KTM 1190 Adventure R JP 2013 Travel Bike Owner Manual

KTM 1190 Adventure R JP 2013 Travel Bike Owner Manual
OWNER'S MANUAL 2013
1190 Adventure R EU
1190 Adventure R FR
1190 Adventure R AUS
1190 Adventure R JP
Art. no. 3211956en
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 (
p. 20)
Engine number (
p. 21)
Key number (
Dealer's stamp
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.
© 2013 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 ........................................ 8
1.1
Symbols used ...................................................... 8
1.2
Formats used....................................................... 8
SAFETY ADVICE.............................................................. 9
2.1
Use definition - intended use ................................ 9
2.2
Safety advice....................................................... 9
2.3
Degrees of risk and symbols ................................ 10
2.4
Tampering warning............................................. 10
2.5
Safe operation ................................................... 11
2.6
Protective clothing ............................................. 12
2.7
Work rules......................................................... 12
2.8
Environment...................................................... 12
2.9
Owner's Manual ................................................. 13
IMPORTANT NOTES...................................................... 14
3.1
Warranty ........................................................... 14
3.2
Operating and auxiliary substances ...................... 14
3.3
Spare parts, accessories ..................................... 14
3.4
Service ............................................................. 14
3.5
Figures ............................................................. 15
3.6
Customer service................................................ 15
VIEW OF VEHICLE ........................................................ 16
4.1
View of vehicle, front left side (example) .............. 16
4.2
View of vehicle, rear right side (example).............. 18
SERIAL NUMBERS ....................................................... 20
5.1
Chassis number ................................................. 20
5.2
Type label ......................................................... 20
5.3
Key number....................................................... 21
5.4
Engine number .................................................. 21
5.5
Fork part number ............................................... 22
3
6
5.6
Shock absorber part number ...............................
CONTROLS...................................................................
6.1
Clutch lever.......................................................
6.2
Hand brake lever................................................
6.3
Throttle grip ......................................................
6.4
Switch on the left side of the handlebar ...............
6.4.1
Combination switch........................................
6.4.2
Light switch ..................................................
6.4.3
Hazard warning flasher switch.........................
6.4.4
Menu switch..................................................
6.4.5
Turn signal switch..........................................
6.4.6
Horn button ..................................................
6.5
Switch on the right side of the handlebar .............
6.5.1
Emergency OFF switch ...................................
6.5.2
Electric starter button ....................................
6.6
Ignition/steering lock ..........................................
6.7
immobilizer .......................................................
6.8
Socket for electrical accessories ..........................
6.9
Opening the filler cap.........................................
6.10 Closing the filler cap ..........................................
6.11 Fuel cocks.........................................................
6.12 Opening the storage compartment .......................
6.13 Closing the storage compartment.........................
6.14 Seat lock...........................................................
6.15 Tool set.............................................................
6.16 Grab handles .....................................................
6.17 Luggage rack plate .............................................
6.18 Passenger footrests ............................................
6.19 Shift lever .........................................................
22
23
23
23
24
24
24
25
25
26
26
27
27
27
28
28
29
29
30
31
32
33
33
34
34
35
35
36
36
TABLE OF CONTENTS
7
6.20 Side stand.........................................................
6.21 Center stand......................................................
COMBINATION INSTRUMENT .......................................
7.1
Overview ...........................................................
7.2
Activation and test .............................................
7.3
Matrix display ....................................................
7.4
Segment display ................................................
7.5
Indicator lamps..................................................
7.6
Message on the matrix display.............................
7.7
Shift warning light .............................................
7.8
Service display ..................................................
7.9
Matrix display menu ...........................................
7.9.1
"Favorites".....................................................
7.9.2
"Trip 1" .........................................................
7.9.3
"Trip 2" .........................................................
7.9.4
"General Info" ................................................
7.9.5
"TPMS" (optional) ..........................................
7.9.6
"Set Favorites" ...............................................
7.9.7
"Settings" ......................................................
7.9.8
"Warnings" ....................................................
7.9.9
"Heat Grip" (optional) .....................................
7.9.10
"MTC/ABS" ....................................................
7.9.11
"Drive Mode" .................................................
7.9.12
Menu overview...............................................
7.9.13
"Language" ....................................................
7.9.14
"Distance" .....................................................
7.9.15
"Temp" .........................................................
7.9.16
"Volume" .......................................................
7.9.17
"Pressure" .....................................................
4
37
38
39
39
39
40
40
41
42
43
44
44
44
45
45
46
46
47
47
48
48
49
49
50
51
52
52
53
53
7.9.18
"Clock/Date" ..................................................
7.9.19
"Fuel Cons" ...................................................
7.9.20
"DRL" ...........................................................
7.9.21
"Shift Light" ..................................................
7.9.22
"Quick Shift" .................................................
7.9.23
"Heat Grips" ..................................................
8
ERGONOMICS ..............................................................
8.1
Handlebar position.............................................
8.2
Adjusting the handlebar position
....................
8.3
Adjusting the wind shield ...................................
8.4
Adjusting the basic setting of the clutch lever.......
8.5
Adjusting the basic position of the hand brake
lever .................................................................
8.6
Rider footrests ...................................................
8.7
Adjusting the footrests
...................................
8.8
Foot brake lever .................................................
8.9
Adjusting the basic position of the foot brake
lever
............................................................
8.10 Checking the basic position of the shift lever ........
8.11 Adjusting the basic position of the shift
lever
............................................................
9
PREPARING FOR USE...................................................
9.1
Advice on first use .............................................
9.2
Running in the engine ........................................
9.3
Loading the vehicle ............................................
10 RIDING INSTRUCTIONS................................................
10.1 Checks and maintenance measures when
preparing for use................................................
10.2 Starting.............................................................
10.3 Starting off........................................................
x
x
54
54
55
55
56
56
57
57
57
58
60
60
61
61
63
x
63
65
x
65
67
67
68
69
71
71
72
73
TABLE OF CONTENTS
10.4 Shifting, riding ..................................................
10.5 Applying the brakes............................................
10.6 Stopping, parking...............................................
10.7 Transport ..........................................................
10.8 Refueling ..........................................................
11 SERVICE SCHEDULE ....................................................
11.1 Additional information ........................................
11.2 Required work ...................................................
11.3 Recommended work ...........................................
12 SUSPENSION SETTING.................................................
12.1 Fork/shock absorber ...........................................
12.2 Adjusting the compression damping of the fork.....
12.3 Adjusting the rebound damping of the fork ...........
12.4 Adjusting the spring preload of the fork................
12.5 Compression damping of the shock absorber.........
12.6 Adjusting the low-speed compression damping of
the shock absorber .............................................
12.7 Adjusting the high-speed compression damping
of the shock absorber .........................................
12.8 Adjusting the rebound damping of the shock
absorber............................................................
12.9 Adjusting the spring preload of the shock
absorber............................................................
