14 electrical system

14 electrical system
OWNER'S MANUAL 2013
990 Supermoto R EU
990 Supermoto R FR
990 Supermoto R AUS/UK
Art. no. 3211959en
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.
Please enter the serial numbers of your vehicle below.
Chassis number/type label
Engine number (
Key number (
Dealer's stamp
p. 21)
p. 21)
The owner's manual contained the latest information for this model at the time of going to print. Minor differences due to developments in
design cannot be ruled out completely.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifications,
prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these
to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options,
deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain special equipment
that does not belong to the regular scope of supply.
© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright owner.
DEAR KTM CUSTOMER
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead to
the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle 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 - intended use ................................ 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 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 side (example) .............. 16
4.2
View of vehicle, rear right side (vehicle differs
slightly from photo) ............................................ 18
SERIAL NUMBERS ....................................................... 20
5.1
Chassis number ................................................. 20
5.2
Type label ......................................................... 20
5.3
Key number....................................................... 21
5.4
Engine number .................................................. 21
3
6
5.5
Fork part number ...............................................
5.6
Shock absorber part number ...............................
CONTROLS...................................................................
6.1
Clutch lever.......................................................
6.2
Hand brake lever................................................
6.3
Throttle grip ......................................................
6.4
Horn button.......................................................
6.5
Light switch ......................................................
6.6
Headlight flasher switch .....................................
6.7
Turn signal switch..............................................
6.8
Emergency OFF switch .......................................
6.9
Electric starter button.........................................
6.10 Ignition/steering lock ..........................................
6.11 Immobilizer .......................................................
6.12 Combination instrument .....................................
6.12.1
Overview .......................................................
6.12.2
Function buttons ...........................................
6.12.3
Tachometer ...................................................
6.12.4
indicator lamps..............................................
6.12.5
Display .........................................................
6.12.6
Speed display................................................
6.12.7
Setting kilometers or miles .............................
6.12.8
Time.............................................................
6.12.9
Setting the clock ...........................................
6.12.10 ODO display ..................................................
6.12.11 Setting/resetting display TRIP 1 ......................
6.12.12 Setting/resetting display TRIP 2 ......................
6.12.13 TRIP F display...............................................
6.12.14 Ambient temperature indicator........................
22
22
23
23
23
24
24
25
25
26
26
27
27
28
28
28
29
29
30
31
32
32
33
33
34
34
35
36
36
TABLE OF CONTENTS
7
8
9
6.12.15 Setting the temperature units..........................
6.12.16 Warning of icy roads.......................................
6.12.17 Coolant temperature indicator .........................
6.13 Opening the filler cap.........................................
6.14 Closing the filler cap ..........................................
6.15 Seat lock...........................................................
6.16 Tool set.............................................................
6.17 Handrails ..........................................................
6.18 Helmet lock.......................................................
6.19 Passenger footrests ............................................
6.20 Shift lever .........................................................
6.21 Foot brake lever .................................................
6.22 Side stand.........................................................
PREPARING FOR USE...................................................
7.1
Information on first use ......................................
7.2
Running in the engine ........................................
7.3
Loading the vehicle ............................................
RIDING INSTRUCTIONS................................................
8.1
Checks and maintenance measures when
preparing for use................................................
8.2
Starting.............................................................
8.3
Starting off........................................................
8.4
Shifting, riding ..................................................
8.5
Braking .............................................................
8.6
Stopping, parking...............................................
8.7
Transport ..........................................................
8.8
Refueling ..........................................................
SERVICE SCHEDULE ....................................................
9.1
Service schedule................................................
4
36
37
38
38
39
40
40
41
41
42
42
43
44
45
45
46
46
49
49
50
52
52
55
57
58
59
61
61
10 TUNING THE CHASSIS .................................................
10.1 Fork/shock absorber ...........................................
10.2 Adjusting the compression damping of the fork.....
10.3 Adjusting the rebound damping of the fork ...........
10.4 Adjusting the spring preload of the fork................
10.5 Compression damping of the shock absorber.........
10.6 Adjusting the low-speed compression damping of
the shock absorber .............................................
10.7 Adjusting the high-speed compression damping
of the shock absorber .........................................
10.8 Adjusting the rebound damping of the shock
absorber............................................................
10.9 Adjusting the spring preload of the shock
absorber
.......................................................
11 SERVICE WORK ON THE CHASSIS.................................
11.1 Raising the motorcycle with the rear wheel
stand ................................................................
11.2 Taking the motorcycle off of the rear wheel
stand ................................................................
11.3 Raising the motorcycle with the front wheel
stand ................................................................
11.4 Taking the motorcycle off of the front wheel
stand ................................................................
11.5 Bleeding the fork legs.........................................
11.6 Removing the seat .............................................
11.7 Mounting the seat ..............................................
11.8 Reinstalling the fuel tank....................................
11.9 Positioning the fuel tank.....................................
11.10 Mounting the helmet lock on the vehicle ..............
11.11 Checking the chain for dirt..................................
x
64
64
64
65
66
68
68
69
70
71
73
73
73
74
74
75
75
76
76
77
79
80
TABLE OF CONTENTS
5
11.12
11.13
11.14
11.15
Cleaning the chain ............................................. 80
Checking the chain tension ................................. 81
Adjusting the chain tension................................. 82
Checking the chain, rear sprocket, engine
sprocket and chain guide .................................... 84
11.16 Adjusting the basic position of the clutch lever ..... 87
11.17 Checking/rectifying the fluid level of the
hydraulic clutch................................................. 87
12 BRAKE SYSTEM ........................................................... 89
12.1 ABS/antilock brake system.................................. 89
12.2 Adjusting the basic position of the hand brake
lever ................................................................. 90
12.3 Checking the front brake discs ............................ 90
12.4 Checking the front brake fluid level ..................... 91
12.5 Adding front brake fluid
................................. 92
12.6 Checking the front brake linings .......................... 93
12.7 Checking the free travel of the foot brake lever...... 94
12.8 Adjusting the basic position of the foot brake
lever ................................................................. 95
12.9 Checking the rear brake disc ............................... 96
12.10 Checking the rear brake fluid level....................... 96
12.11 Adding rear brake fluid
.................................. 97
12.12 Checking the rear brake linings ........................... 99
13 WHEELS, TIRES ......................................................... 101
13.1 Removing the front wheel
............................ 101
13.2 Installing the front wheel
............................. 102
13.3 Removing the rear wheel
.............................. 104
13.4 Installing the rear wheel
.............................. 106
13.5 Checking the rear hub rubber dampers
.......... 108
x
x
x
x
x
x
x
13.6 Checking the tire condition ...............................
13.7 Checking the tire air pressure............................
14 ELECTRICAL SYSTEM .................................................
14.1 Removing the battery
..................................
14.2 Installing the battery
...................................
14.3 Recharging the battery
................................
14.4 Changing the main fuse ....................................
14.5 Changing the ABS fuses ...................................
14.6 Changing the fuses of individual power
consumers.......................................................
14.7 Changing the headlight bulb .............................
14.8 Changing the parking light bulb.........................
14.9 Changing the turn signal bulb ...........................
14.10 Changing the brake light bulb ...........................
14.11 Changing the tail light bulbs .............................
14.12 Changing the license plate lamp........................
14.13 Checking the headlight setting ..........................
14.14 Adjusting the headlight range............................
14.15 Activating/deactivating the ignition key ..............
15 COOLING SYSTEM ......................................................
15.1 Cooling system ................................................
15.2 Checking the antifreeze and coolant level ...........
15.3 Checking the coolant level in the compensating
tank................................................................
15.4 Draining the coolant
....................................
15.5 Filling/bleeding the cooling system
...............
16 TUNING THE ENGINE.................................................
16.1 Checking the play in the throttle cable ...............
16.2 Adjusting the play in the throttle cable
..........
x
x
x
x
x
x
109
110
112
112
114
115
117
119
120
122
125
127
128
132
136
138
138
139
144
144
144
147
148
149
152
152
153
TABLE OF CONTENTS
6
16.3
16.4
16.5
16.6
17
Plug-in connection, ignition timing map .............
Adjusting the ignition curve to the fuel quality ....
Checking the basic position of the shift lever ......
Adjusting the basic position of the shift
lever
..........................................................
SERVICE WORK ON THE ENGINE ................................
17.1 Checking the engine oil level.............................
17.2 Changing the engine oil and filter, cleaning the
oil screens
..................................................
17.3 Draining the engine oil, changing the oil filter,
and cleaning the oil screens
.........................
17.4 Filling up with engine oil
.............................
17.5 Adding engine oil .............................................
CLEANING, CARE .......................................................
18.1 Cleaning motorcycle .........................................
18.2 Checks and maintenance measures for winter
operation.........................................................
STORAGE ...................................................................
19.1 Storage ...........................................................
19.2 Preparing for use after storage...........................
TROUBLESHOOTING ..................................................
IMMOBILIZER BLINK CODE ........................................
ENGINE CONTROL BLINK CODE..................................
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 ...........................................................
x
x
x
x
18
19
20
21
22
23
153
154
155
155
157
157
158
158
163
164
165
165
167
169
169
171
172
175
177
183
183
184
187
187
187
188
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 ...............................................................................
188
189
190
191
192
193
197
201
204
205
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 - intended use
8
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road operation and also for use on race
courses, but not for offroad use.
Info
The motorcycle is only authorized for operation on public roads in the homologated version.
2.2
Safety advice
A number of safety instructions need to be followed to operate the vehicle safely. Therefore, read this manual carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.
Info
The vehicle has various information and warning labels at prominent locations. Do not remove information/warning labels. If they
are missing, you or others may not recognize dangers and may therefore be injured.
2
SAFETY ADVICE
2.3
Degrees of risk and symbols
9
Danger
Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not
taken.
Warning
Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.
Caution
Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.
Note
Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.
Warning
Identifies a danger that will lead to environmental damage if the appropriate measures are not taken.
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
10
1
Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2
Removal or puncturing of any part of the intake system.
3
Lack of proper maintenance.
4
Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
2.5
Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–
Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–
Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2
SAFETY ADVICE
2.6
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 record and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered for damage
resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the service record.
3.2
Operating substances
The fuels and lubricants named in the owner's manual must be used according to specifications.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your KTM dealer will be glad to advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis
is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage
and breakage of components.
Use of the vehicle under difficult conditions, such in rain, high heat or with a heavy load, can lead to considerably more rapid wear of
components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace
parts before the next scheduled service.
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
IMPORTANT NOTES
3.5
Figures
14
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 side (example)
16
C00346-10
4
VIEW OF VEHICLE
1
Rear mirror
2
Clutch lever (
3
Seat
4
Handrails (
5
Level viewer, engine oil
6
Shift lever (
7
Engine number (
8
Compression damping of the shock absorber (
17
p. 23)
p. 41)
p. 42)
p. 21)
p. 68)
4
VIEW OF VEHICLE
4.2
View of vehicle, rear right side (vehicle differs slightly from photo)
18
101566-10
4
VIEW OF VEHICLE
1
Seat lock (
p. 40)
2
Light switch (
2
Headlight flasher switch (
2
Turn signal switch (
2
Horn button (
3
Filler cap
4
Emergency OFF switch (
4
Electric starter button (
5
Hand brake lever (
6
Fork rebound setting and spring preload setting
7
Shock absorber rebound adjustment
8
Passenger footrests (
9
Foot brake lever (
10
Chassis number/type label
11
Fork compression adjustment
p. 25)
p. 25)
p. 26)
p. 24)
p. 26)
p. 27)
p. 23)
p. 42)
p. 43)
19
5
SERIAL NUMBERS
5.1
Chassis number
20
Chassis number 1 is embossed in the steering head at the right.
101093-10
5.2
Type label
Type label 1 is located on the upper frame tube on the right.
C00347-10
5
SERIAL NUMBERS
5.3
Key number
21
The Code number 1 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.
Use the orange programming key to activate and deactivate the black ignition key.
Keep the orange programming key in a safe place: it must only be used for learning
and programming functions.
700563-01
5.4
Engine number
The engine number 1 is stamped on the left side of the engine under the engine sprocket.
101095-10
5
SERIAL NUMBERS
5.5
Fork part number
22
The fork part number 1 is stamped on the inner side of the fork stub.
101567-10
5.6
Shock absorber part number
The shock absorber part number 1 is stamped on the top of the shock absorber above the
adjusting ring on the engine side.
101097-10
6
CONTROLS
6.1
Clutch lever
23
The clutch lever 1 is fitted on the left side of the handlebar.
The clutch is hydraulically operated and self-adjusting.
101098-10
6.2
Hand brake lever
The hand brake lever 1 is fitted on the right side of the handlebar.
The front brake is engaged using the hand brake lever.
101099-10
6
CONTROLS
6.3
Throttle grip
24
The throttle grip 1 is fitted on the right side of the handlebar.
101174-10
6.4
Horn button
The horn button 1 is fitted on the left side of the handlebar.
Possible states
• Horn button
• Horn button
700550-12
in basic position
pressed – The horn is operated in this position.
6
CONTROLS
6.5
Light switch
25
The light switch 1 is fitted on the left side of the handlebar.
Possible states
Low beam on – The 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
high beam and tail light are switched on.
700550-10
6.6
Headlight flasher switch
The headlight flasher switch 1 is fitted on the left side of the handlebar.
Possible states
• Headlight flasher switch in basic position
• Headlight flasher switch pressed – The headlight flasher switch (high beam) is operated in this position.
101100-10
6
CONTROLS
6.7
Turn signal switch
26
The turn signal switch 1 is fitted on the left side of the handlebar.
Possible states
Turn signal off
Left turn signal on – The turn signal switch is pressed to the left. The turn
signal switch automatically returns to the central position after use.
Right turn signal on – The turn signal switch is pressed to the right. The
turn signal switch automatically returns to the central position after use.
700550-11
6.8
To switch off the turn signal, press the turn signal switch towards the switch case.
Emergency OFF switch
The emergency OFF switch 1 is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch on – This position is necessary for operation as it
closes the ignition circuit.
Emergency OFF switch off – In this position, the ignition circuit is interrupted, a running engine stops, and the engine cannot be started.
700552-10
6
CONTROLS
6.9
Electric starter button
27
The electric starter button 1 is fitted on the right side of the handlebar.
Possible states
• Electric starter button
• Electric starter button
in basic position
pressed – The electric starter is actuated in this position.
700552-11
6.10
Ignition/steering lock
The ignition/steering lock is in front of the upper triple clamp.
Info
The ignition may only be switched on using a black ignition key.
Use the orange programming key to activate and deactivate the black ignition key.
Possible states
600825-01
Ignition OFF – In this position, the ignition circuit is interrupted, a running
engine stops, and a non-running engine will not start. The ignition key can
be removed.
Ignition ON – In this position, the ignition circuit is closed and the engine
can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
steering locked. The ignition key can be removed.
6
CONTROLS
6.11
Immobilizer
28
The electronic immobilizer secures the vehicle against unauthorized use.
The immobilizer is activated automatically and the engine electronics are locked when the
ignition key is withdrawn.
The red warning lamp flashes at 15 second intervals after one minute.
The red warning lamp can also indicate errors by flashing.
Info
The ignition key contains electronic components. Never attach multiple ignition keys
to a single key ring; this may cause mutual interference and lead to problems.
400887-01
6.12
Combination instrument
6.12.1
Overview
A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle.
The second black ignition key is activated when the vehicle is shipped.
Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an
authorized KTM workshop, but they need to be activated for use.
The combination instrument is installed in front of the handlebar.
The combination instrument is divided into 4 function areas.
1 Function buttons
2 Tachometer
3 Indicator lights
4 Display
400885-10
6
CONTROLS
6.12.2
Function buttons
29
You can change the display mode with the MODE button 1.
Possible display modes are the distance traveled (ODO), trip master 1 (TRIP 1), trip master 2 (TRIP 2) and the ambient temperature.
Press the SET button 2 to reset the trip master 1 function (TRIP 1) and trip master 2 function (TRIP 2) to 0.0.
Button 3 has no function.
400886-10
6.12.3
Tachometer
The tachometer 1 shows the engine speed in revolutions per minute.
The red marking 2 shows the excess speed range of the engine.
