vehicle, switch off the ignition, and
start it again.
Malfunction in ABS
–
Read out the ABS fault memory using the KTM
diagnostics tool.
Engine vent hose bent
–
Route the vent hose without bends or change it if
necessary.
Engine oil level too high
–
Check the engine oil level. (
Engine oil too thin (low viscosity)
–
Change the engine oil and oil filter and clean the
oil screens. ( p. 151)
Headlight and parking light are not
functioning
Fuse 6 blown
–
Change the fuses of individual power consumers.
( p. 130)
Turn signal, brake light, and horn are
not functional
Fuse 6 blown
–
Change the fuses of individual power consumers.
( p. 130)
Time is not (correctly) displayed
Fuse 7 is blown
–
Change the fuses of individual power consumers.
( p. 130)
–
Set the clock. (
Battery discharged
Ignition not switched off when vehicle
was parked
–
Recharge the battery.
The ABS warning lamp lights up
High oil consumption
p. 128)
p. 151)
p. 53)
(
p. 125)
21
TROUBLESHOOTING
164
Faults
Possible cause
Action
Battery discharged
Battery is not being charged by alternator
–
Check the charging voltage.
–
Check the open-circuit current.
Fuse 7 is blown
–
Change the fuses of individual power consumers.
( p. 130)
–
Set the clock. (
–
Check the wiring harness and plug-in connection.
The combination instrument shows
nothing on the display
Speedometer in combination instrument not functioning
Speedometer wiring harness is damaged or plug-in connection is oxidized
p. 53)
22
BLINK CODE
165
Blink code of FI warning
lamp (MIL)
02 FI warning lamp (MIL) flashes 2x short
Error level condition
Crankshaft position sensor - measurement range or power problem
Blink code of FI warning
lamp (MIL)
06 FI warning lamp (MIL) flashes 6x short
Error level condition
Throttle position sensor circuit A - input signal too low
Throttle position sensor circuit A - input signal too high
Blink code of FI warning
lamp (MIL)
09 FI warning lamp (MIL) flashes 9x short
Error level condition
Manifold absolute pressure sensor - input signal too low
Manifold absolute pressure sensor - input signal too high
Blink code of FI warning
lamp (MIL)
11 FI warning lamp (MIL) flashes 1x long, 1x short
Error level condition
Idle control - engine speed below target value
Idle control - engine speed above target value
Blink code of FI warning
lamp (MIL)
12 FI warning lamp (MIL) flashes 1x long, 2x short
Error level condition
Engine coolant temperature sensor - input signal too low
Engine coolant temperature sensor - input signal too high
22
BLINK CODE
166
Blink code of FI warning
lamp (MIL)
13 FI warning lamp (MIL) flashes 1x long, 3x short
Error level condition
Intake air temperature sensor - input signal too low
Intake air temperature sensor - input signal too high
Blink code of FI warning
lamp (MIL)
14 FI warning lamp (MIL) flashes 1x long, 4x short
Error level condition
Fuel tank sensor - circuit fault
Fuel tank sensor - short circuit to ground
Fuel tank sensor - short circuit to plus
Blink code of FI warning
lamp (MIL)
15 FI warning lamp (MIL) flashes 1x long, 5x short
Error level condition
Rollover sensor - plausibility
Rollover sensor - circuit fault
Rollover sensor - short circuit to ground
Rollover sensor - short circuit to plus
Blink code of FI warning
lamp (MIL)
16 FI warning lamp (MIL) flashes 1x long, 6x short
Error level condition
Radiator fan motor - circuit fault
Radiator fan motor - input signal too low
Radiator fan motor - input signal too high
22
BLINK CODE
167
Blink code of FI warning
lamp (MIL)
17 FI warning lamp (MIL) flashes 1x long, 7x short
Error level condition
Lambda sensor - circuit fault
Lambda sensor - input signal too low
Lambda sensor - input signal too high
Lambda sensor - no function
Blink code of FI warning
lamp (MIL)
18 FI warning lamp (MIL) flashes 1x long, 8x short
Error level condition
Engine diagnosis warning lamp (MIL) - circuit fault