13 SERVICE WORK ON THE CHASSIS.................................
13.1 Raising the vehicle with the center stand .............
13.2 Removing the vehicle from the center stand .........
13.3 Removing the seat .............................................
13.4 Mounting the seat ..............................................
13.5 Checking for chain dirt .......................................
13.6 Cleaning the chain .............................................
5
73
77
79
80
81
83
83
83
86
87
87
87
88
89
90
90
91
92
93
95
95
95
96
97
97
98
13.7
13.8
13.9
Checking the chain tension ................................. 99
Adjusting the chain tension............................... 100
Checking the chain, rear sprocket and engine
sprocket.......................................................... 102
13.10 Checking/rectifying the fluid level of the
hydraulic clutch............................................... 105
13.11 Checking the steering head bearing play............. 106
13.12 Removing the bottom triple clamp cover............. 107
13.13 Installing the bottom triple clamp cover
........ 107
13.14 Removing the front side cover ........................... 108
13.15 Installing the front side cover ............................ 109
13.16 Removing the mask spoiler
.......................... 110
13.17 Installing the mask spoiler
........................... 113
13.18 Removing the front fender ................................ 115
13.19 Installing the front fender
............................ 116
13.20 Removing the tank cover................................... 116
13.21 Installing the tank cover ................................... 118
13.22 Removing the wind shield ................................. 119
13.23 Installing the wind shield.................................. 120
14 BRAKE SYSTEM ......................................................... 121
14.1 ABS/antilock brake system................................ 121
14.2 Checking the brake discs .................................. 122
14.3 Checking the brake fluid level of the front
brake .............................................................. 123
14.4 Adding front brake fluid
............................... 124
14.5 Checking the front brake linings ........................ 126
14.6 Checking the rear brake fluid level..................... 126
14.7 Adding rear brake fluid
................................ 127
14.8 Checking the rear brake linings ......................... 129
x
x
x
x
x
x
TABLE OF CONTENTS
6
15 WHEELS, TIRES .........................................................
15.1 Removing the front wheel
............................
15.2 Installing the front wheel
.............................
15.3 Removing the rear wheel
..............................
15.4 Installing the rear wheel
..............................
15.5 Checking the rear hub rubber dampers
..........
15.6 Checking the tire condition ...............................
15.7 Checking the tire air pressure............................
15.8 Checking spoke tension ....................................
16 ELECTRICAL SYSTEM .................................................
16.1 daytime running light .......................................
16.2 Removing the battery
..................................
16.3 Installing the battery
...................................
16.4 Recharging the battery
................................
16.5 Changing the main fuse ....................................
16.6 Changing the fuses in the fuse box ....................
16.7 Removing the headlight mask with the
headlight.........................................................
16.8 Refitting the headlight mask with the
headlight.........................................................
16.9 Changing the low beam bulb .............................
16.10 Changing the high beam bulb............................
16.11 Checking the headlight setting ..........................
16.12 Adjusting the headlight range............................
17 COOLING SYSTEM ......................................................
17.1 Checking the coolant level in the compensating
tank................................................................
17.2 Correcting the coolant level in the
compensating tank...........................................
x
x
x
x
x
x
x
x
131
131
133
135
137
139
141
142
143
145
145
145
147
148
152
154
156
157
158
159
161
162
163
163
164
18 ENGINE TUNING ........................................................
18.1 "Drive Mode"....................................................
18.2 MTC/motorcycle traction control ........................
19 SERVICE WORK ON THE ENGINE ................................
19.1 Checking the engine oil level.............................
19.2 Changing the engine oil and filter, cleaning the
oil screens
..................................................
19.3 Adding engine oil .............................................
20 CLEANING, CARE .......................................................
20.1 Cleaning motorcycle .........................................
20.2 Checks and maintenance steps for winter
operation.........................................................
21 STORAGE ...................................................................
21.1 Storage ...........................................................
21.2 Preparing for use after storage...........................
22 TROUBLESHOOTING ..................................................
23 TECHNICAL DATA.......................................................
23.1 Engine ............................................................
23.2 Engine tightening torques .................................
23.3 Capacities .......................................................
23.3.1
Engine oil ...................................................
23.3.2
Coolant .......................................................
23.3.3
Fuel ...........................................................
23.4 Chassis ...........................................................
23.5 Electrical system..............................................
23.6 Tires ...............................................................
23.7 Fork................................................................
23.8 Shock absorber ................................................
23.9 Chassis tightening torques ................................
x
166
166
166
168
168
169
173
176
176
178
179
179
180
181
183
183
184
187
187
188
188
188
189
190
190
192
193
TABLE OF CONTENTS
24 SUBSTANCES ............................................................
25 AUXILIARY SUBSTANCES ...........................................
26 STANDARDS ..............................................................
INDEX ...............................................................................
7
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.
8
2
SAFETY ADVICE
2.1
Use definition - intended use
9
KTM sport motorcycles are designed and constructed to meet the normal demands of regular road and light offroad operation (dirt roads),
but not for use on race courses.
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
10
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
1
Removal or puncturing of the main silencer, baffles, header pipes or any other components which conduct exhaust gases.
2
Removal or puncturing of parts of the intake system.
3
Lack of proper maintenance.
4
Replacing moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
2.5
11
Safe operation
Danger
Danger of accidents Danger arising from the rider's judgement being impaired.
–
Do not operate the vehicle while under the influence of alcohol, drugs and certain medications or physically or mentally
impaired.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in unconsciousness and/or death.
–
When running the engine, always make sure there is sufficient ventilation, and do not start or run the engine in an enclosed
space without an effective exhaust extraction system.
Warning
Danger of burns Some vehicle components become very hot when the vehicle is operated.
–
Do not touch hot components such as exhaust system, radiator, engine, shock absorber, and the brake system. Allow these
components to cool down before starting work on them.
Only operate the vehicle when it is in perfect technical condition, in accordance with its intended use, and in a safe and environmentally
compatible manner.
The vehicle should only be used by trained persons. An appropriate driver's license is needed to ride the vehicle on public roads.
Have malfunctions that impair safety promptly eliminated by an authorized KTM workshop.
Adhere to the information and warning labels on the vehicle.
2
SAFETY ADVICE
2.6
Protective clothing
12
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 some of the work. These are not included with the vehicle and can be ordered under the number in parentheses. Ex: valve spring mounter (59029019000)
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.
Where thread lockers are used on screw connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
Parts that you want to reuse following repairs and servicing should be cleaned and checked for damage and wear. Change damaged or
worn parts.
Following repairs or servicing, the vehicle must be checked for roadworthiness.
2.8
Environment
Motorcycling is a wonderful sport and we naturally hope that you can enjoy it to the full. However, it can also lead to problems with the
environment and conflict with other persons. Responsible behavior in handling the motorcycle can help to avoid such problems and conflicts. To protect the future of motorcycle sport, make sure that you use your motorcycle legally, display environmental consciousness, and
respect the rights of others.
2
SAFETY ADVICE
2.9
Owner's Manual
13
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
Warranty
14
The work prescribed in the service schedule must be carried out by an authorized KTM workshop only and confirmed in the customer's
Service and Warranty Booklet and in the KTM dealer.net; otherwise, all warranty claims will be void. No warranty claims can be considered
for damage resulting from manipulations and/or alterations to the vehicle.
Additional information on the guarantee or warranty and the procedures involved can be found in the Service and Warranty Booklet.
3.2
Operating and auxiliary substances
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
Use operating and auxiliary substances (such as fuel and lubricants) as specified in the Owner's Manual.
3.3
Spare parts, accessories
For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed
by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.
Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to
advise you.
The current KTM PowerParts for your vehicle can be found on the KTM website.
International KTM Website: http://www.ktm.com
3.4
Service
A prerequisite for perfect operation and prevention of premature wear is that the service, care and tuning work on the engine and chassis
are properly carried out as described in the owner's manual. Poor adjustment and tuning of the engine and suspension can lead to damage
and breakage of components.
3
IMPORTANT NOTES
15
Using the motorcycle in extreme conditions such as very muddy or wet roads can lead to above-average wear of components such as the
drive train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the service
schedule is reached.
It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much
longer service life for your motorcycle.
3.5
Figures
The figures contained in the manual may depict special equipment.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.
3.6
Customer service
Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.
A list of authorized KTM dealers can be found on the KTM website.