400888-10
6
CONTROLS
6.12.4
indicator lamps
30
The indicator lamps offer additional information about the operating state of the motorcycle.
Possible states
The turn signal indicator light flashes green simultaneously with the turn
signal – The turn signal is switched on.
The idling speed indicator lamp lights up green – The transmission is
shifted to idle.
400889-01
The high beam indicator light lights up blue – The high beam is switched
on.
The temperature warning lamp lights up red – The coolant temperature has
reached a critical value.
The low fuel warning lamp lights up yellow – The fuel level has reached the
reserve mark. The display switches to TRIP F.
The oil pressure warning lamp lights up red – The oil pressure is too low.
FI warning lamp (MIL) lights up/flashes yellow – The OBD (on-board diagnosis) has detected an emission- or safety-critical error.
The immobilizer indicator lamp lights up or flashes red – Status or error
message for immobilizer/alarm system.
The battery warning lamp lights up red – The voltage in the vehicle system
is too low.
ABS warning lamp lights up/flashes yellow – Status or error messages relating to ABS (antilock brake system).
6
CONTROLS
6.12.5
Display
31
When you switch on the ignition, all display segments light up for one second as a function
check.
400892-01
LEnGth
Following the display function check, the LEnGth wheel circumference is shown for one second.
Info
1870 mm corresponds to the circumference of the 17" front wheel with a series production tire.
The display then changes to the last selected mode.
400881-01
6
CONTROLS
6.12.6
Speed display
32
The speed 1 is shown in kilometers per hour km/h or in miles per hour mph.
400838-10
6.12.7
Setting kilometers or miles
Info
If you change the unit, the value ODO is retained and converted accordingly.
Making the setting according to the country.
Condition
The motorcycle is stationary.
6
CONTROLS
33
–
Switch on the ignition by turning the ignition key to the ON
–
Press the MODE button repeatedly until the ODO mode is active.
–
Keep the MODE button pressed until the display mode changes from km/h to mph or
from mph to km/h.
position.
400893-10
6.12.8
Time
The time is shown in area 1 of the display.
Info
After reconnecting the battery or changing the fuse, the time must be reset.
400893-11
6.12.9
Setting the clock
Condition
The motorcycle is stationary.
6
CONTROLS
34
–
Switch on the ignition by turning the ignition key to the ON
–
Press the MODE button repeatedly until the ODO mode is active.
–
Keep the MODE button and the SET button pressed simultaneously.
–
Press the MODE button to set the hour.
–
Press the SET button to set the minute.
–
Keep the MODE button and the SET button pressed simultaneously.
position.
The time display begins to flash.
400893-12
The time is set.
6.12.10 ODO display
In the ODO display mode, the total distance traveled is shown in kilometers or miles.
Info
This value is retained, even if the battery is disconnected and/or the fuse blows.
400839-01
6.12.11 Setting/resetting display TRIP 1
Info
The TRIP 1 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.
6
CONTROLS
35
–
Switch on the ignition by turning the ignition key to the ON
–
Press the MODE button repeatedly until the TRIP 1 mode is active.
–
Keep the SET button pressed.
position.
The TRIP 1 display is set to 0.0.
400840-01
6.12.12 Setting/resetting display TRIP 2
Info
The TRIP 2 trip counter is always running and counts up to 999.9.
The trip counter can be used to measure the distance covered during trips or between two refueling stops. After the value 999.9 is
reached, the trip counter starts at 0.0 again.
–
Switch on the ignition by turning the ignition key to the ON
–
Press the MODE button repeatedly until the TRIP 2 mode is active.
–
Keep the SET button pressed.
The TRIP 2 display is set to 0.0.
400841-01
position.
6
CONTROLS
36
6.12.13 TRIP F display
If the fuel level drops to the reserve mark, the display automatically changes to TRIP F and
starts to count from 0.0, regardless of the previous display mode.
Info
The low fuel warning lamp lights up in parallel to the TRIP F display.
400842-01
6.12.14 Ambient temperature indicator
The ambient temperature 1 is displayed in °C or °F.
400893-13
6.12.15 Setting the temperature units
Condition
The motorcycle is stationary.
6
CONTROLS
37
–
Switch on the ignition by turning the ignition key to the ON
–
Press the MODE button repeatedly until the ambient temperature is active.
–
Keep the MODE button pressed until the display mode changes from °C to °F or from °F
to °C.
position.
400893-14
6.12.16 Warning of icy roads
The ice symbol
The ice symbol
specified value.
Temperature
lights up to indicate an increased danger of slippery roads.
appears in the display when the ambient temperature drops below the
3 °C (37 °F)
The ice symbol goes out in the display when the ambient temperature rises above the
specified value again.
Temperature
400894-10
4 °C (39 °F)
6
CONTROLS
38
6.12.17 Coolant temperature indicator
The temperature display consists of 12 bars. The more bars that light up, the hotter the
coolant. When the upper bar lights up, all bars in the display begin to flash and the temperature warning lamp lights up.
Possible states
• Engine cold – Up to five bars light up.
• The engine is warm – Six to eleven bars light up.
• Engine hot – All twelve bars flash.
700124-01
6.13
Opening the filler cap
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations
and keep it out of the reach of children.
6
CONTROLS
39
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 1 and insert the ignition key.
Note
Danger of damage Ignition key breakage.
–
–
Turn the ignition key 90° counterclockwise and remove the filler cap.
Info
101101-10
6.14
To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced.
The filler cap has a tank air vent system.
Closing the filler cap
101102-01
–
Put the filler cap back on and turn the ignition key 90° clockwise.
–
Remove the ignition key and fold down the cover.
6
CONTROLS
6.15
Seat lock
40
Seat lock 1 is located at the rear under the tail light.
It can be locked with the ignition key.
101104-10
6.16
Tool set
The tool set 1 is located in the storage compartment under the seat.
101571-10
6
CONTROLS
6.17
Handrails
41
The handrails 1 are used for moving the motorcycle around.
If you carry a passenger, the passenger can hold onto the handrails during the trip.
101570-10
6.18
Helmet lock
Warning
Danger of accidents Impairment of ride behavior and vehicle operation if a helmet
or helmet lock is attached to the vehicle.
–
Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out.
The steel cable 1 in the tool set can be used to lock a helmet to the vehicle to prevent it
from being stolen.
101572-10
6
CONTROLS
6.19
Passenger footrests
42
The passenger footrests can be folded up and down.
Possible states
• Passenger footrests folded up – For operation without a passenger.
• Passenger footrests folded down – For operation with a passenger.
101573-01
6.20
Shift lever
Shift lever 1 is mounted on the left side of the engine.
101108-10
6
CONTROLS
43
The gear positions can be seen in the photograph.
The neutral or idle position N is between the first and second gear.
101109-10
6.21
Foot brake lever
Foot brake lever 1 is located in front of the right footrest.
The rear brake is activated using the foot brake lever.
101110-10
6
CONTROLS
6.22
Side stand
44
The side stand 1 is located 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.
The side stand is coupled with the safety starting system – see the riding instructions.
101111-10
Possible states
• Side stand folded out – The vehicle can be supported on the side stand. The safety
starting system is active.
• Side stand folded in – This position is mandatory when riding the motorcycle. The
safety starting system is inactive.
7
PREPARING FOR USE
7.1
Information on first use
45
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.
7
PREPARING FOR USE
46
–
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.
–
Familiarize yourself with the controls.
–
Adjust the basic position of the clutch lever. (
–
Adjust the basic position of hand brake lever. (
–
Adjust the basic position of foot brake lever. (
–
Get used to handling the vehicle on empty suitable terrain before making a longer trip. Try also to ride as slowly as possible to get a
better feeling for the motorcycle.
–
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–
Run the engine in. (
You receive a delivery certificate and the service record at vehicle handover.
7.2
–
p. 87)
p. 90)
p. 95)
p. 46)
Running in the engine
Do not exceed the specified engine speed and load during the running-in period.
Guideline
Maximum engine speed
–
During the first: 1,000 km (621.4 mi)
6,500 rpm
After the first: 1,000 km (621.4 mi)
9,000 rpm
Avoid full-throttle operation!
7.3
Loading the vehicle
Warning
Danger of accidents Unstable handling characteristics.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
7
PREPARING FOR USE
47
Warning
Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
–
Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidents Unstable handling characteristics at high speed.
–
Adapt your speed according to your payload. If the motorcycle is loaded with luggage, ride more slowly.
Maximum speed with luggage
130 km/h (80.8 mph)
Warning
Danger of accidents Destruction of luggage carrier system.
–
If the motorcycle is fitted with luggage cases, note the manufacturer's specifications concerning the maximum payload.
Warning
Danger of accidents Poor visibility for other road users due to slipped baggage.
–
If the tail light is covered, you are less visible to traffic behind you, especially 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.
Warning
Danger of burns A hot exhaust system can burn baggage.
–
Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.
7
PREPARING FOR USE
48
–
If you are carrying 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 maximum permissible total weight and the axle loads.
Guideline
Maximum permissible total weight
400 kg (882 lb.)
Maximum permissible front axle load
160 kg (353 lb.)
Maximum permissible rear axle load
250 kg (551 lb.)
8
RIDING INSTRUCTIONS
8.1
Checks and maintenance measures when preparing for use
49
Info
Before every trip, check the condition of the vehicle and ensure that it is roadworthy.
The vehicle must be in perfect technical condition when it is being operated.
–
Check the engine oil level. (
–
Check the front brake fluid level. (
–
Check the rear brake fluid level. (
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check that the brake system is functioning properly.
–
Check the coolant level in the compensating tank. (
–
Check the chain for dirt. (
–
Check the chain tension. (
p. 81)
–
Check the tire condition. (
p. 109)
–
Check the tire air pressure. (
–
Check that all controls are correctly adjusted and free to move.
–
Check that the electrical equipment is functioning properly.
–
Check that baggage is correctly secured.
–
Sit on the motorcycle and check the rear mirror setting.
–
Check the fuel level.
p. 157)
p. 91)
p. 96)
p. 93)
p. 99)
p. 147)
p. 80)
p. 110)
8
RIDING INSTRUCTIONS
8.2
Starting
50
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–
Never operate the vehicle with a discharged battery or without a battery.
Note
Engine failure High engine speeds in cold engines have a negative effect on the service life of the engine.
–
Always warm up the engine at low engine speeds.
–
Press the emergency OFF switch into the position
–
Switch on the ignition by turning the ignition key to the ON
.
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 the transmission to neutral.
The green idling speed indicator lamp N 1 lights up.
–
B00650-10
Press the electric starter button
.
8
RIDING INSTRUCTIONS
51
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.
–
Take the weight off the side stand and swing it upwards with your foot as far as it will
go.
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 button 2 for 3 - 5 seconds.
The ABS warning lamp starts flashing; ABS is deactivated.
400886-11
8
RIDING INSTRUCTIONS
8.3
Starting off
–
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
8.4
Shifting, riding
Warning
Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.
–
Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
–
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
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 The passenger must be able to hold himself or herself properly on the passenger seat.
–
The passenger must hold on to the rider or supporting strap firmly and place his/her feet on the passenger footrests. Observe
the regulations concerning the minimum age for passengers in your country.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
–
Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on.
52
8
RIDING INSTRUCTIONS
53
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.
Warning
Danger of accidents Unstable handling characteristics.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
–
Check the way your baggage is fixed regularly.
Warning
Danger of accidents Lack of roadworthiness.
–
After a fall, check the vehicle as usual before preparing for use.
Note
Engine failure Unfiltered intake air has a negative effect on the service life of the engine.
–
Never ride the vehicle without an air filter since dust and dirt can get into the engine and result in increased wear.
8
RIDING INSTRUCTIONS
54
Note
Engine damage Engine overheating.
–
If the coolant temperature warning lamp lights up, stop the vehicle and switch off the engine. Let the engine cool, check the coolant
level in the radiator, and correct it if necessary. If you continue riding while the coolant temperature warning lamp is lit, the engine
may be damaged.
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
You can see the positions of the six 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.
101109-10
–
After reaching maximum speed by fully opening the throttle grip, turn the throttle back
so it is ¾ open. This will barely reduce the speed but fuel consumption will be considerably lower.
–
Accelerate only up to a speed suitable for the road surface and weather conditions.
When traveling 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.
–
If the engine stalls (e.g. at a crossroads), pull the clutch lever only and press the electric starter button. You do not have to shift into neutral.
8
RIDING INSTRUCTIONS
55
–
Switch off the engine if you expect to be standing for a long time.
–
If the FI warning lamp (MIL) lights up during a trip, stop immediately. When you shift to
neutral, the FI warning lamp (MIL) starts to flash.
Info
From the flashing rhythm, you can derive a two-digit number, the so-called
flashing code. The flashing code tells you which component has a fault.
–
8.5
If the ice symbol appears on the combination instrument, roads may be icy. Adjust
your speed to the road conditions.
Braking
Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.
–
Clean or dry a dirty or wet brake system by riding and braking gently.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
–
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Failure of brake system.
–
If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your
foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Longer stopping distance due to higher overall weight.
–
Take the longer stopping distance into account when carrying a passenger and baggage.
8
RIDING INSTRUCTIONS
56
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 Excessively forceful braking can cause the wheels to block.
–
ABS must be switched on to be effective.
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.
When braking, first throttle back and then 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 tires.
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 enter a bend. Shift down to a lower gear that is appropriate to your speed.
8
–
RIDING INSTRUCTIONS
On long downhill stretches, use the braking effect of the engine. Do this by changing down two gears, but do not race the engine. You
will require less braking force and the brakes will not overheat.
8.6
Stopping, parking
Warning
Risk of misappropriation Usage by unauthorized persons.
–
Never leave the vehicle while the engine is running. Secure the vehicle against use by unauthorized persons. If you leave the
vehicle, lock the steering and remove the ignition key.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–
Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–
Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
Note
Material damage Damage and destruction of components by excessive load.
–
57
The side stand is designed for the weight of the motorcycle only. Do not sit on the motorcycle when it is supported by the side stand
only. The side stand and/or the frame could be damaged and the motorcycle could fall over.
8
RIDING INSTRUCTIONS
–
Apply the brakes.
–
Shift the transmission to neutral.
–
Switch off the ignition by turning the ignition key to the OFF
58
position.
Info
If you switch off the engine with the emergency OFF switch but the ignition remains switched on at the ignition lock, power
continues to flow to most power consumers and the battery is soon discharged. Therefore, always switch off the engine with the
ignition key; the emergency OFF switch is provided for emergency situations only.
–
Park the motorcycle on a firm surface.
–
Swing the side stand to the front with your foot as far as it will go, and lean the vehicle onto it.
–
Lock the steering by turning the handlebar fully to the left, pressing down the ignition key to the OFF position and turning it to
the position . To make the steering lock engage more easily, move the handlebar back and forth slightly. Remove the ignition key.
8.7
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Fire hazard Some vehicle components become very hot when the vehicle is operated.
–
Do not park the vehicle near flammable or explosive substances. Do not place objects on the vehicle while it is still warm from being
run. Always let the vehicle cool first.
8
RIDING INSTRUCTIONS
59
–
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
8.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel.
Note
Material damage Premature clogging of the fuel filter.
–
In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the
fuel system. (Your authorized KTM workshop will be glad to help.)
8
–
RIDING INSTRUCTIONS
60
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 no higher than level A.
p. 38)
Guideline
Distance A
Total fuel tank
capacity, approx.
401182-10
35 mm (1.38 in)
15 l (4 US gal)
–
Close the filler cap. (
–
Press the SET button 2 for two seconds.
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 199)
p. 39)
The low fuel warning lamp 1 goes out. TRIP F is set to 0.0 and the display returns
to the previous display mode.
Info
If you do not press the SET button 2, the reset takes place automatically after
approx. three minutes.
400885-12
9
SERVICE SCHEDULE
9.1
Service schedule
61
K10N
K75A
K150A
K300A
Check that the electrical equipment is functioning properly.
•
•
•
•
Read out the trouble code memory using the KTM diagnostics tool.
x
Check the measured service values with the KTM diagnostics tool. x
Change the engine oil and filter, clean the oil screens. x ( p. 158)
Check the oil jet for the clutch lubrication. x
•
•
•
•
•
•
•
•
•
•
•
•
Check the front brake linings. (
•
•
•
•
p. 93)
•
•
Check the front brake discs. (
p. 90)
•
•
•
•
Check the rear brake linings. (
p. 99)
•
•
•
•
•
•
•
•
Check that brake lines are undamaged and free of leaks.