Engine diagnosis warning lamp (MIL) - short circuit to ground
Engine diagnosis warning lamp (MIL) - short circuit to plus
Blink code of FI warning
lamp (MIL)
19 FI warning lamp (MIL) flashes 1x long, 9x short
Error level condition
Fuel pump lamp - circuit fault
Low fuel warning lamp - input signal too low
Low fuel warning lamp - input signal too high
Blink code of FI warning
lamp (MIL)
21 FI warning lamp (MIL) flashes 2x long, 1x short
Error level condition
Engine control relay - switch-off delay
22
BLINK CODE
168
Blink code of FI warning
lamp (MIL)
22 FI warning lamp (MIL) flashes 2x long, 2x short
Error level condition
Engine speed signal - circuit fault
Engine speed signal - input signal too low
Engine speed signal - input signal too high
Blink code of FI warning
lamp (MIL)
23 FI warning lamp (MIL) flashes 2x long, 3x short
Error level condition
Travel speed sensor - measurement range or power problem
Blink code of FI warning
lamp (MIL)
24 FI warning lamp (MIL) flashes 2x long, 4x short
Error level condition
System voltage - too low
System voltage - too high
System voltage - implausible value
Blink code of FI warning
lamp (MIL)
25 FI warning lamp (MIL) flashes 2x long, 5x short
Error level condition
Side stand switch - plausibility
Side stand switch - circuit fault
Side stand switch - short circuit to ground
Side stand switch - short circuit to plus
22
BLINK CODE
169
Blink code of FI warning
lamp (MIL)
26 FI warning lamp (MIL) flashes 2x long, 6x short
Error level condition
Sensor A reference voltage - input signal too low
Sensor A reference voltage - input signal too high
Blink code of FI warning
lamp (MIL)
27 FI warning lamp (MIL) flashes 2x long, 7x short
Error level condition
Sensor B reference voltage - input signal too low
Sensor B reference voltage - input signal too high
Blink code of FI warning
lamp (MIL)
33 FI warning lamp (MIL) flashes 3x long, 3x short
Error level condition
Injector - circuit fault
Injector - input signal too low
Injector - input signal too high
Blink code of FI warning
lamp (MIL)
41 FI warning lamp (MIL) flashes 4x long, 1x short
Error level condition
Fuel pump relay - circuit fault
Fuel pump relay - input signal too low
Fuel pump relay - input signal too high
22
BLINK CODE
170
Blink code of FI warning
lamp (MIL)
45 FI warning lamp (MIL) flashes 4x long, 5x short
Error level condition
Lambda sensor heater - circuit fault
Lambda sensor heater - short circuit to ground or open circuit
Lambda sensor heater - input signal too high
Blink code of FI warning
lamp (MIL)
49 FI warning lamp (MIL) flashes 4x long, 9x short
Error level condition
Idle control - input signal too low
Idle control - input signal too high
Idle control - circuit fault
23
TECHNICAL DATA
23.1
Engine
171
Design
1-cylinder 4-stroke engine, water-cooled
Displacement
373 cm³ (22.76 cu in)
Stroke
60 mm (2.36 in)
Bore
89 mm (3.5 in)
Compression ratio
12.6:1
Control
DOHC, 4 valves controlled via cam lever, chain drive
Valve diameter, intake
36 mm (1.42 in)
Valve diameter, exhaust
29 mm (1.14 in)
Valve clearance, intake, cold
0.08… 0.12 mm (0.0031… 0.0047 in)
Valve clearance, exhaust, cold
0.13… 0.17 mm (0.0051… 0.0067 in)
Crankshaft bearing
2 slide bearings
Conrod bearing
Sleeve bearing
Pistons
Forged light alloy
Piston rings
1 compression ring, 1 tapered compression piston ring, 1 oil
scraper ring
Engine lubrication
Pressure circulation lubrication with two rotary pumps
Primary transmission
30:80
Clutch
Clutch in oil bath/mechanically activated
Transmission
6-gear, claw shifted
Transmission ratio
1st gear
12:32
2nd gear
14:26
3rd gear
19:27
23
TECHNICAL DATA
172
4th gear
21:24
5th gear
23:22
6th gear
25:21
Mixture preparation
Electronically controlled fuel injection
Ignition
Contactless controlled fully electronic ignition with digital ignition
adjustment
Alternator
12 V, 296 W
Spark plug