International KTM Website: http://www.ktm.com
4
VIEW OF VEHICLE
4.1
View of vehicle, front left side (example)
16
S00318-10
4
VIEW OF VEHICLE
1
Socket for electrical accessories (
2
Clutch lever (
3
Tool set (
4
Grab handles (
5
Luggage rack plate (
6
Seat lock (
7
Passenger footrests (
8
Center stand (
9
Rider footrests (
10
Shift lever (
p. 36)
11
Side stand (
p. 37)
12
Engine oil level viewer
13
Fuel cocks (
p. 23)
p. 34)
p. 35)
p. 35)
p. 34)
p. 36)
p. 38)
p. 61)
p. 32)
17
p. 29)
4
VIEW OF VEHICLE
4.2
View of vehicle, rear right side (example)
18
S00319-10
4
VIEW OF VEHICLE
1
Combination switch (
p. 24)
2
Filler cap
3
Fork compression adjustment
4
Fork rebound adjustment
5
Emergency OFF switch (
6
Electric starter button (
7
Hand brake lever (
8
Storage compartment
9
Cooling system compensating tank
10
Foot brake lever (
11
Shock absorber compression adjustment
12
Shock absorber rebound adjustment
p. 27)
p. 28)
p. 23)
p. 63)
19
5
SERIAL NUMBERS
5.1
Chassis number
20
The chassis number 1 is stamped on the bottom right of the frame behind the steering
head.
The chassis number is also shown on the type label.
S00257-10
5.2
Type label
The type label 1 is on the top right of the frame behind the steering head.
S00256-10
5
SERIAL NUMBERS
5.3
Key number
21
The key number Code number 1 can be found on the KEYCODECARD.
Info
You need the key number to order a spare key. Keep the KEYCODECARD in a safe
place.
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.
700222-01
5.4
Engine number
The engine number 1 is stamped on the right side of the engine.
S00261-10
5
SERIAL NUMBERS
5.5
Fork part number
22
The fork part number 1 is stamped on the inner side of the fork stub.
S00306-10
5.6
Shock absorber part number
The shock absorber part number 1 is stamped on the upper part of the shock absorber.
S00264-10
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.
S00214-10
6.2
Hand brake lever
The hand brake lever 1 is fitted on the right side of the handlebar.
The hand brake lever is used to activate both the front brake and rear brake at the same
time.
Info
When the Offroad ABS mode is switched on, only the front brake is activated.
When ABS is switched off, only the front brake is activated.
S00215-10
6
CONTROLS
6.3
Throttle grip
24
The throttle grip 1 is fitted on the right side of the handlebar.
S00216-10
6.4
Switch on the left side of the handlebar
6.4.1
Combination switch
The combination switch is fitted on the left side of the handlebar.
Overview of the left combination switch
S00224-10
1
Light switch (
p. 25)
2
Hazard warning flasher switch (
3
Menu switch (
4
Turn signal switch (
5
Horn button (
p. 26)
p. 26)
p. 27)
p. 25)
6
CONTROLS
6.4.2
Light switch
25
The light switch 1 is fitted on the combination switch on the left.
Possible states
Low beam on – Light switch in position A. In this position, the low beam
and tail light are switched on.
High beam on – Light switch in position B. In this position, the high beam
and tail light are switched on.
Headlight flasher. – Push the light switch into position C.
S00219-10
6.4.3
Hazard warning flasher switch
The hazard warning flasher switch 1 is fitted on the combination switch on the left.
The hazard warning flasher is used to indicate emergency situations.
Info
The hazard warning flasher can be activated or deactivated while the ignition is
switched on or up to 60 seconds after the ignition is switched off.
Only keep the hazard warning flasher activated as long as necessary as it depletes
the battery.
602606-10
Possible states
Hazard warning flasher on – All four turn signals and the green turn signal
indicator lights in the combination instrument flash.
6
CONTROLS
6.4.4
Menu switch
26
The menu switch is fitted in the middle of the left combination switch.
The menu buttons are used to control the matrix display on the combination instrument.
Button 1 is the UP button.
Button 2 is the DOWN button.
Button 3 is the SET button.
Button 4 is the BACK button.
S00224-11
6.4.5
Turn signal switch
The turn signal switch 1 is fitted on the combination switch on the left.
Possible states
Turn signal off – Press the turn signal switch.
Turn signal, left, on – Turn signal switch pressed to the left. The turn signal
switch returns automatically to the central position after use.
Turn signal, right, on – Turn signal switch pressed to the right. The turn
signal switch returns automatically to the central position after use.
S00217-10
To switch off the turn signal, press the turn signal switch towards the switch case.
6
CONTROLS
6.4.6
Horn button
27
The horn button 1 is fitted on the combination switch on the left.
Possible states
• Horn button
• Horn button
in basic position.
pressed – The horn is operated in this position.
S00218-10
6.5
Switch on the right side of the handlebar
6.5.1
Emergency OFF switch
The emergency OFF switch 1 is fitted on the right side of the handlebar.
Possible states
Emergency OFF switch off – In this position, the ignition circuit is
interrupted, a running engine stops, and a non-running engine cannot be
started. A message appears on the matrix display.
Emergency OFF switch on – This position is required for operation; the ignition circuit is closed.
S00220-10
6
CONTROLS
6.5.2
Electric starter button
28
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.
is pressed – In this position, the electric starter is actuated.
S00221-10
6.6
Ignition/steering lock
The ignition/steering lock 1 is located in front of the upper triple clamp.
Info
The ignition may only be switched on using a black ignition key.
With the orange programming key, you can activate or deactivate the black ignition
key.
Possible states
S00222-10
Ignition off OFF – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start. The black ignition key can be removed.
Ignition on ON – In this position, the ignition circuit is closed and the
engine can be started.
Steering locked – In this position, the ignition circuit is interrupted and the
steering locked. The black ignition key can be removed.
6
CONTROLS
6.7
immobilizer
29
The electronic immobilizer secures the vehicle against unauthorized use.
The immobilizer is activated automatically and the engine electronics are locked when the
ignition key is withdrawn.
The immobilizer indicator lamp 1 can indicate errors by flashing.
If the optional alarm system is installed, the immobilizer indicator lamp 1 flashes when
the alarm system is switched on.
Info
The ignition key contains electronic components. Never attach multiple ignition keys
to a single key ring; this may cause mutual interference.
401815-10
A lost black ignition key must be deactivated to prevent unauthorized persons from operating the vehicle.
The black ignition keys are activated when delivered.
Another two spare ignition keys (key number on the KEYCODECARD) can be ordered from an
authorized KTM workshop; they need to be activated for use.
6.8
Socket for electrical accessories
Socket 1 for electrical accessories is fitted to the left of the combination instrument.
It is connected to permanent positive and fuse-protected.
Socket for electrical accessories
S00223-10
Voltage
12 V
Maximum current consumption
10 A
6
CONTROLS
6.9
Opening the filler cap
30
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the
eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and
water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel. Store fuel properly
in a suitable canister and keep away from children.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
–
S00225-10
Lift cover 1 of the filler cap and insert ignition key 2 in the fuel tank lock.
6
CONTROLS
31
Note
Danger of damage Ignition key breakage.
–
To take pressure off of the ignition key, push down on the filler cap. Damaged ignition keys must be replaced.
–
Turn ignition key 2 clockwise.
–
Fold open filler cap 3.
–
Fold down filler cap 1.
–
Turn ignition key 2 clockwise.
S00227-10
6.10
Closing the filler cap
S00228-10
6
CONTROLS
32
–
Press down the filler cap and turn back ignition key 2 until the fuel tank lock locks.
Warning
Fire hazard Fuel is highly flammable, poisonous and harmful to your health.
–
–
After closing the filler cap, ensure that it is locked properly. Change clothing that has been contaminated with fuel. Immediately clean contaminated
areas on the skin with soap and water.
Remove ignition key 2 and close cover 3.
S00229-10
6.11
Fuel cocks
A fuel cock 1 is located on each side of the fuel tank.
Info
The fuel cocks must always be open during operation.
The fuel cocks are only closed to remove the fuel tank.
S00341-10
Possible states
• Fuel cocks are closed – A level equalization cannot take place and fuel cannot flow out
of the fuel tank.
• Fuel cocks are open – A level equalization can take place and fuel can flow out of the
fuel tank.