•
•
•
•
Check the rear brake fluid level. (
•
•
•
•
•
•
•
•
•
•
•
•
x
•
•
•
Check the wheel bearing for play.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Check the rear brake disc. (
p. 96)
p. 96)
Check the free travel of the foot brake lever. (
p. 94)
Check the shock absorber and fork for leaks. Perform a fork and shock absorber service if needed
and depending on vehicle use.
Check the swingarm bearings.
Check the tire condition. (
Check the tire air pressure. (
x
p. 109)
p. 110)
Check the chain, rear sprocket, engine sprocket, and chain guide. (
Check the chain tension. (
p. 84)
p. 81)
Lubricate all moving parts (e.g. side stand, hand lever, chain, ...) and check for smooth operation.
x
9
SERVICE SCHEDULE
62
K10N
Clean the dust boots of the fork legs.
Check the front brake fluid level. (
Bleed the fork legs. (
p. 91)
•
p. 75)
Check the steering head bearing play.
•
K75A
K150A
K300A
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Change the spark plugs.
x
Check the valve clearance. x
Check all hoses (e.g. fuel, cooling, bleeding, drainage, ...) and sleeves for cracking, leaks, and
incorrect routing. x
Check the antifreeze and coolant level. ( p. 144)
Check the wiring harness of the throttle valve body for damage and correct routing. x
Check the cables for damage and kink-free routing. x
Check the control cables for damage, kink-free routing and adjustment.
Change the air filter. Clean the air filter box. x
Check the fuel pressure. x
Check the value of the manifold absolute pressure sensor (PM value) with the KTM diagnostics
tool. x
Check the CO adjustment with the KTM diagnostics tool. x
Check/rectify the fluid level of the hydraulic clutch. ( p. 87)
Check the fasteners for tightness. x
Change the coolant. x
Change the front brake fluid. x
Change the rear brake fluid. x
Check the clutch. x
•
•
•
•
•
•
•
•
•
•
•
•
9
SERVICE SCHEDULE
Check the headlight setting. (
63
p. 138)
Check the radiator fan operation.
x
Final inspection: Check the vehicle of roadworthiness and take a test ride.
Read out the fault memory after a test ride using the KTM diagnostics tool.
Make the service entries in the KTM DEALER.NET and service record.
K10N: Once after 1,000 km (621.4 mi)
K75A: Every 7,500 km (4,660 mi) or annually
K150A: Every 15,000 km (9,321 mi) or every 2 years
K300A: Every 30,000 km (18,641 mi) or every 4 years
x
x
K10N
K75A
K150A
K300A
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
10
TUNING THE CHASSIS
10.1
Fork/shock absorber
64
The fork and the shock absorber offer many options of adapting the suspension to your riding style and the payload.
Info
101114-10
To help you adapt the vehicle, we have summarized our findings in Table 1. You
can find the table on the air filter box after you remove the seat. In all settings
except for the spring preload of the shock absorber, the value is adjusted by first
turning the screw all the way in and then setting the value. Do not use excessive
force to turn the adjusting screws against the stop, and take the last perceptible
click as the end position.
These adjustments should be understood as a guideline and should always be the basis of
your own personal chassis adaptation. Do not change the adjustments at random or by more
than ±40%, since otherwise the riding characteristics could deteriorate, particularly at high
speeds.
10.2
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
An optimally adjusted compression damping ensures that the fork does not compress too far and fast when you brake hard or when
the load shifts very fast. It gives the rider good feedback about the road conditions.
10
TUNING THE CHASSIS
–
65
Turn adjusting screws 1 clockwise all the way.
Info
The adjusting screws are located at the bottom end of the fork legs.
Make the same adjustment on both fork legs.
–
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Compression damping
101574-10
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.3
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork rebound behavior.
An optimally adjusted rebound damping brakes the springing energy and enables a fast, vibration-free resetting of the fork to the
zero position.
10
TUNING THE CHASSIS
–
66
Turn adjusting screws 1 clockwise all the way.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–
Turn back counterclockwise by the number of clicks corresponding to the fork type.
Guideline
Rebound damping
101116-10
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.4
Adjusting the spring preload of the fork
Info
The spring preload determines the initial fork position.
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.
10
TUNING THE CHASSIS
–
67
Turn adjusting screws 1 clockwise all the way.
Info
The adjusting screws are located at the top end of the fork legs.
Make the same adjustment on both fork legs.
–
Turn back counterclockwise by the number of turns according to the fork type.
Guideline
Spring preload - Preload Adjuster
101117-10
Comfort
5 turns
Standard
5 turns
Sport
7 turns
Full payload
7 turns
Info
Turn clockwise to increase preload; turn counterclockwise to reduce spring
preload.
Changing the spring preload has no influence on the rebound damping although
the adjusting screws turn during the adjustment work. However, you should also
adjust the rebound damping when you alter the spring preload.
10
TUNING THE CHASSIS
10.5
Compression damping of the shock absorber
101119-01
10.6
68
The compression damping of the shock absorber is divided into two ranges: high-speed and
low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and
not to the vehicle speed.
The high-speed setting, for example, has an effect on the landing after a jump: the rear
wheel suspension compresses more quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the
rear wheel suspension compresses more slowly.
These two ranges can be adjusted separately, although the transition between high-speed
and low-speed is gradual. Thus, changes in the high-speed range affect the compression
damping in the low-speed range and vice versa.
Adjusting the low-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will
be glad to help.)
Info
The low-speed setting can be seen during the slow to normal compression of the shock absorber.
10
TUNING THE CHASSIS
–
69
Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click.
Info
Do not loosen nut 2!
–
Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Compression damping, low-speed
101120-10
Comfort
25 clicks
Standard
20 clicks
Sport
15 clicks
Full payload
15 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.7
Adjusting the high-speed compression damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will
be glad to help.)
Info
The high-speed setting can be seen during the fast compression of the shock absorber.
10
TUNING THE CHASSIS
–
70
Turn adjusting screw 1 clockwise all the way using a socket wrench.
Info
Do not loosen nut 2!
–
Turn back counterclockwise by the number of turns corresponding to the shock
absorber type.
Guideline
Compression damping, high-speed
101120-11
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Full payload
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.8
Adjusting the rebound damping of the shock absorber
Caution
Danger of accidents Disassembly of pressurized parts can lead to injury.
–
The shock absorber is filled with high density nitrogen. Adhere to the description provided. (Your authorized KTM workshop will
be glad to help.)
10
TUNING THE CHASSIS
71
–
Turn adjusting screw 1 clockwise up to the last perceptible click.
–
Turn back counterclockwise by the number of clicks corresponding to the shock
absorber type.
Guideline
Rebound damping
101575-10
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
10.9
Adjusting the spring preload of the shock absorber
x
Warning
Danger of accidents Modifications to the suspension settings can seriously alter the vehicle's ride behavior.
–
Following modifications, ride slowly at first to get the feel of the new ride behavior.
Info
The spring preload defines the initial situation of the spring process on the shock absorber.
The best spring preload setting is achieved when it is set for the weight of the rider and that of any baggage and a passenger, thus
ensuring an ideal compromise between maneuverability and stability.
Before changing the spring preload, make a note of the present setting, e.g., by measuring the length of the spring.
10
TUNING THE CHASSIS
72
Preparatory work
– Take the weight off the rear wheel and swingarm.
Info
The spring preload can be adjusted correctly only if the rear wheel and the
swingarm are fully relieved of weight.
Main work
– Release retaining ring 1.
–
Turn adjusting ring 2 until the spring is fully relaxed.
Hook wrench (T157S)
–
Measure the overall spring length without a load.
–
Tension the spring by turning adjusting ring 2 to the prescribed value.
Guideline
Spring preload
101122-10
–
Comfort
11 mm (0.43 in)
Standard
11 mm (0.43 in)
Sport
11 mm (0.43 in)
Full payload
13 mm (0.51 in)
Tighten retaining ring 1.
11
SERVICE WORK ON THE CHASSIS
11.1
Raising the motorcycle with the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Mount the lifting bushings on the swingarm.
–
Insert the adapter in the rear wheel stand.
Adapter (61029055120)
Rear wheel stand (61029055400)
–
Stand the motorcycle upright, align the wheel stand with the swingarm and the
adapters, and lift the motorcycle.
101577-01
11.2
Taking the motorcycle off of the rear wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Secure the motorcycle against falling over.
–
Remove the rear wheel stand and lean the vehicle on the side stand.
–
Remove the lifting bushings from the swingarm.
73
11
SERVICE WORK ON THE CHASSIS
11.3
Raising the motorcycle with the front wheel stand
74
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
p. 73)
Main work
– Move the handlebar to the straight-ahead position. Align the front wheel stand with the
fork legs using the adapters.
Front wheel stand (61029055300)
Info
Always raise the rear of the motorcycle first.
101576-01
11.4
–
Raise the front of the motorcycle.
Taking the motorcycle off of the front wheel stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
–
Secure the motorcycle against falling over.
–
Remove the front wheel stand.
11
SERVICE WORK ON THE CHASSIS
11.5
Bleeding the fork legs
Preparatory work
– Lean the motorcycle on the side stand.
Main work
– Remove bleeder screws 1 briefly.
Any excess pressure escapes from the interior of the fork.
–
Mount and tighten the bleeder screws.
Info
Carry out this operation on both fork legs.
101118-10
11.6
Removing the seat
101104-10
–
Insert the ignition key in the seat lock 1 and turn it clockwise.
–
Raise the rear of the seat, push it towards the rear, and remove it upwards.
–
Remove the ignition key from the seat lock.
75
11
SERVICE WORK ON THE CHASSIS
11.7
Mounting the seat
–
Position front recesses 1 of the seat on the oval head screws of the fuel tank, lower
the rear and simultaneously push it forward. Both lugs 2 must hook into the frame and
locking bolt 3 must be inserted into the lock housing.
–
Finally, check that the seat is correctly mounted.
The seat engages with an audible click.
101578-10
11.8
Reinstalling the fuel tank
Preparatory work
– Remove the seat. (
p. 75)
Main work
– Remove screws 1 and the spoiler on both sides.
101163-10
76
11
SERVICE WORK ON THE CHASSIS
–
Remove screw 2 on both sides.
Info
The fuel hoses do not need to be disconnected.
101164-10
–
Remove screw 3.
–
Carefully push the fuel tank back.
101165-10
11.9
Positioning the fuel tank
Main work
– Carefully push the fuel tank forward.
77
11
SERVICE WORK ON THE CHASSIS
–
78
Mount and tighten screw 1 with the collar bushing.
Guideline
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
101165-11
–
Install and tighten screw 2 with the bearing sleeve and rubber bushing on both sides.
Guideline
Remaining chassis screws
M8
–
Check the routing of the fuel lines.
–
Position the spoilers on both sides. Mount and tighten screws 3.
25 Nm
(18.4 lbf ft)
101164-10
Guideline
Screw, spoiler
101163-11
M6
3.3 Nm
(2.43 lbf ft)
11
SERVICE WORK ON THE CHASSIS
Finishing work
– Mount the seat. (
11.10
79
p. 76)
Mounting the helmet lock on the vehicle
Warning
Danger of accidents Impairment of ride behavior and vehicle operation if a helmet or helmet lock is attached to the vehicle.
–
Do not use the helmet lock for holding a helmet or other objects during the journey. Always remove the helmet lock before starting out.
Preparatory work
– Remove the seat. (
p. 75)
Main work
– Position the steel cable from the tool set with one loop on hook 1.
Steel cable (60012015000)
–
Guide the steel cable through the helmet opening.
–
Attach the free loop of the steel cable to the hook as well.
–
Position the helmet carefully on the side of the vehicle.
101579-10
Finishing work
– Mount the seat. (
p. 76)
11
SERVICE WORK ON THE CHASSIS
11.11
Checking the chain for dirt
–
80
Check the chain for coarse dirt accumulation.
»
If the chain is very dirty:
–
Clean the chain. (
p. 80)
400678-01
11.12
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.
11
SERVICE WORK ON THE CHASSIS
81
Info
The service life of the chain depends largely on its maintenance.
–
Clean the chain regularly.
–
Rinse off loose dirt with a soft jet of water.
–
Remove old grease remains with chain cleaner.
Chain cleaner (
–
p. 201)
After drying, apply chain spray.
Chain lube for road use (
p. 201)
400725-01
11.13
Checking the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.
Preparatory work
– Lean the motorcycle on the side stand.
11
SERVICE WORK ON THE CHASSIS
82
Main work
– Shift the transmission to neutral.
–
In the area of chain sliding guard, press the chain upward toward the swingarm and
determine chain tension A.
Info
The upper chain section B must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
700570-01
Chain tension
»
If the chain tension does not meet specifications:
–
11.14
7 mm (0.28 in)
Adjust the chain tension. (
p. 82)
Adjusting the chain tension
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain tension is too high, the components of the secondary power train (chain, engine sprocket, rear sprocket, bearings
in transmission and rear wheel) are under additional load. Apart from premature wear, in extreme cases the chain can rupture
or the countershaft of the transmission can break. On the other hand, if the chain is loose, it can fall off the engine sprocket or
the rear sprocket and block the rear wheel or damage the engine. Check the chain tension and correct if necessary.
Preparatory work
– Lean the motorcycle on the side stand.
–
Check the chain tension. (
–
Remove the frame slider.
p. 81)
11
SERVICE WORK ON THE CHASSIS
83
Main work
– Loosen nut 1.
–
Loosen nuts 2.
–
Adjust the chain tension by turning the adjusting screws 3 on the left and right.
Guideline
Chain tension
7 mm (0.28 in)
Turn adjusting screws 3 on the left and right so that the markings on the left and
right chain adjuster 4 are in the same position in relation to reference marks C. 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.
101581-10
–
Tighten nuts 2.
–
Make sure that chain adjusters 4 are resting against adjusting screws 3.
–
Tighten nut 1.
Guideline
Nut, rear wheel spindle
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Info
The wide adjustment range of the chain adjusters (32 mm (1.26 in)) enables
different secondary transmissions with the same chain length.
Chain adjusters 4 can be turned through 180°.
11
SERVICE WORK ON THE CHASSIS
11.15
Checking the chain, rear sprocket, engine sprocket and chain guide
–
84
Check the rear sprocket and engine sprocket for wear.
»
If the rear sprocket or engine sprocket is worn:
–
Change the power set.
x
Info
The rear sprocket, engine sprocket and chain should always be changed
together.
100132-10
11
SERVICE WORK ON THE CHASSIS
85
–
Shift the transmission to neutral.
–
Pull the lower chain section with specified weight A.
Guideline
Weight, chain wear measurement
–
15 kg (33 lb.)
Measure the distance B of 18 chain links in the lower chain section.
Info
Chain wear is not always even, so you should repeat this measurement at different chain positions.
Maximum distance B at the longest
chain section
»
272 mm (10.71 in)
If distance B is greater than the specified measurement:
–
Change the power set.
x
Info
700572-01
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
For safety reasons, the chain has no chain joint.
11
SERVICE WORK ON THE CHASSIS
–
Check the chain sliding guard for wear.
»
If there is no gap between the chain and the upper edge of the screw:
–
–
86
Change the chain sliding guard.
x
Check the chain sliding guard for tightness.
»
If the chain sliding guard is loose:
–
Tighten the chain sliding guard.
Guideline
101582-10
–
M5
5 Nm
(3.7 lbf ft)
–
Screw, chain sliding
guard
M6
6 Nm
(4.4 lbf ft)
Loctite® 243™
Check the chain sliding piece for wear.
»
If the drill hole becomes visible on the chain sliding piece in area C:
–
–
Screw, chain sliding
guard
Change the chain sliding piece.
x
Check the chain sliding piece for tightness.
»
If the chain sliding piece is loose:
–
Tighten the chain sliding piece.
Guideline
101583-10
Screw, chain sliding piece
EJOT PT K60x20
2 Nm (1.5 lbf ft)
11
SERVICE WORK ON THE CHASSIS
11.16
Adjusting the basic position of the clutch lever
Info
Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.
Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handlebar.
The range of adjustment is limited.