BOSCH VR 5 NE
Spark plug electrode gap
0.8 mm (0.031 in)
Spark plug
BOSCH VR 5 NEU
Spark plug electrode gap
1 mm (0.04 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Idle speed
1,650… 1,750 rpm
Starting aid
Electric starter
23.2
Engine tightening torques
Oil nozzle
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, gear sensor
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, ignition pulse generator
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, oil filter cover
M5
8 Nm (5.9 lbf ft)
–
Screw, retaining bracket
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, retaining bracket, stator cable
M5
8 Nm (5.9 lbf ft)
Loctite® 243™
Screw, stator
M5
8 Nm (5.9 lbf ft)
Loctite® 243™
Cylinder head screw
M6
12 Nm (8.9 lbf ft)
–
23
TECHNICAL DATA
173
Nut, water pump impeller
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Oil nozzle
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Plug, water pump drain hole
M6
8 Nm (5.9 lbf ft)
–
Screw, alternator cover
M6
12 Nm (8.9 lbf ft)
–
Screw, bearing retainer
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, camshaft bearing bridge
M6
11 Nm (8.1 lbf ft)
–
Screw, camshaft, decompression shaft
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, chain securing guide
M6
11 Nm (8.1 lbf ft)
Loctite® 243™
Screw, clutch cover
M6
12 Nm (8.9 lbf ft)
–
Screw, clutch spring
M6
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6x35
12 Nm (8.9 lbf ft)
–
Screw, engine case
M6x75
12 Nm (8.9 lbf ft)
–
Screw, engine vent plate
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, freewheel gear retaining bracket
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, lock washer, engine sprocket
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, locking lever
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, oil pump
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, retaining bracket, shaft seal ring,
clutch cover
M6
11 Nm (8.1 lbf ft)
Loctite® 243™
Screw, shift drum locating
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, starter motor
M6
12 Nm (8.9 lbf ft)
–
Screw, timing chain tensioner
M6
12 Nm (8.9 lbf ft)
–
Screw, timing chain tensioning rail
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, unlocking of timing chain tensioner
M6
10 Nm (7.4 lbf ft)
–
23
TECHNICAL DATA
Screw, valve cover
174
M6
12 Nm (8.9 lbf ft)
–
Screw, water pump cover
M6
12 Nm (8.9 lbf ft)
–
Nut, exhaust flange
M8
22 Nm (16.2 lbf ft)
–
Screw plug
M8
12 Nm (8.9 lbf ft)
–
Screw, balancer shaft gear
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Screw, return spring, quick shifter
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Stud, exhaust flange
M8
22 Nm (16.2 lbf ft)
–
Screw, conrod bearing
M8x1
34 Nm (25.1 lbf ft)
–
Oil pressure sensor
M10
14 Nm (10.3 lbf ft)
–
Rotor screw
M10
110 Nm (81.1 lbf ft)
Loctite® 243™
Screw, camshaft drive sprocket
M10
32 Nm (23.6 lbf ft)
Loctite® 243™
Screw, cylinder head
M10
1st stage
30 Nm (22.1 lbf ft)
2nd stage
60 Nm (44.3 lbf ft)
Thread is oiled, head flat is
greased
Water temperature sensor
M10
14 Nm (10.3 lbf ft)
–
Screw plug, cam lever axis
M10x1
9 Nm (6.6 lbf ft)
–
Spark plug
M12
15 Nm (11.1 lbf ft)
–
Nut, inner clutch hub
M16LHx1.5
120 Nm (88.5 lbf ft)
Loctite® 243™
Nut, primary gear/timing chain sprocket
M16x1.5
120 Nm (88.5 lbf ft)
Loctite® 243™
Oil screen screw plug, small
M17x1.5
12 Nm (8.9 lbf ft)
–
Screw plug, alternator cover
M18x1.5
10 Nm (7.4 lbf ft)
–
Oil drain plug
M24x1.5
15 Nm (11.1 lbf ft)
–
Screw plug, alternator cover
M24x1.5
10 Nm (7.4 lbf ft)
–
Nut, balancer shaft gear
M28x1.5
60 Nm (44.3 lbf ft)
Loctite® 243™
23
TECHNICAL DATA
23.3
Capacities
23.3.1
Engine oil
Engine oil
23.3.2
Engine oil (SAE 15W/50) (
p. 184)
1.1 l (1.2 qt.)
Coolant (
10 l (2.6 US gal)
Super unleaded (ROZ 95/RON 95/PON 91) (
p. 184)
Fuel
Total fuel tank capacity, approx.
Fuel reserve, approx.