6
CONTROLS
6.12
Opening the storage compartment
33
–
Press button 1 in the direction of the arrow and lift the cover at the same time.
S00226-10
6.13
Closing the storage compartment
–
S00226-11
Press down cover 1 until the lock engages audibly.
6
CONTROLS
6.14
Seat lock
34
The seat lock 1 is located on the left side of the vehicle.
It can be unlocked using the ignition key.
S00238-10
6.15
Tool set
The tool set 1 is located in the storage compartment under the seat.
S00235-10
6
CONTROLS
6.16
Grab handles
35
The passenger can hold onto grab handles 1 during the trip.
S00236-10
6.17
Luggage rack plate
The luggage rack plate 1 is located behind the seat.
The base plate of a luggage system (optional) can be attached to the luggage rack plate.
The luggage rack plate may not be loaded with more than the specified weight.
Maximum permissible load
on luggage rack plate
8 kg (18 lb.)
Info
Note the information provided by the luggage manufacturer.
S00237-10
6
CONTROLS
6.18
Passenger footrests
36
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.
S00234-10
6.19
Shift lever
The shift lever 1 is fitted on the left side of the engine.
S00231-10
6
CONTROLS
37
The gear positions can be seen in the figure.
The idle position is between the first and second gears.
S00232-10
6.20
Side stand
The side stand 1 is located on the left side of the vehicle.
The side stand is used for parking the motorcycle.
Info
The side stand must be folded up during motorcycle use.
The side stand is coupled with the safety start system; see the instructions in the
"Stopping, parking" chapter.
S00240-10
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.
6
CONTROLS
6.21
Center stand
38
In addition to the side stand, the vehicle is equipped with a center stand 1.
S00258-10
7
COMBINATION INSTRUMENT
7.1
Overview
39
1
Matrix display (
2
Tachometer
p. 40)
3
Shift warning light (
4
Segment display
5
Indicator lamps (
p. 43)
p. 41)
401800-10
7.2
Activation and test
Activation
The combination instrument is activated when the ignition is switched on.
Info
The brightness of the displays is controlled by a brightness sensor in the combination instrument.
401801-01
Test
The segment display, the indicator lamps, and the tachometer are briefly activated for a
function test.
The welcome text and information on the next service ( p. 44) appear on the matrix display.
Info
If the battery was disconnected, the time and date must be set.
7
COMBINATION INSTRUMENT
7.3
Matrix display
40
The matrix display is controlled using the menu switch ( p. 26).
After the ignition is switched on, the display shows when the next service ( p. 44) is due.
If the General warning lamp lights up among the indicator lamps ( p. 41), the corresponding message appears in the matrix display. The Set button is used to confirm receipt
of the information and the message is cleared.
Messages appear
10 s
401821-01
7.4
Segment display
401854-10
1
Fuel level
2
Time
3
Unit for the speedometer
4
Gear display
5
Speed
6
"Drive Mode" (
7
Coolant temperature
8
No function
9
Ice warning
p. 166)
7
COMBINATION INSTRUMENT
7.5
Indicator lamps
41
Possible states
The high beam indicator lamp lights up blue – The high beam is switched
on.
The immobilizer indicator lamp lights up/flashes red – Status or error message for immobilizer/alarm system.
The oil pressure warning lamp lights up red – Engine oil pressure is too
low.
401813-01
The general warning lamp lights up yellow – An operating safety (warning)
message was detected. This is also shown on the matrix display.
The left turn signal lamp flashes green simultaneously with the turn signal
– The left turn signal is switched on.
The idle indicator lamp lights up green – The transmission is shifted to
idle.
The right turn signal lamp flashes green simultaneously with the turn signal
– The right turn signal is switched on.
The engine warning lamp lights up/flashes yellow – The engine control unit
has detected a fault.
The ABS lamp lights up/flashes yellow – ABS is not active. The ABS lamp
also lights up when a fault is detected.
The TC lamp lights up/flashes yellow – Traction control is not enabled or is
currently intervening. The TC lamp also lights up when a fault is detected.
7
COMBINATION INSTRUMENT
7.6
Message on the matrix display
42
Possible states
Engine malfunction – The engine control unit has detected a fault. Visit an
authorized KTM workshop.
General message – General message on operating safety. Visit an authorized KTM workshop.
ABS warning – ABS is not available. Visit an authorized KTM workshop.
401850-01
Traction control – Traction control is not available. Visit an authorized KTM
workshop.
Engine oil pressure – Engine oil pressure is too low. Switch off the engine
immediately. Contact an authorized KTM workshop.
Engine oil level – The engine oil level is too low. Check the engine oil level
and correct it.
Tire air pressure – The tire pressure is incorrect, or the system has failed.
Check the tire pressure.
Lighting system – Lights up if an element of the lighting system has failed.
Change the faulty light, or visit an authorized KTM workshop.
Cooling water temperature – The cooling water temperature is too high.
Switch off the engine. Contact an authorized KTM workshop.
Fuel reserve – The fuel supply is dwindling. Refuel at the next opportunity.
Icy road symbol – The roads may be icy. Adjust your speed to the road conditions.
7
COMBINATION INSTRUMENT
43
Battery voltage – The battery voltage is too low. Recharge the battery with a
suitable battery charger.
Service – A service is due. Contact an authorized KTM workshop.
Emergency OFF switch – The emergency OFF switch is off.
The messages are displayed in the "Warnings" menu.
7.7
Shift warning light
The shift warning light flashes or lights up when the transmission should be shifted.
In the "Shift Light" menu, the engine speed for the shift warning light can be set. The shift
warning light flashes at "RMP1" and lights up at "RPM2".
401855-01
Engine oil temperature
> 35 °C (> 95 °F)
"RPM1" shift warning light
Flashes
"RPM2" shift warning light
Lights up
Engine oil temperature
≤ 35 °C (≤ 95 °F)
The shift warning light always
lights up at
6,500 rpm
7
COMBINATION INSTRUMENT
7.8
Service display
44
After the ignition is switched on, the service display appears briefly.
The service intervals depend on the distance traveled or the elapsed time. The event that
occurs first applies.
The exact service intervals can be found in the service schedule.
401821-01
7.9
Matrix display menu
7.9.1
"Favorites"
–
Press the UP or DOWN button until the "Favorites" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button to select the menu item and activate it with the SET button.
–
Pressing the BACK button twice always opens the "Favorites" menu.
In the "Favorites" menu, you can directly open five menus.
In the "Set Favorites" menu, the "Favorites" menu can be configured.
401827-01
7
COMBINATION INSTRUMENT
7.9.2
"Trip 1"
–
45
Press the UP or DOWN button until the "Trip 1" menu appears on the matrix display.
"Trip 1" shows the distance since the last reset, such as between two refueling stops.
"Trip 1" runs continuously and counts the distance up to 9999.
"Ø Speed 1" indicates the average speed based on "Trip 1" and "Trip Time 1".
"Ø Cons 1" indicates the average fuel consumption based on "Trip 1" and "Trip Time 1".
"Trip Time 1" indicates the riding time based on "Trip 1" and starts running as soon as a
speed signal comes in.
"Fuel Range" indicates the possible range with the fuel reserve.
Press and hold the
button for 3–5
seconds.
401826-01
7.9.3
All entries in the "Trip 1" menu are cleared.
"Trip 2"
–
Press the UP or DOWN button until the "Trip 2" menu appears on the matrix display.
"Trip 2" shows the distance since the last reset, such as between two refueling stops.
"Trip 2" runs continuously and counts the distance up to 9999.
"Ø Speed 2" indicates the average speed based on "Trip 2" and "Trip Time 2".
"Ø Cons 2" indicates the average fuel consumption based on "Trip 2" and "Trip Time 2".
"Trip Time 2" indicates the riding time based on "Trip 2" and starts running as soon as a
speed signal comes in.