Turn the adjusting screw by hand only, and do not apply any force.
Do not make any adjustments while riding!
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw 1.
101166-10
11.17
Checking/rectifying the fluid level of the hydraulic clutch
Info
The fluid level rises with increasing wear of the clutch lining disc.
Do not use brake fluid.
87
11
SERVICE WORK ON THE CHASSIS
88
–
Move the clutch fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws 1.
–
Remove cover 2 with membrane 3.
–
Check the fluid level.
Fluid level below container rim
»
If the coolant level does not meet specifications:
–
101167-10
Correct the fluid level of the hydraulic clutch.
Hydraulic fluid (15) (
–
4 mm (0.16 in)
p. 199)
Position the cover with the membrane. Mount and tighten the screws.
12
BRAKE SYSTEM
12.1
ABS/antilock brake system
89
The ABS unit 1, which consists of a hydraulic unit, ABS control unit, and return pump, is
installed under the seat. The front and rear wheels each have a wheel speed sensor 2.
Warning
40
0
3
Danger of accidents Functional limitations of the ABS
2
0
–
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.
0
1
Warning
Danger of accidents Rolling over of the vehicle
–
0
2
401410-10
It is not always possible to prevent rolling over of the vehicle in extreme riding
situations (e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your
riding style to the road conditions and your riding ability.
The ABS operates with two independent brake circuits (front and rear brakes). During normal operation, the brake system operates like a conventional brake system without ABS.
When the ABS control unit detects the tendency of a wheel to lock, the ABS begins regulating the braking pressure. The control process causes the hand and foot brake levers to
vibrate slightly.
12
BRAKE SYSTEM
90
The ABS warning lamp 3 must light up briefly after the ignition is switched on and should
then goes out after starting off. If it does not go out after starting off or if it lights up while
riding, this indicates a fault in the ABS system. In this case, the ABS is no longer enabled
and the wheels may lock during braking. The brake system itself stays functional; only ABS
control is not available.
The ABS warning lamp may also light up if the rotating speeds of the front and rear wheels
differ greatly under extreme riding conditions, for example when making wheelies or if the
rear wheel spins. This causes the ABS to switch off.
To reenable the ABS, the vehicle must be stopped and the ignition switched off. The ABS
is reenabled when the vehicle is switched on again. The ABS warning lamp goes out when
you start off.
Button 4 can be used to switch ABS off manually (see Starting).
12.2
Adjusting the basic position of the hand brake lever
–
Pull the hand brake lever forward.
–
Adjust the basic setting of the hand brake lever to your hand size by turning adjusting
wheel 1.
Info
Do not make any adjustments while riding!
101124-10
12.3
Checking the front 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.)
12
BRAKE SYSTEM
91
–
Check the thickness of the brake disc in several places to see if it conforms to measurement A.
Info
Wear reduces the thickness of the brake discs in area 1 of the brake discs.
Brake discs - wear limit
Front
»
100135-10
If the brake disc thickness is less than the specified value:
–
–
Change the brake discs.
x
Check the brake discs for damage, cracking and deformation.
»
If the brake discs exhibit damage, cracking or deformation:
–
12.4
4.5 mm (0.177 in)
Change the brake discs.
x
Checking the front brake fluid level
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–
Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
glad to help.)
12
BRAKE SYSTEM
92
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Check the brake fluid level in the brake fluid reservoir 1.
»
If the brake fluid has dropped below marking MIN:
–
Add front brake fluid.
x(
p. 92)
101175-10
12.5
Adding front brake fluid
x
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–
Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
glad to help.)
12
BRAKE SYSTEM
93
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 is corrosive and will damage painted surfaces.
Use only clean brake fluid from a sealed container.
–
Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws.
–
Remove cover 1 with membrane 2.
–
Add brake fluid to the MAX mark.
Brake fluid DOT 4 / DOT 5.1 (
–
101176-10
12.6
p. 197)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
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.)
12
BRAKE SYSTEM
94
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 all brake linings on both brake calipers to ensure they have minimum thickness A.
≥ 1 mm (≥ 0.04 in)
Minimum thickness A
»
If the minimum thickness is less than specified:
–
–
12.7
x
Check all brake linings on both brake calipers for damage and cracking.
»
101584-10
Change the front brake linings.
If damage or wear is encountered:
–
Change the front brake linings.
x
Checking 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.
12
BRAKE SYSTEM
95
–
Move the foot brake lever back and forth between the end stop and the contact to the
piston rod and check free travel A.
Guideline
Free travel at foot brake lever
3… 5 mm (0.12… 0.2 in)
Info
The piston rod should not move.
»
101125-10
12.8
If the free travel does not meet specifications:
–
Adjust the free travel to the specified value.
Adjusting the basic position 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.
–
Release nut 1 and turn push rod 2 until the foot brake lever is in the desired position.
At least two thread turns are visible at the lower nut.
Info
The range of adjustment is limited.
101585-10
–
Check the free travel of the foot brake lever. (
–
Tighten nut 1.
p. 94)
12
BRAKE SYSTEM
12.9
Checking the rear brake disc
96
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 brake disc in several places to see if it conforms to measurement A.
Info
Wear reduces the thickness of the brake disc in area 1 of the brake disc.
Brake disc - wear limit
Rear
»
400480-10
If the brake disc thickness is less than the specified value:
–
–
Change the brake disc.
x
Check the brake disc for damage, cracking and deformation.
»
If damage, cracks or deformation are visible on the brake disc:
–
12.10
4.5 mm (0.177 in)
Change the brake discs.
x
Checking the rear brake fluid level
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
12
BRAKE SYSTEM
97
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.)
–
Stand the vehicle upright.
–
Check the brake fluid level of the brake fluid reservoir.
»
If the fluid level reaches the MIN marking 1:
–
Add rear brake fluid.
x(
p. 97)
101588-10
12.11
Adding rear brake fluid
x
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
12
BRAKE SYSTEM
98
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 is corrosive and will damage painted surfaces.
Use only clean brake fluid from a sealed container.
101589-10
–
Remove screws 1.
–
Remove cover 2 with membrane 3.
12
BRAKE SYSTEM
99
–
Add brake fluid to level A.
Brake fluid DOT 4 / DOT 5.1 (
–
p. 197)
Position the cover with the membrane. Mount and tighten the screws.
Info
Clean up overflowed or spilt brake fluid immediately with water.
101590-10
12.12
Checking the rear brake linings
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–
Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
12
BRAKE SYSTEM
100
–
Check the brake linings for minimum thickness A.
≥ 1 mm (≥ 0.04 in)
Minimum thickness A
»
If the minimum thickness is less than specified:
–
–
»
x
If damage or wear is encountered:
–
101586-10
Change the rear brake linings.
Check the brake linings for damage and cracking.
Change the rear brake linings.
x
13
WHEELS, TIRES
13.1
Removing the front wheel
101
x
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
–
Raise the motorcycle with the front wheel stand. (
p. 73)
p. 74)
Main work
– Take the speed sensor cable out of the clamp.
–
Remove screw 1 and pull wheel speed sensor 2 out of the hole with the sleeve.
–
Remove screws 3 from both brake calipers.
–
Press back the brake linings with a light lateral tilting of the brake calipers on the brake
disc. Pull the brake calipers carefully back from the brake discs and hang them to one
side.
Info
101587-10
Do not pull the hand brake lever when the brake calipers are removed.
–
Loosen screws 4 and 5.
–
Unscrew screw 4 about six turns and press your hand on the screw to push the wheel
spindle out of the axle clamp. Remove screw 4.
Warning
Danger of accidents Reduced braking efficiency due to damaged brake discs.
–
101591-10
–
Always lay down the wheel in such a way that the brake discs are not damaged.
Holding the front wheel, withdraw the wheel spindle. Take the front wheel out of the
fork.
13
WHEELS, TIRES
13.2
Installing the front wheel
102
x
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
–
Check the wheel bearing for damage and wear.
»
If the wheel bearing is damaged or worn:
–
–
Replace the wheel bearing.
x
Clean, grease, and mount the left and right spacers and the shaft seal rings.
Long-life grease (
p. 202)
–
Clean screw 1 and wheel spindle 2.
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
–
Mount and tighten screw 1.
The arrow on the spoke points in the direction of motion.
Guideline
Bolt, front axle
B00634-10
M25x1.5
45 Nm
(33.2 lbf ft)
13
WHEELS, TIRES
103
–
Slide the sleeve onto the wheel speed sensor 3 and push them into the hole together.
Mount and tighten screw 4.
Guideline
Screw, wheel speed sensor
101587-11
M6
6 Nm
(4.4 lbf ft)
Loctite® 243™
–
Fasten the speed sensor cable in the bracket.
–
Position the brake calipers and check that the brake linings are seated correctly.
–
Mount screws 5 on both brake calipers but do not tighten yet.
–
Operate the hand brake lever repeatedly until the brake linings are in contact with the
brake disc and there is a pressure point. Fix the hand brake lever in the activated position.
–
Tighten screws 5 on both brake calipers.
The brake calipers straighten.
Guideline
Screw, front brake caliper
M10x1.25
45 Nm
(33.2 lbf ft)
–
Release the fixation of the hand brake lever.
–
Take the motorcycle off of the front wheel stand. (
–
Take the motorcycle off of the rear wheel stand. (
p. 74)
p. 73)
Loctite® 243™
13
WHEELS, TIRES
104
–
Pull the front brake and compress the fork powerfully a few times.
–
Tighten screws 6.
The fork legs straighten.
Guideline
Screw, fork stub
M8
15 Nm
(11.1 lbf ft)
101592-10
13.3
Removing the rear wheel
x
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
p. 73)
13
WHEELS, TIRES
105
Main work
– Remove screw 1 and pull wheel speed sensor 2 out of the hole.
–
Remove nut 3. Remove chain adjuster 4.
–
Pull out wheel spindle 5 to the point where the chain adjuster is no longer in contact
with the adjusting screw.
–
Push the rear wheel forward as far as possible and take the chain off the rear sprocket.
–
Withdraw the wheel spindle.
–
Pull the rear wheel back until the brake caliper support is suspended freely between the
brake disc and rim.
101593-10
Warning
Danger of accidents Reduced braking efficiency due to damaged brake discs.
–
101594-01
Always lay down the wheel in such a way that the brake discs are not damaged.
13
WHEELS, TIRES
106
–
Take the rear wheel carefully out of the swingarm without damaging the rim and/or
brake disc.
Info
Do not operate the foot brake when the rear wheel is removed.
13.4
Installing the rear wheel
x
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the brake discs.
–
Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary.
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.
–
»
B00635-10
p. 108)
If the wheel bearing is damaged or worn:
–
–
x(
Check the wheel bearing for damage and wear.
Replace the wheel bearing.
x
Remove bushing 1. Clean and grease the mating surfaces of the bushing and the shaft
seal ring.
Long-life grease (
p. 202)
–
Install the bushing.
–
Clean and grease the thread of the wheel spindle and nut.
13
WHEELS, TIRES
107
Long-life grease (
p. 202)
–
Clean the fixing locations on the brake caliper support and swingarm.
–
Engage the counter bearing of the brake caliper support A and swingarm. Carefully lift
the rear wheel into the swingarm and engage the brake disc. Lay the chain on the rear
sprocket and mount the wheel spindle.
–
Mount chain adjuster 2 and nut 3.
Info
Mount the left and right chain adjusters in the same position.
–
Push the rear wheel forward so that the chain adjusters are in contact with the adjusting screws, and tighten the nut.
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 reference marks B.
Nut, rear wheel spindle
–
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Insert wheel speed sensor 4 into the hole. Mount and tighten screw 5.
Guideline
Screw, wheel speed sensor
M6
101593-11
–
Loctite® 243™
Operate the foot brake lever repeatedly until the brake linings lie on the brake disc and
there is a pressure point.
Finishing work
– Take the motorcycle off of the rear wheel stand. (
–
6 Nm
(4.4 lbf ft)
Check the chain tension. (
p. 81)
p. 73)
13
WHEELS, TIRES
13.5
Checking the rear hub rubber dampers
108
x
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 5 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.
Preparatory work
– Raise the motorcycle with the rear wheel stand. (
–
Remove the rear wheel.
x(
p. 73)
p. 104)
Main work
– Remove the rear sprocket carrier.
–
Check the rubber dampers of the rear hub for damage and wear.
»
If the rubber dampers of the rear hub are damaged or worn:
–
–
Change the rear hub shock absorber.
x
Position the rear sprocket carrier.
Info
A pin/rubber damper pair that is low in play increases the service life of the rubber damper.
B00636-01
Finishing work
– Install the rear wheel.
x(
p. 106)
–
Take the motorcycle off of the rear wheel stand. (
–
Check the chain tension. (
p. 81)
p. 73)
13
WHEELS, TIRES
13.6
Checking the tire condition
109
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.
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
The type, condition and air pressure of the tires all have a major impact on the handling of the motorcycle.
Worn tires have a negative effect on vehicle handling, especially on wet surfaces.
13
WHEELS, TIRES
110
–
Check the front and rear tires for cuts, run-in objects and other damage.
»
If the tires exhibit cuts, run-in objects or other damage:
–
–
Change the tires.
Check the depth of the tread.
Info
Note local national regulations concerning the minimum tread depth.
Minimum tread depth
400602-10
»
If the tread depth is less than the minimum permissible depth:
–
–
≥ 2 mm (≥ 0.08 in)
Change the tires.
Check the age of the tires.
Info
The tire's date of 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 be changed after 5 years at the latest, regardless of the actual state of wear.
»
If a tire is more than five years old:
–
13.7
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.
13
WHEELS, TIRES
111
–
Remove the protection cap.
–
Check the tire air pressure when the tires are cold.
Tire air pressure, solo
Front
2.4 bar (35 psi)
Rear
2.4 bar (35 psi)
Tire air pressure with passenger/full payload
400695-01
»
2.4 bar (35 psi)
Rear
2.6 bar (38 psi)
If the tire pressure does not meet specifications:
–
–
Front
Correct the tire pressure.
Mount the protection cap.
Info
The rubber seal in the protection cap prevents air from leaking out of the tire if
the valve is faulty.
14
ELECTRICAL SYSTEM
14.1
Removing the battery
112
x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
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.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 75)
14
ELECTRICAL SYSTEM
113
Main work
– Disconnect negative (minus) cable 1 of the battery.
101595-10
101596-10
–
Remove positive terminal cover 2.
–
Disconnect the positive (plus) cable 3 of the battery.
–
Detach rubber band 4.
–
Pull the battery up and out of the battery holder.
14
ELECTRICAL SYSTEM
14.2
Installing the battery
114
x
Main work
– Position the battery in the battery holder.
Info
The terminals of the battery must face in the direction of travel.
–
Attach rubber band 1.
–
Position washer A and detach positive cable 2 of the battery.
–
Position positive terminal cover 3.
–
Position washer B and detach negative cable 4 of the battery.
101597-10
101598-10
Finishing work
– Mount the seat. (
–
Set the clock. (
p. 76)
p. 33)
14
ELECTRICAL SYSTEM
14.3
Recharging the battery
115
x
Warning
Risk of injury Battery acid and battery gases cause serious chemical burns.
–
Keep batteries out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
Avoid contact with battery acid and battery gases.
–
Keep the battery away from sparks or open flames. Charge only in well-ventilated areas.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–
Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
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.
14
ELECTRICAL SYSTEM
116
Info
Even when there is no load on the battery, it discharges steadily.
The charging level and the method of charging are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
–
Disconnect the negative (minus) cable of the battery to avoid damage to the motorcycle's electronics.
p. 75)
14
ELECTRICAL SYSTEM
117
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 the 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 1.
Charge the battery to no more than 10% of the capacity specified on battery
housing 2.
–
Switch off the charger after charging. Reconnect 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
700588-01
Finishing work
– Mount the seat. (
14.4
p. 76)
Changing the main fuse
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
–
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
3 months
14
ELECTRICAL SYSTEM
118
Info
The main fuse protects all power consumers of the vehicle. The main fuse is under the seat.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 75)
Main work
– Remove protection covers 1.
–
Remove the faulty main fuse 2.
Info
A defective fuse can be identified by the burned-out fuse wire A.
A reserve fuse 3 is located in the starter relay.
–
Install a new main fuse.