23.4
1.6 l (1.7 qt.)
Coolant
Coolant
23.3.3
175
p. 185)
1.5 l (1.6 qt.)
Chassis
Frame
Lattice frame of steel tubes, powder-coated
Fork
WP Suspension
Shock absorber
WP Suspension
Brake system
Front
Disc brake with four-pot brake caliper
Rear
Disc brake with single-piston brake caliper, floating
Suspension travel
Front
125 mm (4.92 in)
Rear
150 mm (5.91 in)
Brake discs - diameter
23
TECHNICAL DATA
176
Front
300 mm (11.81 in)
Rear
230 mm (9.06 in)
Brake discs - wear limit
Front
4.5 mm (0.177 in)
Rear
3.6 mm (0.142 in)
Tire air pressure, solo
Front
2.0 bar (29 psi)
Rear
2.0 bar (29 psi)
Tire air pressure with passenger/full payload
Front
2.0 bar (29 psi)
Rear
2.2 bar (32 psi)
Secondary ratio
15:45
Chain
5/8 x 1/4” (520) O‑ring
Steering head angle
66.5°
Wheelbase
1,340±15 mm (52.76±0.59 in)
Seat height, unloaded
820 mm (32.28 in)
Ground clearance, unloaded
178 mm (7.01 in)
Weight without fuel, approx.
152.5 kg (336.2 lb.)
Maximum permissible front axle load
125 kg (276 lb.)
Maximum permissible rear axle load
210 kg (463 lb.)
Maximum permissible overall weight
335 kg (739 lb.)
23
TECHNICAL DATA
23.5
Electrical system
177
Battery
ETZ-9-BS
Battery voltage: 12 V
Nominal capacity: 8 Ah
Maintenance-free
Fuse
75011088005
5A
Fuse
75011088010
10 A
Fuse
75011088015
15 A
Fuse
90111088025
25 A
Fuse
75011088030
30 A
Low beam
H11 / Sockel PGJ19-2
12 V
55 W
High beam
H11 / Sockel PGJ19-2
12 V
55 W
Parking light
LED
Instrument lights and indicator lamps
LED
Turn signal
LED
Brake/tail light
LED
License plate lamp
LED
23.6
Tires
Front tires
Rear tires
110/70 ZR 17 M/C 54W TL
Metzeler SPORTEC M5 Interact
150/60 ZR 17 M/C 66W TL
Metzeler SPORTEC M5 Interact
Additional information is available in the Service section under:
http://www.ktm.com
23
TECHNICAL DATA
23.7
Fork
178
Fork part number
90801000000
Fork
WP Suspension
Fork length
736 mm (28.98 in)
Fork oil
23.8
460 ml (15.55 fl. oz.)
Fork oil (SAE 4) (48601166S1) (
p. 185)
Shock absorber
Shock absorber part number
90804010000
Shock absorber
WP Suspension
Spring preload
Comfort
3 clicks
Standard
5 clicks
Sport
7 clicks
Full payload
8 clicks
Static sag
15 mm (0.59 in)
Riding sag
45… 50 mm (1.77… 1.97 in)
Fitted length
304 mm (11.97 in)
23.9
Chassis tightening torques
Exhaust clamp
PT®
10 Nm (7.4 lbf ft)
–
4 Nm (3 lbf ft)
–
Screw, chain guard
EJOT
Remaining nuts, chassis
M4
3 Nm (2.2 lbf ft)
–
Remaining screws, chassis
M4
3 Nm (2.2 lbf ft)
–
K60x30
23
TECHNICAL DATA
Screw, EFI control unit
179
M4
3 Nm (2.2 lbf ft)
–
Nut, reflector on retaining plate
M5
7 Nm (5.2 lbf ft)
–
Nut, retaining plate on license plate
holder
M5
4 Nm (3 lbf ft)
–
Remaining nuts, chassis
M5
5 Nm (3.7 lbf ft)
–
Remaining screws, chassis
M5
5 Nm (3.7 lbf ft)
–
Screw, ABS hose clamp
M5
6 Nm (4.4 lbf ft)
–
Screw, anti-rotation lock, handlebar stub
M5
4 Nm (3 lbf ft)
–
Screw, battery compartment
M5
4 Nm (3 lbf ft)
–
Screw, chain guard
M5
7 Nm (5.2 lbf ft)
Loctite® 204™
Screw, cover in front of battery compartment
M5
4 Nm (3 lbf ft)
–
Screw, fuel pump
M5