"Fuel Range" indicates the possible range with the fuel reserve.
401825-01
Press and hold the
button for 3–5
seconds.
All entries in the "Trip 2" menu are cleared.
7
COMBINATION INSTRUMENT
7.9.4
"General Info"
–
46
Press the UP oder DOWN button until the "General Info" menu appears on the matrix display.
"Air Temp" indicates the ambient air temperature.
"Date" indicates the date.
"ODO" indicates the total distance covered.
"Battery" indicates the battery voltage.
"Oil Temp" indicates the engine oil temperature.
401824-01
7.9.5
"TPMS" (optional)
–
Press the UP or DOWN button until the "TPMS" menu appears on the matrix display.
Guideline
Tire air pressure, solo/with passenger/full payload
401845-01
Front: with cold tires
2.4 bar (35 psi)
Rear: with cold tires
2.9 bar (42 psi)
The "TPMS" menu displays the tire pressure of the front and rear tires.
"Front" indicates the tire air pressure at the front.
"Rear" indicates the tire air pressure at the rear.
7
COMBINATION INSTRUMENT
7.9.6
"Set Favorites"
47
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Set Favorites" menu appears on the matrix display. Pressing the SET button opens the menu.
–
Press the UP or DOWN button to select the menu. Press the SET button to set the menu
for quick selection.
In the "Set Favorites" menu, the "Favorites" menu can be configured.
401843-01
7.9.7
"Settings"
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
Setting for units or various values are made in the "Settings" menu. Some functions can be
enabled or disabled.
401841-01
7
COMBINATION INSTRUMENT
7.9.8
"Warnings"
48
Condition
• Message or warning
–
Press the UP or DOWN button until the "Warnings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Use the UP or DOWN button to navigate through the warnings.
In the "Warnings" menu, warnings that occurred are displayed and stored until they are no
longer active.
401840-01
7.9.9
"Heat Grip" (optional)
401838-01
–
Press the UP or DOWN button until the "Heat Grip" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Use the UP or DOWN button to navigate through the menu. Use the SET button to select
a heating level or to switch off the heated grips.
7
COMBINATION INSTRUMENT
7.9.10
"MTC/ABS"
49
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "MTC/ABS" menu appears on the matrix display.
In the "MTC/ABS" menu, "MTC" and "ABS" can be switched off.
In "ABS mode", a choice can be made between "Road" and "Offroad".
Info
After the ignition is switched on, traction control and ABS are enabled again.
When the "Offroad" ABS mode is enabled, ABS only controls the front wheel. The
rear wheel is not controlled by ABS and may block during braking maneuvers.
When the "Road" ABS mode is enabled, the brakes are also applied to the rear wheel
when the front brake is activated. ABS can intervene on both wheels.
401837-01
7.9.11
"Drive Mode"
–
Press the UP or DOWN button until the "Drive Mode" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Use the UP or DOWN button to navigate through the menu. The SET button can be used
to select engine and traction control settings that are coordinated with each other.
SPORT – homologated performance with very direct response; the traction control
allows greater slip on the rear wheel
STREET – homologated performance with very direct response; the traction control
allows normal slip on the rear wheel
401829-01
RAIN – reduced homologated performance for better ridability; the traction control
allows normal slip on the rear wheel
OFFROAD – reduced homologated performance for better ridability; the traction
control allows high slip on the rear wheel
7
COMBINATION INSTRUMENT
7.9.12
Menu overview
50
401849-01
7
COMBINATION INSTRUMENT
KTM start screen
Menu buttons
"Favorites"
"Trip 1"
"Trip 2"
"General Info"
"TPMS" (optional)
"Set Favorites"
"Settings"
"Warnings" (only active if messages are present)
"Heat Grip" (optional)
"MTC/ABS"
"Drive Mode"
7.9.13
"Language"
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the SET button again to select the language.
The menu languages are English, German, Italian, French, and Spanish.
401842-10
51
7
COMBINATION INSTRUMENT
7.9.14
"Distance"
52
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Distance" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select kilometers "km" or miles "mi" for the distance.
401842-11
7.9.15
"Temp"
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Temp" is highlighted in black on the matrix display.
Pressing the SET button again sets the unit of measure.
Select "°C" or "°F" for the temperature indicator.
401842-12
7
COMBINATION INSTRUMENT
7.9.16
"Volume"
53
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Volume" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select "liters" or "gallons" for the fuel consumption display.
401842-13
7.9.17
"Pressure"
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until ">Pressure" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select "bar" or "psi" for the tire pressure display.
401842-14
7
COMBINATION INSTRUMENT
7.9.18
"Clock/Date"
54
Condition
• The vehicle is stationary.
401823-01
7.9.19
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Clock/Date" is highlighted in black on the matrix display. Pressing the SET button again opens the menu.
–
Use the UP or DOWN button to navigate through the menu. Use the SET button to set
the time and date.
If the battery was disconnected, the time and date must be set in the matrix display.
"Fuel Cons"
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Fuel Cons" is highlighted in black on the matrix display. Pressing the SET button again sets the unit of measure.
Select one of the available consumption displays.
401842-16
7
COMBINATION INSTRUMENT
7.9.20
"DRL"
55
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "DRL" is highlighted in black on the matrix display.
Pressing the SET button again switches daytime running light on or off.
Switch the daytime running light on or off.
Info
401842-17
7.9.21
Note the legal regulations regarding the daytime running light.
"Shift Light"
Condition
• The vehicle is stationary.
401846-01
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Shift Light" is highlighted in black on the matrix display. Pressing the SET button again opens the menu.
–
Press the UP or DOWN button to select the function. Use the SET button to set the
engine speed for the shift warning light.
When the engine speed reaches "RPM 1", the shift warning light flashes.
When the engine speed reaches "RPM 2", the shift warning light lights up continuously.
Switch the "Shift Light" function on or off.
7
COMBINATION INSTRUMENT
7.9.22
"Quick Shift"
56
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
The "Quick Shift" function cannot be activated.
Info
This function is not available in this model.
401842-20
7.9.23
"Heat Grips"
Condition
• The vehicle is stationary.
–
Press the UP or DOWN button until the "Settings" menu appears on the matrix display.
Pressing the SET button opens the menu.
–
Press the UP or DOWN button until "Heat Grips" is highlighted in black on the matrix display. Pressing the SET button again switches the heat grips menu on or off.
Switch the heat grips menu on and off.
401842-21
8
ERGONOMICS
8.1
Handlebar position
57
The holes on the handlebar support are placed at a distance of A from the center.
Hole distance A
3.5 mm (0.138 in)
The handlebar can be mounted in two different positions. In this way, the handlebar can be
mounted in the position that is most comfortable for the rider.
401666-11
8.2
Adjusting the handlebar position
x
Warning
Danger of accidents Handlebar breakage.
–
If the handlebar is bent or straightened it will cause material fatigue, and the handlebar can break. Always replace handlebar.
–
Remove screws 1. Remove the handlebar clamps. Remove the handlebar and lay it to
one side.
Info
Protect the motorcycle and its attachments against damage by covering them.
Do not bend the cables and lines.
308080-01
–
Remove screws 2. Remove the handlebar support.
–
Place the handlebar support in the required position. Mount and tighten screws 2.
8
ERGONOMICS
58
Guideline
Screw, handlebar support
M10
40 Nm
(29.5 lbf ft)
Loctite® 243™
Info
Position the left and right handlebar supports evenly.
–
Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
–
Position the handlebar clamps. Mount and evenly tighten screws 1.
Guideline
Screw, handlebar clamp
8.3
M8
Adjusting the wind shield
–
S00342-10
Release clamping lever 1 by pulling in the direction of the arrow.
20 Nm
(14.8 lbf ft)
8
ERGONOMICS
59
–
Move the wind shield in the required position.
–
Lock clamping lever 1 by pushing in the direction of the arrow.