Fuse (58011109130) (
p. 190)
Tip
Place the spare fuse in the starter relay so that it is available if needed.
–
Attach the protection covers 1.
101599-10
Finishing work
– Mount the seat. (
p. 76)
14
ELECTRICAL SYSTEM
14.5
Changing the ABS fuses
119
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
–
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
Two fuses for the ABS are located under the seat. These fuses protect the return pump and the hydraulic unit of the ABS. The third
fuse, which protects the ABS control unit, is located in the fuse box.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 75)
To change the fuse of the ABS hydraulic unit:
– Take off the protection cap and remove fuse 1.
–
Insert the new fuse.
Fuse (58011109130)
–
101600-10
Mount the protection cap.
14
ELECTRICAL SYSTEM
120
To change the fuse of the ABS return pump:
– Take off the protection cap and remove fuse 2.
–
Insert the new fuse.
Fuse (58011109130)
–
Mount the protection cap.
101601-10
Finishing work
– Mount the seat. (
14.6
p. 76)
Changing the fuses of individual power consumers
Warning
Fire hazard The electrical system can be overloaded if the wrong fuses are used.
–
Use only fuses with the prescribed amperage. Never by-pass or repair fuses.
Info
The fuse box containing the fuses of individual power consumers is located under the seat.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 75)
14
ELECTRICAL SYSTEM
121
Main work
– Open fuse box cover 1.
–
Check the fuses.
Info
A faulty fuse can be identified by the burned-out fuse wire A.
–
Remove the faulty fuse.
Guideline
101602-10
Fuse 1 - 10 A - ignition, fuel pump, hazard warning flasher
Fuse 2 - 15 A - high beam, low beam, parking light, tail light, license plate lamp
Fuse 3 - 10 A - horn, brake light, turn signal
Fuse 4 - 10 A - radiator fan
Fuse 5 - 10 A - ignition (EFI control unit), immobilizer
Fuse 6 - 10 A - combination instrument, auxiliary equipment (permanent positive),
alarm system (optional), socket
Fuse 7 - 10 A - supplementary equipment (accessories connected to the ignition
switch)
Fuse 8 - 10 A - ABS
Fuse 9 - not used
Fuse 10 - not used
Fuse SPARE - 10 A/15 A - spare fuses
–
Use spare fuses with the correct rating only.
Fuse (75011088010) (
p. 189)
Fuse (75011088015) (
p. 189)
14
ELECTRICAL SYSTEM
122
Tip
Insert a spare fuse so that it is available if needed.
–
Close the fuse box cover.
Finishing work
– Mount the seat. (
14.7
p. 76)
Changing the headlight bulb
Note
Damage to reflector Reduced brightness.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
Preparatory work
– Switch off all power consumers and switch off the engine.
Main work
– Remove screws 1.
101145-10
14
ELECTRICAL SYSTEM
123
–
Cover the fender with a cloth.
–
Swing the headlight mask forward and pull it upward out of holding lugs 2.
–
Disconnect connector 3.
–
Remove protection cap 4.
–
Push off retaining clamp 5 on both sides, squeeze and fold down.
–
Remove headlight bulb 6.
–
Position the new headlight bulb in the headlight housing.
101146-10
700592-10
Low beam/high beam (H4/socket P43t) (
p. 190)
Info
Insert the headlight bulb so that the catches latch into the recesses.
700593-01
14
ELECTRICAL SYSTEM
124
–
Position the retaining clamp.
–
Mount protection cap 4.
–
Plug in connector 3.
–
Position holes 7 onto holding lugs 2.
700592-10
101146-11
14
ELECTRICAL SYSTEM
–
125
Position the headlight mask. Mount and tighten screws 1.
Guideline
Remaining chassis screws
–
M6
10 Nm (7.4 lbf ft)
Check that the lighting is functioning properly.
101145-10
14.8
Changing the parking light bulb
Note
Damage to reflector Reduced brightness.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
Preparatory work
– Switch off all power consumers and switch off the engine.
Main work
– Remove screws 1.
101145-10
14
ELECTRICAL SYSTEM
126
–
Cover the fender with a cloth.
–
Swing the headlight mask forward and pull it upward out of holding lugs 2.
–
Pull parking light 4 carefully out of the holder.
–
Remove the bulb.
–
Position a new light bulb in the holder.
101146-10
Parking light (W5W/socket W2.1x9.5d) (
–
700594-01
p. 190)
Carefully position the socket with the bulb into the holder in the headlight.
14
ELECTRICAL SYSTEM
127
–
Position holes 5 onto holding lugs 2.
–
Position the headlight mask. Mount and tighten screws 1.
101146-12
Guideline
Remaining chassis screws
–
M6
10 Nm (7.4 lbf ft)
Check that the lighting is functioning properly.
101145-10
14.9
Changing the turn signal bulb
Note
Damage to reflector Reduced brightness.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
14
ELECTRICAL SYSTEM
128
–
Remove the screw on the rear of the turn signal housing.
–
Carefully remove diffuser 1.
–
Press bulb 2 carefully into the socket, turn it counterclockwise by about 30°, and pull
it out of the socket.
–
Press the new bulb carefully into the socket and turn it clockwise until it stops.
Turn signal (RY10W/socket BAU15s) (
101147-10
14.10
p. 190)
–
Check the turn signal to make sure it is functioning properly.
–
Position the diffuser.
–
Insert the screw and first turn it counterclockwise until it engages in the thread. Tighten
the screw slightly.
Changing the brake light bulb
Note
Damage to reflector Reduced brightness.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
Preparatory work
– Remove the seat. (
p. 75)
14
ELECTRICAL SYSTEM
129
Main work
– Remove screws 1.
–
Remove the grab handles.
–
Remove screws 2.
–
Remove screws 3 on the left and right rear side part.
–
Remove the rear side part.
101603-10
101604-10
14
ELECTRICAL SYSTEM
130
–
Remove screws 4.
–
Remove the top part.
–
Turn bulb socket 5 counterclockwise all the way and take it out of the tail light.
–
Push the bulb carefully into the socket, turn it counterclockwise and pull it out of the
socket.
–
Press the new bulb carefully into the socket and turn it clockwise until it stops.
101605-10
Brake light (PR21W/socket BAW15s) (
101606-10
p. 190)
–
Insert the bulb socket into the tail light and turn clockwise until it stops.
–
Check that the brake light system is functioning properly.
14
ELECTRICAL SYSTEM
131
–
Position the rear top part.
–
Mount and tighten screws 4.
Guideline
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
Remaining chassis screws
M5
5 Nm (3.7 lbf ft)
Remaining frame bolts
EJOT PT K50x12
T20
1.2 Nm
(0.89 lbf ft)
101605-10
–
Position the rear side parts.
–
Mount and tighten screws 2.
Guideline
–
Mount and tighten screws 3 on the left and right rear side part.
Guideline
Remaining frame bolts
101604-10
EJOT PT K50x12
T20
1.2 Nm
(0.89 lbf ft)
14
ELECTRICAL SYSTEM
132
–
Position the grab handles.
–
Mount and tighten screws 1.
Guideline
Screw, handrail
M8
20 Nm
(14.8 lbf ft)
101603-10
Finishing work
– Mount the seat. (
14.11
p. 76)
Changing the tail light bulbs
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
– Remove the seat. (
p. 75)
14
ELECTRICAL SYSTEM
133
Main work
– Remove screws 1.
–
Remove the grab handles.
–
Remove screws 2.
–
Remove screws 3 on the left and right rear side part.
–
Remove the rear side part.
101603-10
101604-10
14
ELECTRICAL SYSTEM
134
–
Remove screws 4.
–
Remove the top part.
–
Carefully pull bulb sockets 5 out of the holder.
–
Remove the bulb.
–
Position a new light bulb in the holder.
101605-10
Tail light (WR5W/socket W2.1x9.5d) (
101152-10
p. 190)
–
Carefully position the sockets with the bulbs into the holder in the tail light.
–
Check that the tail light bulbs are functioning properly.
14
ELECTRICAL SYSTEM
135
–
Position the rear top part.
–
Mount and tighten screws 4.
Guideline
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
Remaining chassis screws
M5
5 Nm (3.7 lbf ft)
Remaining frame bolts
EJOT PT K50x12
T20
1.2 Nm
(0.89 lbf ft)
101605-10
–
Position the rear side parts.
–
Mount and tighten screws 2.
Guideline
–
Mount and tighten screws 3 on the left and right rear side part.
Guideline
Remaining frame bolts
101604-10
EJOT PT K50x12
T20
1.2 Nm
(0.89 lbf ft)
14
ELECTRICAL SYSTEM
136
–
Position the grab handles.
–
Mount and tighten screws 1.
Guideline
Screw, handrail
M8
101603-10
Finishing work
– Mount the seat. (
14.12
p. 76)
Changing the license plate lamp
Main work
– Remove screws 1.
–
101607-10
Remove the license plate lamp cover.
20 Nm
(14.8 lbf ft)
14
ELECTRICAL SYSTEM
137
–
Carefully pull socket 2 out of the holder.
–
Remove the bulb.
–
Position a new light bulb in the holder.
License plate lamp (W5W/socket W2.1x9.5d) (
p. 190)
–
Carefully position the socket with the bulb into the holder.
–
Position the cover.
–
Mount and tighten screws 1.
101608-10
101607-10
Finishing work
– Check that the license plate lamp is functioning properly.
14
ELECTRICAL SYSTEM
14.13
Checking the headlight setting
A
0
138
–
Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark
at the level of the center of the headlight.
–
Make another mark at a distance of B under the first mark.
Guideline
0
B
Distance B
–
5 cm (2 in)
Park the vehicle at a distance of A vertically in front of the wall and switch on the low
beam headlight.
Guideline
400726-10
Distance A
5 m (16 ft)
–
The rider, with luggage and passenger if applicable, now mounts the motorcycle.
–
Check the headlight setting.
The light-dark boundary must lie exactly on the lower mark when the motorcycle is
ready to operate with the rider mounted along with any luggage and a passenger if
applicable.
»
If the boundary between light and dark does not meet specifications:
–
14.14
Adjust the headlight range.
Adjusting the headlight range
Preparatory work
– Check the headlight setting. (
p. 138)
14
ELECTRICAL SYSTEM
139
Main work
– Turn adjusting screw 1 to adjust the headlight range.
Guideline
For a motorcycle with rider, the light/dark boundary must be exactly on the lower
mark (the mark is created in: Checking headlight adjustment).
Info
101153-10
14.15
Turn clockwise to increase the headlight range; turn counterclockwise to reduce
the headlight range.
If you have a payload, you may have to correct the headlight range.
Activating/deactivating the ignition key
Info
The orange programming key must only be used for activating and deactivating!
If a black ignition key is lost or replaced, the black ignition keys must be individually activated/deactivated using the orange programming key. This will also prevent the vehicle from being operated without authorization with the lost black ignition key.
You can activate or deactivate up to four black ignition keys. Only the black ignition keys programmed during an activation procedure are valid. All black ignition keys not programmed during the activation procedure are invalid, but can be reprogrammed in a
further activation procedure.
14
ELECTRICAL SYSTEM
140
Loss of a black ignition key (second black ignition key available):
The following procedure deactivates all activated black ignition keys that are not
included in the procedure.
–
Press the emergency OFF switch into the position
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
.
401184-10
FI warning lamp
Immobilizer indicator lamp
101609-10
lights up.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
–
Insert the black ignition key in the ignition lock.
–
Switch on the ignition by turning the ignition key to the ON
FI warning lamp
.
position.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
on again.
lights up, switches off briefly, and switches
–
Switch off the ignition by turning the ignition key to the OFF
–
Remove the black ignition key.
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
FI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
position.
(MIL) lights up, switches off, and then starts to flash.
.
14
ELECTRICAL SYSTEM
141
Immobilizer indicator lamp lights up, switches off briefly and flashes; the
number of flashes equals the number of functional black ignition keys including the orange programming key. In this case, twice.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
.
The lost black ignition key is deactivated.
The existing black ignition key is reactivated.
Loss of both black ignition keys (no black ignition key available):
This procedure is important to prevent misuse of the lost black ignition key.
–
Press the emergency OFF switch into the position
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
.
401184-11
FI warning lamp
Immobilizer indicator lamp
101609-10
lights up.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Switch on the ignition by turning the orange programming key to the ON position
FI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
.
.
(MIL) lights up, switches off, and then starts to flash.
Immobilizer indicator lamp lights up, switches off briefly and flashes; the
number of flashes equals the number of functional black ignition keys including the orange programming key. In this case once, since all black ignition keys
are deactivated.
14
ELECTRICAL SYSTEM
142
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
.
All black ignition keys are deactivated.
–
Order a new black ignition key according to the key number on the KEYCODECARD
and activate it.
Activating the ignition key:
– Press the emergency OFF switch into the position
.
–
Insert the orange programming key in the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
FI warning lamp
Immobilizer indicator lamp
lights up.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
–
Insert the black ignition key in the ignition lock.
–
Switch on the ignition by turning the ignition key to the ON
FI warning lamp
.
(MIL) lights up, switches off, and then starts to flash.
.
position.
(MIL) lights up, switches off, and then starts to flash.
The immobilizer indicator lamp
again.
lights up, switches off briefly, and lights up
–
Switch off the ignition by turning the ignition key to the OFF
–
Remove the black ignition key.
–
To activate further ignition keys, repeat the last 4 steps with the respective ignition
key.
–
Insert the orange programming key into the ignition lock.
–
Switch on the ignition by turning the orange programming key to the ON position
FI warning lamp
position.
(MIL) lights up, switches off, and then starts to flash.
.
14
ELECTRICAL SYSTEM
143
The immobilizer indicator lamp lights up, switches off briefly and flashes;
the number of flashes equals the number of functional black ignition keys
including the orange programming key.
–
Switch off the ignition by turning the orange programming key to the OFF position
–
Pull out the orange programming key.
.
All black ignition keys are activated included in this job sequence are activated.
15
COOLING SYSTEM
15.1
Cooling system
144
The water pump 1 in the engine forces the coolant to flow.
The pressure in the cooling system resulting from heat is regulated by a valve in the radiator cap. This permits the specified coolant temperature without causing any malfunctions.
125 °C (257 °F)
101155-10
Cooling takes place by means of 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.
The heat expansion causes the surplus coolant to flow into the compensating tank 2. When
the temperature falls, this surplus coolant is sucked back into the cooling system.
700621-10
15.2
Checking the antifreeze and coolant level
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
15
COOLING SYSTEM
145
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact
a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
–
Remove the seat. (
–
Reset the fuel tank. (
p. 75)
p. 76)
Main work
– Remove radiator cap 1 and cover 2 from the compensating tank.
–
Check the coolant antifreeze.
−25… −45 °C (−13… −49 °F)
»
If the coolant antifreeze does not meet specifications:
–
–
Correct the coolant antifreeze.
Check the coolant level in the compensating tank.
The coolant level must be between the upper marking 3 and lower marking 4.
101156-10
»
If the coolant level in the compensating tank does not meet specifications, but the
tank is not empty:
–
Add coolant to the upper marking.
Alternative 1
Coolant (
p. 197)
15
COOLING SYSTEM
146
Alternative 2
Coolant (mixed ready to use) (
»
p. 197)
If there is no coolant in the compensating tank:
–
Check the cooling system for leaks.
x
Info
Do not start up the motorcycle!
–
Fill/bleed the cooling system.
x(
–
Mount cover 2 of the compensating tank.
–
Check the coolant level in the radiator.
p. 149)
The radiator must be completely filled.
»
If the coolant level does not meet specifications:
–
Correct the coolant level and determine the reason for the coolant loss.
Alternative 1
Coolant (
p. 197)
Alternative 2
101157-10
Coolant (mixed ready to use) (
»
If more coolant needed to be added than the specified value:
> 0.50 l (> 0.53 qt.)
–
–
p. 197)
Fill/bleed the cooling system.
Mount radiator cap 1.
x(
p. 149)
15
COOLING SYSTEM
15.3
Checking the coolant level in the compensating tank
147
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact
a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Condition
The engine is cold.
The radiator is completely full.
Preparatory work
– Stand the motorcycle on a horizontal surface.
Main work
– Check the coolant level in the compensating tank 1.