5 Nm (3.7 lbf ft)
–
Screw, fuel tank cover
M5
5 Nm (3.7 lbf ft)
–
Screw, rollover sensor
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, side stand switch
M5
5 Nm (3.7 lbf ft)
Loctite® 243™
Screw, tail end lower part
M5
4 Nm (3 lbf ft)
–
Cap bolt, footrest
M6
9 Nm (6.6 lbf ft)
–
Nut, foot brake lever adjustment
M6
10 Nm (7.4 lbf ft)
–
Nut, license plate bracket
M6
8.5 Nm (6.27 lbf ft)
–
Nut, shift rod
M6
10 Nm (7.4 lbf ft)
–
Nut, shift rod
M6LH
10 Nm (7.4 lbf ft)
–
Nut, tail light
M6
7 Nm (5.2 lbf ft)
–
Remaining nuts, chassis
M6
10 Nm (7.4 lbf ft)
–
Remaining screws, chassis
M6
10 Nm (7.4 lbf ft)
–
23
TECHNICAL DATA
180
Screw, ABS module on ABS module
retaining bracket
M6
7 Nm (5.2 lbf ft)
–
Screw, ABS module retaining bracket on
silent block
M6
7 Nm (5.2 lbf ft)
–
Screw, air filter box lid
M6
3 Nm (2.2 lbf ft)
–
Screw, air filter box, on frame
M6
6 Nm (4.4 lbf ft)
–
Screw, battery compartment
M6
6 Nm (4.4 lbf ft)
–
Screw, brake fluid container, front brake
M6
8 Nm (5.9 lbf ft)
–
Screw, brake fluid container, rear brake
M6
7 Nm (5.2 lbf ft)
–
Screw, brake line guide on bottom triple
clamp
M6
7 Nm (5.2 lbf ft)
Loctite® 243™
Screw, cable holder, side stand switch
M6
9 Nm (6.6 lbf ft)
Loctite® 243™
Screw, chain guard
M6
7 Nm (5.2 lbf ft)
–
Screw, chain sliding guard
M6
7 Nm (5.2 lbf ft)
–
Screw, compensating tank
M6
9 Nm (6.6 lbf ft)
–
Screw, engine sprocket cover on frame
M6
7 Nm (5.2 lbf ft)
–
Screw, foot brake cylinder
M6
9 Nm (6.6 lbf ft)
Loctite® 243™
Screw, footrest bracket
M6
7 Nm (5.2 lbf ft)
–
Screw, front fender on axle clamp
M6
7 Nm (5.2 lbf ft)
–
Screw, front fender, top side
M6
7 Nm (5.2 lbf ft)
–
Screw, front mask
M6
7 Nm (5.2 lbf ft)
–
Screw, front mask structure on headlight
bracket
M6
6 Nm (4.4 lbf ft)
–
Screw, front seat fixing
M6
6 Nm (4.4 lbf ft)
–
Screw, front spoiler
M6
7 Nm (5.2 lbf ft)
–
23
TECHNICAL DATA
181
Screw, front spoiler retaining bracket,
rear
M6
6 Nm (4.4 lbf ft)
–
Screw, front spoiler retaining bracket,
rear, on engine
M6
9 Nm (6.6 lbf ft)
–
Screw, front spoiler, right, on footrest
bracket
M6
7 Nm (5.2 lbf ft)
–
Screw, ground cable, on frame
M6
7 Nm (5.2 lbf ft)
–
Screw, handlebar stub
M6
7 Nm (5.2 lbf ft)
Loctite® 243™
Screw, handlebar weight
M6
9 Nm (6.6 lbf ft)
–
Screw, ignition coil
M6
9 Nm (6.6 lbf ft)
–
Screw, ignition lock
M6
11 Nm (8.1 lbf ft)
–
Screw, license plate holder on license
plate bracket
M6
7 Nm (5.2 lbf ft)
–
Screw, magnetic holder on side stand
M6
4 Nm (3 lbf ft)
Loctite® 243™
Screw, mirror holder
M6
9 Nm (6.6 lbf ft)
–
Screw, passenger seat
M6
7 Nm (5.2 lbf ft)
–
Screw, radiator air inlet, on frame
M6
6 Nm (4.4 lbf ft)
–
Screw, radiator holder
M6
6 Nm (4.4 lbf ft)
–
Screw, rear ABS sensor wheel
M6
6 Nm (4.4 lbf ft)
Loctite® 204™
Screw, rear fender
M6
7 Nm (5.2 lbf ft)
–
Screw, retaining bracket, EFI control
unit
M6
6 Nm (4.4 lbf ft)
–
Screw, shift lever linkage
M6
11 Nm (8.1 lbf ft)
Loctite® 243™
Screw, side cover
M6
7 Nm (5.2 lbf ft)
–
Screw, side cover on front mask
M6
6 Nm (4.4 lbf ft)
–