S00247-10
S00342-11
8
ERGONOMICS
8.4
Adjusting the basic setting of the clutch lever
60
–
Adjust the basic setting of the clutch lever to your hand size by turning adjusting
screw 1.
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!
S00244-10
8.5
Adjusting the basic position of the hand brake lever
–
Adjust the basic position of the hand brake lever to your hand size by turning adjusting
wheel 1.
Info
Push the hand brake lever forward and turn the adjusting wheel.
Do not make any adjustments while riding.
S00243-10
8
ERGONOMICS
8.6
Rider footrests
61
The rider footrests can be mounted in one of two positions.
Possible states
• Rider footrests, low A
• Rider footrests, high B
S00230-10
8.7
Adjusting the footrests
x
Info
The operations are the same for the left and right sides.
S00248-10
–
Remove cotter pin 1 with washer 2.
–
Remove pin 3 of the rider footrest.
–
Take off the rider footrest 4 with the spring.
8
ERGONOMICS
62
–
Remove screws 5.
–
Adjust the footrest bracket to the desired position.
–
Mount and tighten screws 5.
S00249-10
S00250-10
Guideline
Screw, front footrest bracket
S00249-10
M8
25 Nm
(18.4 lbf ft)
Loctite® 243™
8
ERGONOMICS
63
–
Mount the rider footrest with spring 4 and pin 3.
Pliers for footrest spring (58429083000)
–
Mount washer 2 and cotter pin 1.
S00251-10
8.8
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.
S00233-10
8.9
Adjusting the basic position of the foot brake lever
x
Warning
Danger of accidents Brake system failure.
–
If there is no free travel on the foot brake lever, pressure builds up on the rear brake circuit. The rear brake can fail due to overheating. Adjust the free travel on foot brake lever according to specifications.
8
ERGONOMICS
64
–
Disconnect spring 1.
–
Loosen nut 2.
–
Remove screw 3.
–
To adjust the basic position of the foot brake lever to individual requirements, turn ball
joint 4 accordingly.
Info
The range of adjustment is limited.
The screw must be screwed into the ball joint by at least 5 turns.
S00283-10
–
Hold ball joint 4 and tighten nut 2.
Guideline
Remaining chassis nuts
–
M6
10 Nm (7.4 lbf ft)
M6
10 Nm (7.4 lbf ft)
Mount and tighten screw 3.
Guideline
Remaining chassis nuts
–
Attach spring 1.
8
ERGONOMICS
8.10
Checking the basic position of the shift lever
65
–
Sit on the vehicle in the riding position and determine 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
8.11
Adjusting the basic position of the shift lever
–
101873-10
10… 20 mm (0.39… 0.79 in)
x
Remove screw 1 and take off shift lever 2.
x(
p. 65)
8
ERGONOMICS
66
–
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.
–
101874-10
Mount and tighten the screw.
Guideline
Screw, shift lever
M6
18 Nm
(13.3 lbf ft)
Loctite® 243™
9
PREPARING FOR USE
9.1
Advice on first use
67
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.
9
PREPARING FOR USE
68
Warning
Danger of accidents Failure of brake system.
–
If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your
foot off the foot brake lever when you are not braking.
Info
When using your vehicle, remember that others may feel disturbed by excessive noise.
–
Make sure that the pre-delivery inspection work has been carried out by an authorized KTM workshop.
You receive a delivery certificate and the Service and Warranty Booklet at vehicle handover.
–
Before your first trip, read the entire Owner's Manual carefully.
–
Get to know the controls.
–
Adjust the motorcycle to your requirements, as described in the "Ergonomics" chapter.
–
Get used to handling the motorcycle on a suitable piece of land before making a longer trip. Try also to ride as slowly as possible and
in a standing position to get a better feeling for the motorcycle.
–
Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.
–
Run the engine in.
9.2
–
Running in the engine
During the running-in phase, do not exceed the specified engine speed.
Guideline
Maximum engine speed
–
During the first: 1,000 km (620 mi)
6,500 rpm
After the first: 1,000 km (620 mi)
10,250 rpm
Avoid fully opening the throttle!
9
PREPARING FOR USE
69
Info
If the maximum engine speed is exceeded before the first service, the shift warning light flashes.
9.3
Loading the vehicle
Warning
Danger of accidents Unstable handling characteristics.
–
Do not exceed the maximum permitted weight and axle loads. The overall weight consists of: motorcycle operational and with a
full tank, driver and passenger with protective clothing and helmet, baggage.
Warning
Danger of accidents Unstable handling characteristics due to incorrect mounting of suitcase and/or tank rucksack.
–
Mount and secure suitcase and tank rucksack according to the manufacturer's instructions.
Warning
Danger of accidents Unstable handling characteristics at high speed.
–
Adapt your speed according to your payload. Ride more slowly if your motorcycle is loaded with cases or other baggage.
Maximum speed with luggage
150 km/h (93.2 mph)
Warning
Danger of accidents Risk of breakage of suitcase system.
–
If you have fitted suitcases on your motorcycle, read the manufacturer's specifications concerning the maximum payload.
Warning
Danger of accidents Poor visibility for other road users due to slipped baggage.
–
If the tail light is covered, you are less visible to traffic behind you, especially in the dark. Check that your baggage is fixed
properly at regular intervals.
9
PREPARING FOR USE
70
Warning
Danger of accidents Changed handling characteristics and longer stopping distance with excessive payload.
–
Adapt your speed according to your payload.
Warning
Danger of accidents Unstable handling characteristics due to slipped baggage.
–
Check the way your baggage is fixed regularly.
Warning
Danger of burns A hot exhaust system can burn baggage.
–
Fasten your baggage in such a way that it cannot be burned or singed by the hot exhaust system.
–
If you 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 permitted total weight and the axle loads.
Guideline
Maximum permissible total weight
440 kg (970 lb.)
Maximum permissible front axle load
159 kg (351 lb.)
Maximum permissible rear axle load
281 kg (619 lb.)
10
RIDING INSTRUCTIONS
10.1
Checks and maintenance measures when preparing for use
71
Info
Before every trip, check the condition of the vehicle and ensure that it is roadworthy.
The vehicle must be in perfect technical condition when it is being operated.
–
Check the engine oil level. (
p. 168)
–
Check the brake fluid level of the front brake. (
–
Check the rear brake fluid level. (
–
Check the front brake linings. (
–
Check the rear brake linings. (
–
Check 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. 99)
–
Check the tire condition. (
p. 141)
–
Check the tire air pressure. (
–
Check the spoke tension. (
–
Check the settings of all controls and ensure that they can be operated smoothly.
–
Check that the electrical equipment is functioning properly.
–
Check that baggage is correctly secured.
–
Check the setting of the rear mirror.
–
Check the fuel level.
p. 123)
p. 126)
p. 126)
p. 129)
p. 163)
p. 97)
p. 142)
p. 143)
10
RIDING INSTRUCTIONS
10.2
Starting
72
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 to the position ON
–
Switch on the ignition by turning the black ignition key to the position ON
.
.
After you switch on the ignition, you can hear the fuel pump working for about two
seconds. The function check of the combination instrument is run at the same
time.
The ABS lamp lights up and goes back out after starting off.
–
Shift the transmission to idle
.
The green idling speed indicator lamp
602607-01
lights up.
10
RIDING INSTRUCTIONS
–
73
Press the electric starter button
.
Info
Do not press the electric starter button until the combination instrument function check is finished.
When starting, DO NOT open the throttle. If you open the throttle during the starting procedure, fuel is not injected by the engine management system and the
engine cannot start.
Press the electric starter button for at most 5 seconds. Wait for a least 5 seconds before trying again.
This motorcycle is equipped with a safety starting system. You can only start
the engine if the transmission is in neutral or if the clutch lever is pulled when
a gear is engaged. If the side stand is folded out and you shift into gear, the
engine stops.