The coolant level must be between the upper marking 2 and lower marking 3.
»
101158-10
If the coolant level in the compensating tank does not meet specifications, but the
tank is not empty:
–
Remove the compensating tank cover.
–
Add coolant to the upper marking.
Alternative 1
Coolant (
p. 197)
15
COOLING SYSTEM
148
Alternative 2
Coolant (mixed ready to use) (
–
»
p. 197)
Mount the cover of the compensating tank.
If there is no coolant in the compensating tank:
–
Check the cooling system for leaks.
x
Info
Do not start up the motorcycle!
–
15.4
Draining the coolant
Fill/bleed the cooling system.
x(
p. 149)
x
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact
a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
Preparatory work
– Remove the seat. (
–
Reset the fuel tank. (
p. 75)
p. 76)
15
COOLING SYSTEM
149
Main work
– Place a suitable container under the radiator.
–
Remove radiator cap 1.
–
Remove screw 2.
–
Completely drain the coolant.
–
Mount screw 2 with a new seal ring and tighten it.
Guideline
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
101159-10
–
Place a suitable container under the engine.
–
Remove screw 3.
–
Completely drain the coolant.
–
Mount screw 3 with a new seal ring and tighten it.
Guideline
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
101160-10
15.5
Filling/bleeding the cooling system
x
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Avoid contact between coolant and skin, eyes and clothing. If it gets into your eyes, rinse immediately with water and contact
a doctor. Wash affected skin areas immediately with soap and water. If coolant is swallowed, contact a doctor immediately.
Change clothes that have come into contact with coolants. Keep coolant out of the reach of children.
15
COOLING SYSTEM
150
Preparatory work
– Remove the seat. (
–
Reset the fuel tank. (
p. 75)
p. 76)
Main work
– Ensure that the drain plug on the radiator and the water pump cover are tightened.
–
Remove bleeder screw 1.
–
Position the vehicle as shown and secure it against rolling. Height difference A must
be reached.
101161-10
Guideline
Height difference A
50 cm (19.7 in)
Info
A
0
400677-10
To make sure that all of the air can escape from the cooling system, raise the
front of the vehicle. A poorly bled cooling system is less effective at cooling and
the engine can overheat.
15
COOLING SYSTEM
151
–
Remove the radiator cap and pour in coolant until it emerges without bubbles at the
vent hole, and then immediately mount and tighten the bleeder screw 1.
Alternative 1
Coolant (
p. 197)
Alternative 2
Coolant (mixed ready to use) (
101162-10
p. 197)
–
Fill the radiator completely with coolant. Mount the radiator cap.
–
Lean the vehicle on the side stand.
–
Check the coolant level in the compensating tank. (
p. 147)
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 run it until it reaches operating temperature.
–
Stop the engine and allow it to cool down.
–
When the engine is cool, check the coolant level in the radiator and add coolant if necessary.
–
Check the coolant level in the compensating tank. (
Six bars of the temperature display light up.
Finishing work
– Position the fuel tank. (
–
Mount the seat. (
p. 76)
p. 77)
p. 147)
16
TUNING THE ENGINE
16.1
Checking the play in the throttle cable
152
–
Check the throttle grip for smooth operation.
–
Move the handlebar to the straight-ahead position. Move the throttle grip backwards
and forwards to ascertain the play in the throttle cable.
Play in throttle cable
»
3… 5 mm (0.12… 0.2 in)
If the throttle cable play does not meet specifications:
–
Adjust the play in the throttle cable.
x(
p. 153)
Danger
400192-10
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:
–
Adjust the play in the throttle cable.
x(
p. 153)
16
TUNING THE ENGINE
16.2
Adjusting the play in the throttle cable
153
x
–
Move the handlebar to the straight-ahead position.
–
Use the KTM diagnostics tool to set the throttle stepper motor to the basic position.
–
Push back sleeve 1.
–
Loosen lock nut 2.
–
Set the play in the throttle cable by turning adjusting screw 3.
Guideline
Play in throttle cable
101610-10
16.3
3… 5 mm (0.12… 0.2 in)
–
Tighten lock nut 2.
–
Slide on sleeves 1.
–
Check the throttle grip for ease of movement.
Plug-in connection, ignition timing map
The plug-in connection is located under the seat in front of the tail light.
By disconnecting the connector, the ignition timing map for fuel with an octane rating
below 95 (ROZ 95/RON 95/PON 91) is activated. While the engine will have a slightly
lower power output, this setting prevents engine damage by hindering spark knocking due
to poor fuel quality.
Possible states
• Plug-in connection disconnected – Fuel with an octane rating of 80 to 94 (RON) can
be used for one tank full.
• Plug-in connection closed – Fuel with an octane rating of 95 or higher can be used.
101611-10
16
TUNING THE ENGINE
16.4
Adjusting the ignition curve to the fuel quality
Preparatory work
– Switch off the ignition by turning the ignition key to the OFF
–
Remove the seat. (
154
position.
p. 75)
To activate the ignition curve for low octane fuel:
Note
Engine failure Low-quality fuel damages the engine.
–
–
Operate the vehicle with fuel with an octane rating below 95 (ROZ 95/RON 95/PON 91) for no more than one tank full.
–
The ignition curve must be adjusted to low octane fuel.
Disconnect the connector.
Plug-in connection disconnected – Fuel with an octane rating of 80 to 94 (RON) can be used for one tank full. (
Activate the ignition curve for fuel with an octane rating of 95 or higher (ROZ 95/RON 95/PON 91):
– Join the connector.
Plug-in connection closed – Fuel with an octane rating of 95 or higher can be used. (
Finishing work
– Mount the seat. (
p. 76)
p. 153)
p. 153)
16
TUNING THE ENGINE
16.5
Checking the basic position of the shift lever
–
155
Sit on the vehicle in the riding position and determine the distance A between the
upper edge of your boot and the shift lever.
Distance between shift lever and upper
edge of boot
»
A
0
If the distance does not meet specifications:
–
Adjust the basic position of the shift lever.
400692-10
16.6
Adjusting the basic position of the shift lever
–
101172-10
10… 20 mm (0.39… 0.79 in)
x
Remove screw 1 and remove shift lever 2.
x(
p. 155)
16
TUNING THE ENGINE
156
–
Clean gear teeth A of the shift lever and shift shaft.
–
Mount the shift lever on the shift shaft in the required position and engage the gearing.
Info
The range of adjustment is limited.
The shift lever must not come into contact with any other vehicle components
during the shift procedure.
–
101173-10
Mount and tighten the screw.
Guideline
Screw, shift lever
M6
10 Nm
(7.4 lbf ft)
Loctite® 243™
17
SERVICE WORK ON THE ENGINE
17.1
Checking the engine oil level
157
Preparatory work
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 run it until it reaches operating temperature.
Six bars of the temperature display light up.
Main work
– Switch off the engine.
–
Park the motorcycle on a horizontal surface in a vertical position (not on the side
stand).
Info
After switching off the engine, wait one minute before checking the level.
–
Check the engine oil level at oil level viewer 1.
101168-10
The engine oil level must be between the upper marking 2 and lower marking 3.
»
If the engine oil level is not at the specified level:
–
Add engine oil. (
p. 164)
17
SERVICE WORK ON THE ENGINE
17.2
Changing the engine oil and filter, cleaning the oil screens
158
x
–
Drain the engine oil, change the oil filter, and clean the oil screens.
–
Fill up with engine oil.
x(
x(
p. 163)
B00119-01
17.3
Draining the engine oil, changing the oil filter, and cleaning the oil screens
x
Warning
Danger of scalding Engine oil and gear oil get very hot when the motorcycle is ridden.
–
Wear appropriate protective clothing and safety gloves. In case of burns, rinse immediately with lukewarm water.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Drain the engine oil only when the engine is warm.
p. 158)
17
SERVICE WORK ON THE ENGINE
–
Place a suitable container under the engine.
–
Remove the oil drain plug 1 with the magnet and seal ring.
–
Fully drain the engine oil out of the engine.
–
Remove screws 2 and cover 3.
–
Pull oil screen 4 out of the engine case with pliers.
700611-10
700610-10
700612-10
159
17
SERVICE WORK ON THE ENGINE
–
Place a suitable container under the engine.
–
Remove oil drain plug 5.
–
Fully drain the engine oil out of the oil tank.
–
Remove screws 6 and move oil line 7 to one side.
–
Pull oil screen 8 out of the oil tank.
–
Remove fitting 9 and move the oil line to one side.
–
Remove screws . Remove the oil filter cover bk with the O-ring.
–
Pull oil filter bl out of the oil filter housing.
101171-10
700615-10
Circlip pliers reverse (51012011000)
700617-10
–
Completely drain the engine oil.
–
Clean all oil screens and oil drain plugs with a magnet.
–
Clean all sealing surfaces.
160
17
SERVICE WORK ON THE ENGINE
161
–
Insert oil filter bl.
–
Lubricate the O-ring of the oil filter cover.
–
Mount the oil filter cover bk. Mount and tighten the screws.
Guideline
Remaining engine screws
–
M5
6 Nm (4.4 lbf ft)
Position the oil line. Mount and tighten fitting 9.
Guideline
Nut, oil line
700618-10
700614-10
M16x1.5
25 Nm
(18.4 lbf ft)
–
Check seal ring bm of the oil screen for damage and correct seating.
–
Insert oil screen 8 into the oil tank.
17
SERVICE WORK ON THE ENGINE
–
162
Position oil line 7. Mount and tighten screws 6.
Guideline
Remaining engine screws
–
M6
10 Nm (7.4 lbf ft)
Mount oil drain plug 5 with the magnet and new gasket and tighten.
Guideline
Oil drain plug with magnet
M12x1.5
25 Nm
(18.4 lbf ft)
101171-10
–
Mount oil drain plug 1 with the magnet and new seal ring and tighten.
Guideline
Oil drain plug with magnet
M22x1.5
35 Nm
(25.8 lbf ft)
700611-10
–
Slide oil screen 4 into the engine case with the TOP marking facing up.
–
Check the form ring in cover 3 for damage and correct seating.
–
Position the cover. Mount and tighten the screws.
Guideline
Screw, clutch cover
700616-10
M6
10 Nm (7.4 lbf ft)
17
SERVICE WORK ON THE ENGINE
17.4
Filling up with engine oil
163
x
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
–
The oil must be added in two steps.
Engine oil
101169-10
3.0 l (3.2 qt.)
External
temperature:
≥ 0 °C (≥ 32 °F)
Engine oil
(SAE 10W/50)
( p. 198)
External
temperature:
< 0 °C (< 32 °F)
Engine oil (SAE
5W/40) ( p. 198)
–
Remove plug 1 and add engine oil to the top marking 2.
–
Mount the plug.
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 run it until it reaches operating temperature.
Six bars of the temperature display light up.
–
Check the lubrication system for leaks.
–
Switch off the engine.
–
Park the motorcycle on a horizontal surface in a vertical position (not on the side
stand).
17
SERVICE WORK ON THE ENGINE
17.5
164
–
Remove the plug.
–
Add engine oil to the top marking 2.
–
Mount the plug.
Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
The engine oil level must be corrected when the engine is warm.
–
Remove plug 1 and add engine oil to the top marking 2.
Condition
External temperature: ≥ 0 °C (≥ 32 °F)
Engine oil (SAE 10W/50) (
p. 198)
Condition
External temperature: < 0 °C (< 32 °F)
Engine oil (SAE 5W/40) (
101169-10
p. 198)
Info
For optimal performance of the engine oil, do not mix different types of engine
oil.
We recommend changing the engine oil, if necessary.
–
Mount the plug.
18
CLEANING, CARE
18.1
Cleaning motorcycle
165
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.
–
Close off the exhaust system to keep water from entering.
–
First remove coarse dirt particles with a gentle spray of water.
–
Spray very dirty areas with a normal motorcycle cleaner and then clean with a paintbrush.
Motorcycle cleaner (
401061-01
p. 202)
18
CLEANING, CARE
166
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.
–
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. 80)
Cleaning and preserving materials for metal, rubber and plastic (
–
Treat all painted parts with a mild paint polish.
High-luster polish for paint (
p. 202)
p. 201)
18
CLEANING, CARE
167
–
Treat all plastic parts and powder-coated parts with a mild cleaning and care product.
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic
surfaces ( p. 202)
–
Lubricate the ignition/steering lock.
Universal oil spray (
18.2
p. 203)
Checks and maintenance measures for winter operation
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive
road salt.
If the vehicle was operated in road salt, clean it with cold water after use. Warm water would enhance the corrosive effects of salt.
–
Clean the motorcycle. (
–
Clean the brake system.
p. 165)
Info
After EVERY trip on salted roads, thoroughly clean the brake calipers and brake
linings after they have cooled down while they are installed; use cold water and
dry them well.
After riding on salted roads, thoroughly wash the motorcycle with cold water and
dry it well.
401060-01
–
Treat the engine, the swingarm, and all other bare or galvanized parts (except brake
discs) with a wax-based anti-corrosion substance.
Info
To prevent serious reduction of the braking efficiency, make sure no
anti-corrosion substance gets on to the brake discs.
18
CLEANING, CARE
168
–
Clean the chain. (
p. 80)
19
STORAGE
19.1
Storage
169
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Avoid contact between fuel and skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse immediately
with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed, contact a doctor immediately. Change clothing that has come into contact with fuel. Store fuel in a suitable canister according to regulations
and keep it out of the reach of children.
Info
If you want to garage the motorcycle for a longer period, take the following actions.
Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should
do this during the storage period (less overload of the authorized KTM workshop). In this way, you can avoid long waiting times at
the authorized KTM workshop at the start of the new season.
–
Clean the motorcycle. (
–
Change the engine oil and filter, clean the oil screens.
–
Check the antifreeze and coolant level. (
–
When refueling for the last time before taking the motorcycle out of service, add fuel
additive.
Fuel additive (
p. 165)
x(
p. 158)
p. 144)
p. 201)
–
Ride the motorcycle until the low fuel warning lamp lights up and the display changes
to TRIP F so that you can fill up with fresh fuel when you take the motorcycle back into
service.
–
Check the tire air pressure. (
–
Remove the battery.
–
Recharge the battery.
401058-01
x(
x(
p. 110)
p. 112)
p. 115)
19
STORAGE
170
Guideline
Storage temperature of battery without
direct sunshine
–
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 raising the motorcycle.
–
Raise the motorcycle with the rear wheel stand. (
–
Raise the motorcycle with the front wheel stand. (
–
Cover the motorcycle with a tarp or cover that is permeable to air.
p. 73)
p. 74)
Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot warm
up properly, the water vapor produced during combustion condenses and causes
valves and exhaust system to rust.
19
STORAGE
19.2
Preparing for use after storage
171
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. (
–
Refuel. (
–
Perform checks and maintenance measures when preparing for use. (
–
Take a test ride.
x(
x(
p. 74)
p. 73)
p. 115)
p. 114)
p. 33)
p. 59)
p. 49)
20
TROUBLESHOOTING
172
Faults
Possible cause
Action
The engine does not turn when the
starter button is pressed
Operating error
–
Carry out the start procedure. (
Battery discharged
–
Recharge the battery.
–
Check the closed current.
1, or 5 fuse blown
–
Change the fuses of individual power consumers.
( p. 120)
Main fuse burned out
–
Change the main fuse. (
Ignition/steering lock or emergency
OFF switch defective
–
Check the emergency OFF switch.
Faulty safety starting system
–
x
Check the ignition/steering lock. x
Check the safety starting system. x
ICU is not activated
–
Activate the immobilizer control unit.
Malfunction in CAN bus communication
–
Read out the trouble code memory using the
KTM diagnostics tool.
Combination instrument defective
–
Check the combination instrument.
Control unit for electric start lock
defective
–
Check the control unit of the electric start
lock.
Engine turns only if the clutch lever is
drawn
The vehicle is in gear
–
Shift the transmission to neutral.
Faulty safety starting system
–
Check the safety starting system.
Engine turns although a gear is
engaged
Faulty safety starting system
–
x
Check the safety starting system. x
Engine turns but does not start
Coupling of fuel hose connection not
connected
–
Reconnect coupling of fuel hose connection.
Defect in fuel injection system
–
Read out the fault memory using the KTM diagnostics tool.