Screw, voltage regulator
M6
10 Nm (7.4 lbf ft)
–
23
TECHNICAL DATA
182
Screw, voltage regulator holder
M6
11 Nm (8.1 lbf ft)
–
Screw, wheel speed sensor holder
M6
9 Nm (6.6 lbf ft)
Loctite® 243™
Screw, windshield
M6
9 Nm (6.6 lbf ft)
–
Nut, rear sprocket screw
M8
27 Nm (19.9 lbf ft)
–
Remaining nuts, chassis
M8
25 Nm (18.4 lbf ft)
–
Remaining screws, chassis
M8
25 Nm (18.4 lbf ft)
–
Screw, chain guard
M8
11 Nm (8.1 lbf ft)
–
Screw, engine bearer on frame
M8
24 Nm (17.7 lbf ft)
–
Screw, foot brake lever
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
Screw, front brake disc
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, front wheel spindle
M8
20 Nm (14.8 lbf ft)
–
Screw, fuel tank attachment, rear, on
frame
M8
16 Nm (11.8 lbf ft)
–
Screw, horn
M8
7 Nm (5.2 lbf ft)
–
Screw, main silencer
M8
23 Nm (17 lbf ft)
–
Screw, passenger footrest bracket
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Screw, rear brake disc
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, shift lever
M8
17 Nm (12.5 lbf ft)
Loctite® 243™
Screw, top triple clamp
M8
15 Nm (11.1 lbf ft)
–
Screw, front brake caliper
M8x1
30 Nm (22.1 lbf ft)
Loctite® 204™
Fitting, engine mounting bracket
M10
50 Nm (36.9 lbf ft)
–
Remaining nuts, chassis
M10
45 Nm (33.2 lbf ft)
–
Remaining screws, chassis
M10
45 Nm (33.2 lbf ft)
–
Banjo bolt, brake line
M10x1
24 Nm (17.7 lbf ft)
–
Fitting, shock absorber, bottom
M10x1.25
50 Nm (36.9 lbf ft)
–
23
TECHNICAL DATA
183
Screw, front footrest bracket
M10x1.25
50 Nm (36.9 lbf ft)
–
Screw, side stand bracket
M10x1.25
33 Nm (24.3 lbf ft)
Loctite® 243™
Stud, rear sprocket
M10x1.25
50 Nm (36.9 lbf ft)
–
Nut, rear wheel spindle
M14x1.5
90 Nm (66.4 lbf ft)
–
Screw, top steering head
M16x1.5
52 Nm (38.4 lbf ft)
Loctite® 204™
Lambda sensor
M18x1.5
15 Nm (11.1 lbf ft)
–
24
SUBSTANCES
184
Brake fluid DOT 4 / DOT 5.1
Standard/classification
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding
properties.
Recommended supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Only use high quality coolant with corrosion inhibitor for aluminum motors (even in countries with high temperatures). Using inferior
antifreeze can result in corrosion and foaming.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13…
−49 °F)
Recommended supplier
Motorex®
– COOLANT M3.0
Engine oil (SAE 15W/50)
Standard/classification
– JASO T903 MA ( p. 188)
–
SAE (
p. 188) (SAE 15W/50)
anti-corrosion/antifreeze
distilled water
24
SUBSTANCES
185
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties.
Partially synthetic engine oil
Recommended supplier
Motorex®
– Formula 4T
Fork oil (SAE 4) (48601166S1)
Standard/classification
– SAE ( p. 188) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
Super unleaded (ROZ 95/RON 95/PON 91)
Standard/classification
– DIN EN 228 (ROZ 95/RON 95/PON 91)
Guideline
– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.
–
Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.
Info
Do not use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).