602608-01
–
10.3
–
Remove the motorcycle from the center stand or side stand.
Starting off
Pull the clutch lever, engage 1st gear, release the clutch lever slowly and simultaneously open the throttle carefully.
10.4
Shifting, riding
Warning
Danger of accidents Abrupt load alterations can cause the vehicle to get out of control.
–
Avoid abrupt load alterations and sudden braking actions, and adapt your speed to the road conditions.
Warning
Danger of accidents If you change down at high engine speed, the rear wheel can lock up.
–
Do not change into a low gear at high engine speed. The engine races and the rear wheel can lock up.
10
RIDING INSTRUCTIONS
74
Warning
Danger of accidents Malfunctions caused by incorrect ignition key position.
–
Do not change the ignition key position during a journey.
Warning
Danger of accidents Distraction from traffic activity by adjustments to the vehicle.
–
Make all adjustments when the vehicle is at a standstill.
Warning
Risk of injury Falling off of the passenger.
–
The passenger must be seated properly on the passenger seat and hold on to the front rider or the grab handles. The feet must
be positioned on the passenger footrests. Note the regulations governing the minimum age of passengers.
Warning
Danger of accidents Danger of accidents caused by dangerous driving.
–
Comply with traffic regulations and ride defensively and foresightedly to detect sources of danger early on.
Warning
Danger of accidents Reduced road grip with cold tires.
–
On every journey, take the first miles carefully at moderate speed until the tires reach operating temperature and optimal road
grip is ensured.
Warning
Danger of accidents Reduced road grip with new tires.
–
New tires have a smooth rolling surface and therefore cannot provide full road grip. The entire rolling surface must be roughened in the first 200 kilometers (124.3 miles) by moderate riding at alternating angles. The full grip levels are not achieved
until the tires have been run in.
10
RIDING INSTRUCTIONS
75
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.
Note
Engine failure Overheating of engine.
–
If the coolant temperature warning lamp lights up, stop and switch off the engine. Allow the engine to cool down and check the
coolant level in the radiator, and top up if necessary. If you continue with the coolant temperature warning lamp alight, you may have
engine failure.
Info
If you hear unusual noises while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.
10
RIDING INSTRUCTIONS
76
–
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 lever, and open the throttle.
Info
You can see the positions of the 6 forward gears in the figure. The idle position
is between the first and second gears. First gear is used for starting off or for
steep inclines.
S00232-10
–
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. Particularly in bends, do not shift, and accelerate very carefully.
–
To shift down, brake if necessary and close the throttle at the same time.
–
Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and
open the throttle or shift again.
–
If the engine stalls (e.g. at a crossroads), just pull the clutch lever and press the electric starter button. You do not have to shift into neutral.
–
Switch off the engine if you expect to be standing for a long time.
–
If the oil pressure warning lamp lights up during a trip, stop immediately and switch
off the engine. Contact an authorized KTM workshop.
–
If the engine warning lamp lights up during a trip, please contact an authorized KTM
workshop as soon as possible.
Info
From the flash rhythm you can deduce a two-digit number, the so-called blink
code. The blink code tells you which component is affected by a malfunction.
–
If the general warning lamp
sage for 10 seconds.
lights up during a trip, the matrix display shows a mes-
10
RIDING INSTRUCTIONS
77
Info
Very important messages are stored in the "Warnings" menu.
–
10.5
If the icy road symbol appears in the combination instrument, the roads may be icy.
Adjust your speed to the road conditions.
Applying the brakes
Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.
–
Clean or dry a dirty or wet brake system by riding and braking gently.
Warning
Danger of accidents Reduced braking efficiency caused by spongy pressure point of front or rear brake.
–
Check the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Failure of brake system.
–
If the foot brake lever is not released, the brake linings drag continuously. The rear brake may fail due to overheating. Take your
foot off the foot brake lever when you are not braking.
Warning
Danger of accidents Longer stopping distance due to higher overall weight.
–
Take the longer stopping distance into account when carrying a passenger and baggage.
Warning
Danger of accidents Delayed brake action on salted roads.
–
There may be salt deposits on the brake discs. In order to restore the normal braking efficiency, you will need to remove the
deposits from the discs by carefully applying the brakes.
10
RIDING INSTRUCTIONS
78
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 Vehicle rollover
–
–
It is not always possible to prevent vehicle rollover in extreme riding situations (e. g. luggage loaded with a high center of gravity, varying road surfaces, steep descents, full braking without disengaging the gear). Adapt your riding style to the road conditions and your riding ability.
When braking, release the throttle and apply the front and rear brakes at the same time.
Info
When ABS is enabled, you can achieve maximum braking power even on low grip surfaces such as sandy, wet, or slippery terrain without locking of the wheels.
Warning
Danger of accidents Locking of the wheels due to braking action of the engine.
–
Pull the clutch during emergency braking, full brake application and when braking on a slippery surface.
Warning
Danger of accidents Road grip is reduced when braking with the motorcycle at an angle or on a laterally inclined surface.
–
–
Braking should be completed before you enter into a bend.
Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.
10
–
RIDING INSTRUCTIONS
79
On long downhill stretches, use the braking effect of the engine. Change down one or two gears, but do not over-rev the engine. In this
way, you have to brake far less and the brakes do not overheat.
10.6
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 to or destruction of components due to excessive load.
–
The side stand is only designed for the weight of the motorcycle. Do no sit on the motorcycle when it is resting on the side stand. The
side stand or the frame may become damaged and the motorcycle may fall over.
10
RIDING INSTRUCTIONS
80
Note
Material damage Damage and destruction of components from excessive load.
–
The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when it is resting on
the center stand. The center stand or the frame may become damaged and the motorcycle may fall over.
–
Pull the motorcycle up onto the center stand at the grab handles.
–
Apply the brakes on the motorcycle.
–
Shift the transmission to idle
–
Switch off the ignition by turning the black ignition key to the position OFF
.
.
Info
If the engine is switched off with the emergency OFF switch and the ignition remains switched on at the ignition lock, power
continues to flow to most power consumers. This discharges the battery. You should therefore always switch off the engine with
the ignition key – the emergency OFF switch is intended for emergencies only.
–
Park the motorcycle on a firm surface.
Alternative 1
– Swing the side stand forward with your foot as far as it will go and lean the vehicle on it.
Alternative 2
– Raise the vehicle with the center stand. (
–
p. 95)
Lock the steering by turning the handlebar to the left, pressing the black ignition key down in the position OFF and turning it to the
position LOCK . To make the steering lock engage more easily, move the handlebar a little to the left and right. Remove the black
ignition key.
10.7
Transport
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
10
RIDING INSTRUCTIONS
81
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.
–
Switch off the engine.
–
Use tension belts or other suitable devices to secure the motorcycle against accidents
or falling over.
401475-01
10.8
Refueling
Danger
Fire hazard Fuel is highly flammable.
–
Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no fuel is
spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–
The fuel in the fuel tank expands when warm and may emerge if overfilled. Follow the instructions on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–
Fuel must not come into contact with the skin, eyes, or clothing. Do not breathe in the fuel vapors. If contact occurs with the
eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and
water. If fuel is swallowed, contact a physician immediately. Change clothing that is contaminated with fuel.
10
RIDING INSTRUCTIONS
82
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.)
–
Only refuel with clean fuel that meets the specified standards.
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–
Do not allow fuel to get into the ground water, the ground, or the sewage system.
–
Switch off the engine.
–
Open the filler cap. (
–
Fill the fuel tank with fuel up to the lower edge A of the filler neck.
Total fuel tank
capacity, approx.
–
S00239-10
Close the filler cap. (
p. 30)
23 l (6.1 US gal)
p. 31)
Super unleaded (ROZ 95/RON 95/PON
91) ( p. 199)
11
SERVICE SCHEDULE
11.1
Additional information
83
Any further work that results from the required work or from the recommended work must be ordered separately and can be invoiced separately.