–
x ( p. 115)
x
Air filter very dirty
p. 117)
x
x
x
x
x
Engine has too little power
p. 50)
–
Change the air filter.
x
20
TROUBLESHOOTING
173
Faults
Possible cause
Action
Engine has too little power
Defect in fuel injection system
–
Read out the fault memory using the KTM diagnostics tool.
Engine overheats
Too little coolant in cooling system
–
Check the cooling system for leaks.
–
Check the antifreeze and coolant level.
( p. 144)
Radiator fins very dirty
–
Clean radiator fins.
Foam formation in cooling system
–
Drain the coolant.
–
Fill/bleed the cooling system.
Buckled or damaged radiator hose
–
Change the radiator hose.
Fuse 4 blown
–
Change the fuses of individual power consumers.
( p. 120)
Thermostat defective
–
Check the thermostat.
Defect in radiator fan system
–
Check the radiator fan system.
Air in cooling system
–
FI warning lamp (MIL) lights up/flashes
Defect in fuel injection system
–
Engine dies during a trip
Lack of fuel
–
Refuel. (
1, or 5 fuse blown
–
Change the fuses of individual power consumers.
( p. 120)
x
The ABS warning lamp lights up
x(
x
p. 148)
x(
p. 149)
x
x
x
Fill/bleed the cooling system. x ( p. 149)
Read out the fault memory using the KTM diagnostics tool. x
p. 59)
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.
p. 119)
x
High oil consumption
Engine oil level too high
–
Check the engine oil level. (
p. 157)
20
TROUBLESHOOTING
174
Faults
Possible cause
Action
High oil consumption
Engine oil too thin (low viscosity)
–
Change the engine oil and filter, clean the oil
screens.
( p. 158)
The headlight and tail light are not
functioning
Fuse 2 blown
–
Change the fuses of individual power consumers.
( p. 120)
Turn signal, hazard warning flasher,
brake light and horn are not functional
Fuse 1 or 3 blown
–
Change the fuses of individual power consumers.
( p. 120)
Battery discharged
Ignition not switched off when vehicle
was parked
–
Recharge the battery.
Battery is not charged by the alternator
–
Check the charging voltage.
Combination instrument shows nothing
in the display
Fuse 6 blown
–
Change the fuses of individual power consumers.
( p. 120)
Speedometer in combination instrument not functioning
Wiring harness of the wheel speed sensor damaged or connector oxidized
–
Check the wheel speed sensor.
x
x(
p. 115)
x
x
21
IMMOBILIZER BLINK CODE
Blink code of immobilizer indicator lamp
12 Immobilizer indicator lamp flashes 1x short, 1 second pause, 2x short
Error level condition
All ignition keys inactive
Blink code of immobilizer indicator lamp
13 Immobilizer indicator lamp flashes 1x short, 1 second pause, 3x short
Error level condition
ICU antenna malfunction
Blink code of immobilizer indicator lamp
14 Immobilizer indicator lamp flashes 1x short, 1 second pause, 4x short
Error level condition
Malfunction in transponder of black ignition key
Blink code of immobilizer indicator lamp
15 Immobilizer indicator lamp flashes 1x short, 1 second pause, 5x short
Error level condition
Black ignition key inactive
Blink code of immobilizer indicator lamp
16 Immobilizer indicator lamp flashes 1x short, 1 second pause, 6x short
Error level condition
Malfunction, ICU encryption for black ignition key
175
21
IMMOBILIZER BLINK CODE
Blink code of immobilizer indicator lamp
21 Immobilizer indicator lamp flashes 2x short, 1 second pause, 1x short
Error level condition
ICU is not activated
Blink code of immobilizer indicator lamp
31 Immobilizer indicator lamp flashes 3x short, 1 second pause, 1x short
Error level condition
Malfunction, encryption query from EFI control unit to immobilizer control unit
Blink code of immobilizer indicator lamp
32 Immobilizer indicator lamp flashes 3x short, 1 second pause, 2x short
Error level condition
Malfunction in CAN bus communication
Blink code of immobilizer indicator lamp
60 Immobilizer indicator lamp flashes 6x short
Error level condition
E²PROM malfunction
176
22
ENGINE CONTROL BLINK CODE
Blink code of FI warning
lamp (MIL)
02 FI warning lamp (MIL) flashes 2x short
Error level condition
Circuit ignition pulse generator - circuit fault
Blink code of FI warning
lamp (MIL)
06 FI warning lamp (MIL) flashes 6x short
Error level condition
Throttle valve sensor circuit A - input signal too low
Throttle valve sensor circuit A - input signal too high
Blink code of FI warning
lamp (MIL)
07 FI warning lamp (MIL) flashes 7x short
Error level condition
Throttle position sensor circuit B - input signal too low
Throttle position sensor circuit B - 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 cylinder 1 - input signal too low
Manifold absolute pressure sensor cylinder 1 - input signal too high
Blink code of FI warning
lamp (MIL)
11 FI warning lamp (MIL) flashes 1x long, 1x short
Error level condition
Manifold absolute pressure sensor cylinder 2 - input signal too low
Manifold absolute pressure sensor cylinder 2 - input signal too high
177
22
ENGINE CONTROL BLINK CODE
Blink code of FI warning
lamp (MIL)
12 FI warning lamp (MIL) flashes 1x long, 2x short
Error level condition
Coolant temperature sensor - input signal too low
Coolant temperature sensor - input signal too high
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
Ambient air pressure sensor - input signal too low
Ambient air pressure sensor - input signal too high
Blink code of FI warning
lamp (MIL)
15 FI warning lamp (MIL) flashes 1x long, 5x short
Error level condition
Rollover sensor - input signal too low
Rollover sensor - input signal too high
Blink code of FI warning
lamp (MIL)
17 FI warning lamp (MIL) flashes 1x long, 7x short
Error level condition
Lambda sensor cylinder 1, sensor 1 - circuit fault
178
22
ENGINE CONTROL BLINK CODE
Blink code of FI warning
lamp (MIL)
18 FI warning lamp (MIL) flashes 1x long, 8x short
Error level condition
Lambda sensor cylinder 2, sensor 1 - circuit fault
Blink code of FI warning
lamp (MIL)
24 FI warning lamp (MIL) flashes 2x long, 4x short
Error level condition
Power supply - circuit fault
Blink code of FI warning
lamp (MIL)
25 FI warning lamp (MIL) flashes 2x long, 5x short
Error level condition
Side stand - circuit fault
Blink code of FI warning
lamp (MIL)
33 FI warning lamp (MIL) flashes 3x long, 3x short
Error level condition
Injector cylinder 1 - circuit fault
Blink code of FI warning
lamp (MIL)
34 FI warning lamp (MIL) flashes 3x long, 4x short
Error level condition
Injector cylinder 2 - circuit fault
179
22
ENGINE CONTROL BLINK CODE
Blink code of FI warning
lamp (MIL)
37 FI warning lamp (MIL) flashes 3x long, 7x short
Error level condition
Ignition coil 1, cylinder 1 - circuit fault
Blink code of FI warning
lamp (MIL)
38 FI warning lamp (MIL) flashes 3x long, 8x short
Error level condition
Ignition coil 1, cylinder 2 - circuit fault
Blink code of FI warning
lamp (MIL)
41 FI warning lamp (MIL) flashes 4x long, 1x short
Error level condition
Fuel pump control - interruption/short circuit to ground
Fuel pump control - input signal too high
Blink code of FI warning
lamp (MIL)
45 FI warning lamp (MIL) flashes 4x long, 5x short
Error level condition
Heating lambda sensor cylinder 1, sensor 1 - interruption/short circuit to ground
Heating lambda sensor cylinder 1, sensor 1 - input signal too high
Blink code of FI warning
lamp (MIL)
46 FI warning lamp (MIL) flashes 4x long, 6x short
Error level condition
Heating lambda sensor cylinder 2, sensor 1 - interruption/short circuit to ground
Heating lambda sensor cylinder 2, sensor 1 - input signal too high
180
22
ENGINE CONTROL BLINK CODE
Blink code of FI warning
lamp (MIL)
49 FI warning lamp (MIL) flashes 4x long, 9x short
Error level condition
Motor drive circuit A - circuit fault
Blink code of FI warning
lamp (MIL)
50 FI warning lamp (MIL) flashes 5x long
Error level condition
Motor drive circuit B - circuit fault
Blink code of FI warning
lamp (MIL)
54 FI warning lamp (MIL) flashes 5x long, 4x short
Error level condition
Secondary air valve - interruption/short circuit to ground
Secondary air valve - input signal too high
Blink code of FI warning
lamp (MIL)
68 FI warning lamp (MIL) flashes 6x long, 8x short
Error level condition
Manifold absolute pressure sensor cylinder 1 - connection leaks
Blink code of FI warning
lamp (MIL)
69 FI warning lamp (MIL) flashes 6x long, 9x short
Error level condition
Manifold absolute pressure sensor cylinder 2 - connection leaks
181
22
ENGINE CONTROL BLINK CODE
Blink code of FI warning
lamp (MIL)
81 FI warning lamp (MIL) flashes 8x long, 1x short
Error level condition
Immobilizer control unit - circuit fault
Blink code of FI warning
lamp (MIL)
91 FI warning lamp (MIL) flashes 9x long, 1x short
Error level condition
CAN bus communication error
182
23
TECHNICAL DATA
23.1
Engine
183
Design
2-cylinder 4-stroke Otto motor, 75° V arrangement, water-cooled
Displacement
999 cm³ (60.96 cu in)
Stroke
62.4 mm (2.457 in)
Bore
101 mm (3.98 in)
Compression ratio
11.5:1
Control
DOHC, 4 valves per cylinder, chain-driven
Valve - diameter
Exhaust
33 mm (1.3 in)
Intake
38 mm (1.5 in)
Valve clearance
Exhaust at: 20 °C (68 °F)
0.25… 0.30 mm (0.0098… 0.0118 in)
Intake at: 20 °C (68 °F)
0.10… 0.15 mm (0.0039… 0.0059 in)
Crankshaft bearing
Sleeve bearing
Conrod bearing
Sleeve bearing
Piston
Forged light alloy
Piston ring
1 L-ring, 1 tapered compression piston ring, 1 oil scraper ring
Engine lubrication
Dry sump lubrication system with two rotor pumps
Primary transmission
35:67
Clutch
Multidisc clutch in oil bath/hydraulically activated
Transmission
6-gears, claw-shifted
Transmission ratio
1st gear
12:35
2nd gear
15:32
23
TECHNICAL DATA
184
3rd gear
18:30
4th gear
20:27
5th gear
24:27
6th gear
27:26
Mixture preparation
Electronic fuel injection
Ignition system
Contactless controlled fully electronic ignition with digital ignition
adjustment
Alternator
12 V, 450 W
Spark plug
NGK LKAR8BI9
Spark plug electrode gap
0.8 mm (0.031 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Idle speed
1,400… 1,500 rpm
Cold start device
Electric starter
23.2
Engine tightening torques
Screw, damping plate, clutch cover
EJOT Altracs M6x10
10 Nm (7.4 lbf ft)
Loctite® 243™
Hose clip, intake flange
M4
1.5 Nm (1.11 lbf ft)
–
Screw, oil spray tube
M4
6 Nm (4.4 lbf ft)
Loctite® 243™
Remaining engine screws
M5
6 Nm (4.4 lbf ft)
–
Screw, bearing retainer
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, connecting angle on valve cover
M5
3 Nm (2.2 lbf ft)
Loctite® 243™
Screw, gear sensor
M5
3 Nm (2.2 lbf ft)
Loctite® 243™
Screw, locking lever
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Nut, cylinder head
M6
8 Nm (5.9 lbf ft)
–
23
TECHNICAL DATA
185
Plug, vacuum connection
M6
5 Nm (3.7 lbf ft)
Loctite® 243™
Remaining engine screws
M6
10 Nm (7.4 lbf ft)
–
Screw in alternator cover
M6
10 Nm (7.4 lbf ft)
–
Screw, bearing bolt in alternator cover
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, camshaft bearing support
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch spring
M6
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6
10 Nm (7.4 lbf ft)
–
Screw, freewheel holder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, freewheel hub
M6
13 Nm (9.6 lbf ft)
Loctite® 648™
Screw, oil pump housing
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, pulse generator
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift drum locating
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, shift lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, starter motor
M6
10 Nm (7.4 lbf ft)
–
Screw, stator
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, valve cover
M6
10 Nm (7.4 lbf ft)
–
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
–
Screw, water pump wheel
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Vacuum connection
M6
2.5 Nm (1.84 lbf ft)
Loctite® 243™
Oil jet
M6x0.75
4 Nm (3 lbf ft)
Loctite® 243™
Screw, camshaft bearing support
M8
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
–
23
TECHNICAL DATA
186
Screw, clutch cover
M8
15 Nm (11.1 lbf ft)
–
Screw, cylinder head
M8
Step 1
18 Nm (13.3 lbf ft)
Step 2
23 Nm (17 lbf ft)
Loctite® 243™
Screw, timing chain guide rail
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Screw, timing chain tensioning rail
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Stud, exhaust flange
M8
15 Nm (11.1 lbf ft)
–
Nut, cylinder head (exterior)
M10
Step 1
23 Nm (17 lbf ft)
Step 2
34 Nm (25.1 lbf ft)
Only applies when using:
Box wrench attachment
13 mm (60029081000)
Lubricated with engine oil
Nut, cylinder head on timing chain shaft
M10
Step 1
25 Nm (18.4 lbf ft)
Step 2
38 Nm (28 lbf ft)
Lubricated with engine oil
Plug, clutch lubrication
M10
15 Nm (11.1 lbf ft)
–
Screw, bearing bolt of timing gears
M10
30 Nm (22.1 lbf ft)
–
Stud, cylinder head in engine case
M10
20 Nm (14.8 lbf ft)
–
Oil pressure sensor
M10x1
10 Nm (7.4 lbf ft)
–
Screw, conrod bearing
M10x1
Step 1
25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
60°
–
Spark plug
M12x1.25
18 Nm (13.3 lbf ft)
–
23
TECHNICAL DATA
187
Engine coolant temperature sensor
M12x1.5
12 Nm (8.9 lbf ft)
–
Plus, cylinder head (2nd cylinder)
M12x1.5
25 Nm (18.4 lbf ft)
–
Plug, oil filter housing
M14x1.5
15 Nm (11.1 lbf ft)
Loctite® 243™
Bleeder flange, alternator cover
M16x1.5
10 Nm (7.4 lbf ft)
Loctite® 243™
Plug, timing-chain tensioner
M16x1.5
20 Nm (14.8 lbf ft)
–
Rotor screw
M16x1.5
150 Nm (110.6 lbf ft)
Loctite® 243™
Nut, balancer shaft
M20x1.5
120 Nm (88.5 lbf ft)
Loctite® 243™
Nut, engine sprocket
M20x1.5
100 Nm (73.8 lbf ft)
Loctite® 243™
Screw-in fitting, cooling system
M20x1.5
10 Nm (7.4 lbf ft)
Loctite® 577™
Nut, inner clutch hub
M22x1.5
130 Nm (95.9 lbf ft)
Loctite® 243™
Oil drain plug with magnet
M22x1.5
35 Nm (25.8 lbf ft)
–
Screw in alternator cover
M24x1.5
8 Nm (5.9 lbf ft)
–
Nut, primary gear
M33LHx1.5
130 Nm (95.9 lbf ft)
Loctite® 243™
23.3
Capacities
23.3.1
Engine oil
Engine oil
23.3.2
Coolant
3.0 l (3.2 qt.)
External temperature: ≥ 0 °C
(≥ 32 °F)
Engine oil (SAE 10W/50)
( p. 198)
External temperature: < 0 °C
(< 32 °F)
Engine oil (SAE 5W/40)
( p. 198)
Coolant
2.10 l (2.22 qt.)
Coolant (
p. 197)
Coolant (mixed ready to use) (
p. 197)
23
TECHNICAL DATA
23.3.3
Fuel
Total fuel tank capacity, approx.
Fuel reserve, approx.
23.4
15 l (4 US gal)
188
Super unleaded (ROZ 95/RON 95/PON 91) (
p. 199)
3.5 l (3.7 qt.)