25
AUXILIARY SUBSTANCES
Chain cleaner
Recommended supplier
Motorex®
– Chain Clean
Chain lube for road use
Guideline
Recommended supplier
Motorex®
– Chainlube Road
Fuel additive
Recommended supplier
Motorex®
– Fuel Stabilizer
Long-life grease
Recommended supplier
Motorex®
– Bike Grease 2000
Motorcycle cleaner
Recommended supplier
Motorex®
– Moto Clean
186
25
AUXILIARY SUBSTANCES
Perfect Finish and high gloss polish for paints
Recommended supplier
Motorex®
– Moto Polish & Shine
Preserving materials for paints, metal and rubber
Recommended supplier
Motorex®
– Moto Protect
Special cleaner for glossy and matte paint finishes, metal and plastic surfaces
Recommended supplier
Motorex®
– Quick Cleaner
Universal oil spray
Recommended supplier
Motorex®
– Joker 440 Synthetic
187
26
STANDARDS
188
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Antilock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Auxiliary substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
189
Brake linings
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 106
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Brakes, applying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
C
Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Capacity
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 175
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Chain
chain dirt accumulation, checking . . . . . . . . . . . . . . . . . 84
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Battery cover
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Blink code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165-170
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Clutch cable play
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 104
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Combination instrument
activation and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
B
Clutch lever play
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
INDEX
190
average fuel consumption 1/average fuel consumption 2
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
average fuel consumption 2/service menu . . . . . . . . . . .
average speed/average fuel consumption 1 menu . . . . . .
coolant temperature indicator . . . . . . . . . . . . . . . . . . . .
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
display TRIP F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
distance menu 1 TRIP 1 . . . . . . . . . . . . . . . . . . . . . . . .
distance menu 2 TRIP 2 . . . . . . . . . . . . . . . . . . . . . . . .
filling level display in fuel tank . . . . . . . . . . . . . . . . . . .
function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
info display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
range/riding time menu . . . . . . . . . . . . . . . . . . . . . . . .
riding time/average speed menu . . . . . . . . . . . . . . . . . .
service/range menu . . . . . . . . . . . . . . . . . . . . . . . . . . .
total distance menu ODO . . . . . . . . . . . . . . . . . . . . . . .
warning notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant
draining
. 47
. 48
. 46
. 44
. 41
. 43
. 51
. 52
. 42
. 39
. 40
. 45
. 50
. 46
. 49
. 51
. 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
compensating tank, checking . . . . . . . . . . . . . . . . . . . . 139
compensating tank, correcting . . . . . . . . . . . . . . . . . . . 143
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Filling up
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
free travel, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 111
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Front rider's seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
INDEX
191
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
I
Front spoiler
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Indicator lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuse
individual power consumers, changing . . . . . . . . . . . . . . 130
Fuses, ABS
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
G
Grab handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
H
Hand brake lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Headlight range of low beam
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
K
Kilometers or miles
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
L
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Loading the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Low beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Low beam headlight adjustment
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
M
High beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Motorcycle
cleaning . . . . . . . . . . . . . . . . .
raising with the front wheel stand
raising with the rear wheel stand .
taking off of the front wheel stand
taking off of the rear wheel stand
High beam flasher button . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
O
High beam headlight adjustment
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Headlight range of the high beam
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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156
. 79
. 78
. 80
. 78
INDEX
192
Oil screens
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Right side cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
P
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Passenger seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Play in throttle cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Preparing for use
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
checks and maintenance when preparing for use . . . . . . . . 60
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
R
Rear hub rubber dampers
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
S
Safe operation .
Seat lock . . . .
Service . . . . . .
Service schedule
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. . . 10
. . . 29
. . . 13
72-74
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Shift speed RPM 1
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Shift speed RPM 2
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Shifting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Shock absorber
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 75
Side cover, left
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INDEX
193
Steering
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Use definition
T
Technical data
capacities . . . . . . . . . . .
chassis . . . . . . . . . . . . .
chassis tightening torques
electrical system . . . . . .
engine . . . . . . . . . . . . .
engine tightening torques
fork . . . . . . . . . . . . . . .
shock absorber . . . . . . . .
tires . . . . . . . . . . . . . . .
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175
175
178
177
171
172
178
178
177
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Time
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162-164
U
...................................8
V
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . . . 158
Work rules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
*3213250en*
3213250en
10/2014
KTM Motorrad AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM
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