Chassis
Frame
Lattice frame made of chrome molybdenum steel tubing, powdercoated
Fork
WP Suspension Up Side Down 4860 ROMA PA
Shock absorber
WP Suspension 4618 BAVP DCC
Suspension travel
Front
160 mm (6.3 in)
Rear
180 mm (7.09 in)
Brake system
Front
Double disc brake with radially screwed four-piston brake calipers,
float-mounted brake discs
Rear
Single disc brake with dual-piston brake caliper, rigid-mounted
brake disc
Brake system
Two independent brake circuits with ABS (antilock brake system) Brembo/Bosch
Brake discs - diameter
Front
305 mm (12.01 in)
Rear
240 mm (9.45 in)
Brake discs - wear limit
Front
4.5 mm (0.177 in)
23
TECHNICAL DATA
189
Brake disc - wear limit
Rear
4.5 mm (0.177 in)
Tire air pressure, solo
Front
2.4 bar (35 psi)
Rear
2.4 bar (35 psi)
Tire air pressure with passenger/full payload
Front
2.4 bar (35 psi)
Rear
2.6 bar (38 psi)
Secondary drive ratio
17:41
Chain
5/8 x 5/16” X‑ring
Steering head angle
65.6°
Wheelbase
1,505±15 mm (59.25±0.59 in)
Seat height, unloaded
875 mm (34.45 in)
Ground clearance, unloaded
195 mm (7.68 in)
Weight without fuel, approx.
192 kg (423 lb.)
Maximum permissible front axle load
160 kg (353 lb.)
Maximum permissible rear axle load
250 kg (551 lb.)
Maximum permissible total weight
400 kg (882 lb.)
23.5
Electrical system
Battery
YTZ14S
Battery voltage: 12 V
Nominal capacity: 11.2 Ah
maintenance-free
Fuse
75011088010
10 A
Fuse
75011088015
15 A
23
TECHNICAL DATA
190
Fuse
58011109130
30 A
Low beam/high beam
H4/socket P43t
12 V
60/55 W
Parking light
W5W/socket W2.1x9.5d
12 V
5W
Instrument lights and indicator lamps
LED
Turn signal
RY10W/socket BAU15s
12 V
10 W
Tail light
WR5W/socket W2.1x9.5d
12 V
5W
Brake light
PR21W/socket BAW15s
12 V
21 W
License plate lamp
W5W/socket W2.1x9.5d
12 V
5W
23.6
Tires
Front tires
Rear tires
120/70 ZR 17 M/C 58W TL
Continental ContiSportAttack
180/55 ZR 17 M/C 73W TL
Continental ContiSportAttack
Additional information is available in the Service section under:
http://www.ktm.com
23
TECHNICAL DATA
23.7
Fork
191
Fork part number
14.18.7L.21
Fork
WP Suspension Up Side Down 4860 ROMA PA
Compression damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Rebound damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Spring preload - Preload Adjuster
Comfort
5 turns
Standard
5 turns
Sport
7 turns
Full payload
7 turns
Spring length with preload spacer(s)
386 mm (15.2 in)
Spring rate
Medium (standard)
7.5 N/mm (42.8 lb/in)
Fork length
877 mm (34.53 in)
Air chamber length
100±20 mm (3.94±0.79 in)
Fork oil per fork leg
732 ml (24.75 fl. oz.)
Fork oil (SAE 4) (48601166S1) (
p. 199)
23
TECHNICAL DATA
23.8
Shock absorber
192
Shock absorber part number
15.18.7L.21
Shock absorber
WP Suspension 4618 BAVP DCC
Compression damping, low-speed
Comfort
25 clicks
Standard
20 clicks
Sport
15 clicks
Full payload
15 clicks
Compression damping, high-speed
Comfort
2 turns
Standard
1.5 turns
Sport
1 turn
Full payload
1 turn
Rebound damping
Comfort
20 clicks
Standard
15 clicks
Sport
10 clicks
Full payload
10 clicks
Spring preload
Comfort
11 mm (0.43 in)
Standard
11 mm (0.43 in)
Sport
11 mm (0.43 in)
Full payload
13 mm (0.51 in)
Spring rate
23
TECHNICAL DATA
193
Medium (standard)
140 N/mm (799 lb/in)
Spring length
200 mm (7.87 in)
Gas pressure
10 bar (145 psi)
Static sag
20 mm (0.79 in)
Fitted length
372 mm (14.65 in)
Shock absorber fluid
Shock absorber oil (SAE 2.5) (50180342S1) (
23.9
p. 199)
Chassis tightening torques
Remaining frame bolts
EJOT Delta PT 50x12
1.2 Nm (0.89 lbf ft)
–
Remaining frame bolts
EJOT PT K50x12 T20
1.2 Nm (0.89 lbf ft)
–
Remaining frame bolts
EJOT PT K50x18 T20
2 Nm (1.5 lbf ft)
–
Screw, brake line holder
EJOT PT K60x20
2 Nm (1.5 lbf ft)
–
Screw, chain sliding piece
EJOT PT K60x20
2 Nm (1.5 lbf ft)
–
Screw, combination instrument
EJOT Delta PT 45x12
1 Nm (0.7 lbf ft)
–
Screw, side stand switch
M4
2 Nm (1.5 lbf ft)
Loctite® 243™
Remaining chassis nuts
M5
5 Nm (3.7 lbf ft)
–
Remaining chassis screws
M5
5 Nm (3.7 lbf ft)
–
Screw, brake line holder
M5
2 Nm (1.5 lbf ft)
–
Screw, chain sliding guard
M5
5 Nm (3.7 lbf ft)
–
Screw, closure flange, fuel tank
M5
3.3 Nm (2.43 lbf ft)
–
Screw, engine oil level viewer
M5
3.3 Nm (2.43 lbf ft)
–
Screw, foot brake lever stub
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Nut, tail light
M6
8 Nm (5.9 lbf ft)
–
Remaining chassis nuts
M6
10 Nm (7.4 lbf ft)
–
23
TECHNICAL DATA
194
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
–
Screw, chain sliding guard
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, foot brake cylinder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, fuel pump
M6
6 Nm (4.4 lbf ft)
–
Screw, fuel tap
M6
6 Nm (4.4 lbf ft)
–
Screw, holder on ABS unit
M6
6 Nm (4.4 lbf ft)
–
Screw, magnetic holder on side stand
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, seat bracket, fuel tank
M6
3.3 Nm (2.43 lbf ft)
–
Screw, splash protector
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, spoiler
M6
3.3 Nm (2.43 lbf ft)
–
Screw, wheel speed sensor
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Nut, manifold on cylinder head
M8
Tightening sequence:
Tighten the nuts uniformly.
Do not bend the metal.
–
Remaining chassis nuts
M8
25 Nm (18.4 lbf ft)
–
Remaining chassis screws
M8
25 Nm (18.4 lbf ft)
–
Screw, bottom triple clamp
M8
15 Nm (11.1 lbf ft)
–
Screw, exhaust clamp on distributor
pipe
M8
35 Nm (25.8 lbf ft)
–
Screw, exhaust clamp on main silencer
M8
20 Nm (14.8 lbf ft)
–
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
–
Screw, front brake disc
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
–
Screw, handrail
M8
20 Nm (14.8 lbf ft)
–
Screw, ignition lock (ratchet screw)
M8
Loctite® 243™
23
TECHNICAL DATA
195
Screw, rear brake disc
M8
30 Nm (22.1 lbf ft)
Loctite® 243™
Screw, rear footrest bracket
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, spring holder on side stand
bracket
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, steering stem
M8
20 Nm (14.8 lbf ft)
–
Screw, top triple clamp
M8
20 Nm (14.8 lbf ft)
–
Remaining chassis nuts
M10
45 Nm (33.2 lbf ft)
–
Remaining frame bolts
M10
45 Nm (33.2 lbf ft)
–
Screw connection, engine mounting
bracket
M10
45 Nm (33.2 lbf ft)
–
Screw, handlebar support
M10
20 Nm (14.8 lbf ft)
–
Screw, side stand
M10
35 Nm (25.8 lbf ft)
Loctite® 243™
Screw, side stand bracket
M10
45 Nm (33.2 lbf ft)
Loctite® 243™
Banjo bolt, brake line
M10x1
20 Nm (14.8 lbf ft)
–
Brake light switch
M10x1
20 Nm (14.8 lbf ft)
–
Screw connection, rear hub shock
absorber/rear sprocket
M10x1.25
50 Nm (36.9 lbf ft)
Loctite® 243™
Screw, front brake caliper
M10x1.25
45 Nm (33.2 lbf ft)
Loctite® 243™
Screw, lower subframe
M10x1.25
45 Nm (33.2 lbf ft)
Loctite® 243™
Screw, upper subframe
M10x1.25
45 Nm (33.2 lbf ft)
Loctite® 243™
Oil drain plug with magnet
M12x1.5
25 Nm (18.4 lbf ft)
–
Screw connection, suction line
M14x1.5
45 Nm (33.2 lbf ft)
Loctite® 577™
Screw, bottom shock absorber
M14x1.5
80 Nm (59 lbf ft)
Thread greased
Screw, top shock absorber
M14x1.5
80 Nm (59 lbf ft)
Thread greased
Nut, oil line
M16x1.5
25 Nm (18.4 lbf ft)
–
23
TECHNICAL DATA
196
Nut, swingarm pivot
M19x1.5
130 Nm (95.9 lbf ft)
Thread greased
Screw, steering head
M20x1.5
12 Nm (8.9 lbf ft)
–
Bolt, front axle
M25x1.5
45 Nm (33.2 lbf ft)
–
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
Thread greased
24
SUBSTANCES
197
Brake fluid DOT 4 / DOT 5.1
According to
– DOT
Guideline
– Use only brake fluid that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Castrol and Motorex® products.
Supplier
Castrol
– RESPONSE BRAKE FLUID SUPER DOT 4
Motorex®
– Brake Fluid DOT 5.1
Coolant
Guideline
– Use only suitable coolant (also in countries with high temperatures). Use of low-quality antifreeze can lead to corrosion and foaming.
KTM recommends Motorex® products.
Mixture ratio
Antifreeze protection: −25… −45 °C (−13…
−49 °F)
50 % corrosion inhibitor/antifreeze
50 % distilled water
Coolant (mixed ready to use)
Antifreeze
Supplier
Motorex®
– COOLANT G48
−40 °C (−40 °F)
24
SUBSTANCES
198
Engine oil (SAE 10W/50)
According to
– JASO T903 MA (
–
SAE (
p. 204)
p. 204) (SAE 10W/50)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Fully synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
Engine oil (SAE 5W/40)
According to
– JASO T903 MA (
–
SAE (
p. 204)
p. 204) (SAE 5W/40)
Guideline
– Use only engine oils that comply with the specified standards (see specifications on the container) and that possess the corresponding
properties. KTM recommends Motorex® products.
Synthetic engine oil
Supplier
Motorex®
– Power Synt 4T
24
SUBSTANCES
199
Fork oil (SAE 4) (48601166S1)
According to
– SAE ( p. 204) (SAE 4)
Guideline
– Use only oils that comply with the specified standards (see specifications on the container) and that possess the corresponding properties.
Hydraulic fluid (15)
According to
– ISO VG (15)
Guideline
– Use only hydraulic oil that complies with the specified standard (see specifications on the container) and that possesses the corresponding properties. KTM recommends Motorex® products.
Supplier
Motorex®
– Hydraulic Fluid 75
Shock absorber oil (SAE 2.5) (50180342S1)
According to
– SAE ( p. 204) (SAE 2.5)
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)
According to
– DIN EN 228 (ROZ 95/RON 95/PON 91)
24
SUBSTANCES
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).
200
25
AUXILIARY SUBSTANCES
Chain cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chain Clean
Chain lube for road use
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Chainlube Road
Cleaning and preserving materials for metal, rubber and plastic
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Protect & Shine
Fuel additive
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Fuel Stabilizer
201
25
AUXILIARY SUBSTANCES
High-luster polish for paint
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Polish
Long-life grease
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Bike Grease 2000
Motorcycle cleaner
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Moto Clean 900
Paint cleaner and polish for high-gloss and matte finishes, bare metal and plastic surfaces
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Clean & Polish
202
25
AUXILIARY SUBSTANCES
Universal oil spray
Guideline
– KTM recommends Motorex® products.
Supplier
Motorex®
– Joker 440 Synthetic
203
26
STANDARDS
204
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Antifreeze
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
205
Brake light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Brake linings
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 93
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Antilock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
B
C
Baggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
dirt, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Blink code
engine control . . . . . . . . . . . . . . . . . . . . . . . . . . 177-182
immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175-176
Brake disc, rear
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Chain guide
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Brake discs, front
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Clutch
fluid level, checking/correcting . . . . . . . . . . . . . . . . . . . . 87
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 87
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 91
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Combination instrument
clock, setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . 38
display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INDEX
206
display, ambient temperature .
function buttons . . . . . . . . . .
indicator lamps . . . . . . . . . .
kilometers or miles, setting . .
ODO display . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . .
speed display . . . . . . . . . . . .
tachometer . . . . . . . . . . . . .
temperature units, setting . . .
time . . . . . . . . . . . . . . . . . .
TRIP 1 display, setting/resetting
TRIP 2 display, setting/resetting
TRIP F display . . . . . . . . . . . .
warning of slippery roads . . . .
Coolant
draining
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. 36
. 29
. 30
. 32
. 34
. 28
. 32
. 29
. 36
. 33
. 34
. 35
. 36
. 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Coolant level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
compensating tank, checking . . . . . . . . . . . . . . . . . . . . 147
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
filling/bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine oil
adding .
changing
draining
refilling .
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164
158
158
163
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Filler cap
closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 95
free travel, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
compression damping, adjusting . . . . . . . . . . . . . . . . . .
fork legs, bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . .
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . .
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . .
Fork part number
64
. 64
. 75
. 65
. 66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INDEX
207
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fuel tank
positioning
reinstalling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fuse
individual power consumers, changing . . . . . . . . . . . . . . 120
Fuses, ABS
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
I
Ignition curve
adjusting to fuel quality . . . . . . . . . . . . . . . . . . . . . . . . 154
plug-in connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Ignition key
activating/deactivating . . . . . . . . . . . . . . . . . . . . . . . . . 139
Ignition lock .
Immobilizer . .
Indicator lamps
Intended use .
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. 27
. 28
. 30
..8
H
K
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 90
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Handrails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Headlight
headlight range, adjusting . . . . . . . . . . . . . . . . . . . . . . 138
Headlight adjustment
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
L
License plate lamp
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
M
Headlight bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Headlight flasher switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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
Helmet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
mounting on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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165
. 74
. 73
. 74
. 73
INDEX
O
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Oil screens
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
P
Parking
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Parking light bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Play in throttle cable
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Preparing for use
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
checks and maintenance measures when preparing for use . 49
information on first use . . . . . . . . . . . . . . . . . . . . . . . . . 45
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
R
Rear hub rubber dampers
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
208
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Refueling
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
S
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-63
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . 155
basic position, checking . . . . . . . . . . . . . . . . . . . . . . . 155
Shifting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
compression damping, general . . . . . . . . . . . . . . . . . . .
compression damping, high-speed, adjusting . . . . . . . . .
compression damping, low-speed, adjusting . . . . . . . . . .
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . .
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . .
64
. 68
. 69
. 68
. 70
. 71
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . . 22
INDEX
Side stand . .
Spare parts .
Starting . . .
Steering lock
Stopping . . .
Storage . . .
209
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. 44
. 13
. 50
. 27
. 57
169
T
Tail lamp bulbs
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Technical data
capacities . . . . . . . . . . .
chassis . . . . . . . . . . . . .
chassis tightening torques
electrical system . . . . . .
engine . . . . . . . . . . . . .
engine tightening torques
fork . . . . . . . . . . . . . . .
shock absorber . . . . . . . .
tires . . . . . . . . . . . . . . .
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187
188
193
189
183
184
191
192
190
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172-174
Turn signal bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
U
Use definition
...................................8
V
Vehicle
loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
View of vehicle
front left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
rear right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
W
Warning of slippery roads . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Winter operation
checks and maintenance measures . . . . . . . . . . . . . . . . 167
Work rules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
*3211959en*
3211959en
11/2012
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM
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