11.2
Required work
Every two years
Every year
Every 30,000 km (18,600 mi)
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
Read out the trouble code memory using the KTM diagnostics tool.
Check the fuel pressure.
x
○
●
●
●
●
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
x
Check the functioning of the electrical equipment.
Change the engine oil and filter, clean the oil screens.
Check the brake discs. (
p. 122)
Check the front brake linings. (
Check the rear brake linings. (
p. 126)
p. 129)
p. 169)
○
Retighten the spokes.
x
Check the spoke tension. (
Check the rim run-out. x
p. 143)
Check the tire condition. (
p. 141)
Check the tire air pressure. (
x(
p. 142)
Check the rear brake fluid level. (
p. 126)
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
11
SERVICE SCHEDULE
84
Every two years
Every year
Every 30,000 km (18,600 mi)
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
Check the shock absorber and fork for leaks. Perform a fork service and shock absorber service as needed
and depending on how the vehicle will be used.
Check the chain, rear sprocket and engine sprocket. (
Check the chain tension. (
p. 99)
p. 123)
Check the coolant level in the compensating tank. (
●
●
●
●
●
●
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
●
●
●
●
●
p. 102)
Check the brake lines for damage and leakage.
Check the brake fluid level of the front brake. (
○
p. 163)
○
Change the air filter. Clean the air filter box.
x
Check the cables for damage and routing without sharp bends. (fuel tank removed) x
Change the spark plugs. (air filter removed) x
Check the valve clearance. (air filter and spark plugs removed) x
Change the secondary air system membranes. x
Change the front brake fluid. x
Change the rear brake fluid. x
Check the steering head bearing play. (
p. 106)
●
●
●
●
●
●
●
●
●
●
●
○
●
●
●
●
11
SERVICE SCHEDULE
85
Every two years
Every year
Every 30,000 km (18,600 mi)
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
Check the headlight setting. (
p. 161)
Final check: Check the vehicle for roadworthiness and take a test ride.
Read out the error memory after the test ride using the KTM diagnostics tool.
Check the CO adjustment with the KTM diagnostics tool.
x
x
Make the service entry in the KTM DEALER.NET and in the Service and Warranty Booklet.
○
One-time interval
●
Periodic interval
x
○
●
●
○
●
●
●
●
○
●
●
●
●
○
●
●
○
●
●
●
●
11
SERVICE SCHEDULE
11.3
Recommended work
86
Every four years
Every two years
Every year
Every 15,000 km (9,300 mi)
After 1,000 km (620 mi)
Check the oil jet for the clutch lubrication.
Check the swingarm bearing.
○
x
●
x
Check the wheel bearing for play.
●
●
x
Grease all moving parts (e.g., side stand, hand lever, chain, ...) and check for smooth operation.
x
○
Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect
routing.
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
x
Check the antifreeze.
○
x
Check/rectify the fluid level of the hydraulic clutch. (
Change the hydraulic clutch fluid.
Check the screws and nuts for tightness.
Change the coolant.
○
One-time interval
●
Periodic interval
x
p. 105)
x
x
○
●
●
●
12
SUSPENSION SETTING
12.1
Fork/shock absorber
87
The fork and the shock absorber offer many options of adapting the suspension to the riding
style and the payload.
Info
The recommendations for the suspension setting are shown in Table 1. The table is
found on the left inside cover of the fuel tank.
101875-10
12.2
These adjustments are guidelines and should always be the basis for a suspension setting.
If the guidelines are not adhered to, the riding characteristics could deteriorate, particularly
at high speeds.
Adjusting the compression damping of the fork
Info
The hydraulic compression damping determines the fork suspension behavior.
–
Turn the white adjusting screw 1 all the way clockwise.
Info
Adjusting screw 1 is located at the upper end of the left fork leg.
The compression damping is located in the left fork leg COMP (white adjusting
screw). The rebound damping is located in the right fork leg REB (red adjusting
screw).
–
S00262-10
Turn counterclockwise by the number of clicks corresponding to the fork type.
12
SUSPENSION SETTING
88
Guideline
Compression damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Full payload
7 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.3
Adjusting the rebound damping of the fork
Info
The hydraulic rebound damping determines the fork suspension behavior.
–
Turn the red adjusting screw 1 all the way clockwise.
Info
Adjusting screw 1 is located at the upper end of the right fork leg.
The rebound damping is located in the right fork leg REB (red adjusting screw).
The compression damping is located in the left fork leg COMP (white adjusting
screw).
–
S00263-10
Turn counterclockwise by the number of clicks corresponding to the fork type.
12
SUSPENSION SETTING
89
Guideline
Rebound damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Full payload
7 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.4
Adjusting the spring preload of the fork
–
Turn adjusting screws 1 counterclockwise all the way.
Info
Make the same adjustment on both fork legs.
–
Turn clockwise by the number of turns corresponding to the fork type.
Guideline
Spring preload - Preload Adjuster
S00260-10
Comfort
2 turns
Standard
5 turns
Sport
5 turns
Full payload
8 turns
12
SUSPENSION SETTING
90
Info
Turn clockwise to increase the spring preload; turn counterclockwise to reduce
the spring preload.
Adjusting the spring preload has no influence on the absorption setting of the
rebound damping.
Basically, however, you should set the rebound damping higher with a higher
spring preload.
12.5
Compression damping of the shock absorber
The compression damping of the shock absorber is divided into two ranges: high-speed and low-speed.
High-speed and low-speed refer to the compression speed of the rear wheel suspension and not to the vehicle speed.
The high-speed setting, for example, has an effect when riding over an asphalt edge: the rear wheel suspension compresses quickly.
The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses 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.
12.6
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 takes effect during the slow to normal compression of the shock absorber.
12
SUSPENSION SETTING
–
91
Turn adjusting screw 1 clockwise with a screwdriver up to the last perceptible click.
Info
Do not loosen fitting 2!
–
Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
Guideline
Compression damping, low-speed
S00265-10
Comfort
15 clicks
Standard
10 clicks
Sport
8 clicks
Full payload
8 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.7
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 takes effect during the fast compression of the shock absorber.
12
SUSPENSION SETTING
–
92
Turn adjusting screw 1 all the way clockwise with a socket wrench.
Info
Do not loosen fitting 2!
–
Turn counterclockwise by the number of turns corresponding to the shock absorber
type.
Guideline
Compression damping, high-speed
S00266-10
Comfort
1.5 turns
Standard
1.5 turns
Sport
1 turn
Full payload
1 turn
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.8
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.)
12
SUSPENSION SETTING
93
–
Turn adjusting screw 1 clockwise up to the last perceptible click.
–
Turn counterclockwise by the number of clicks corresponding to the shock absorber
type.
Guideline
Rebound damping
S00267-10
Comfort
15 clicks
Standard
10 clicks
Sport
8 clicks
Full payload
8 clicks
Info
Turn clockwise to increase damping; turn counterclockwise to reduce damping.
12.9
Adjusting the spring preload 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.)
12
SUSPENSION SETTING
94
–
Turn handwheel 1 counterclockwise as far as it will go.
–
Turn it clockwise by the number of turns corresponding to the shock absorber type and
use.
Guideline
Spring preload
S00268-10
Comfort
4 turns
Standard
4 turns
Sport
4 turns
Full payload
16 turns
Info
Turn clockwise to increase the spring preload; turn counterclockwise to reduce
the spring preload.
13
SERVICE WORK ON THE CHASSIS
13.1
Raising the vehicle with the center stand
95
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
Note
Material damage Damage and destruction of components from excessive load.
–
The center stand is only designed for the weight of the motorcycle and the baggage. Do no sit on the motorcycle when it is resting on
the center stand. The center stand or the frame may become damaged and the motorcycle may fall over.
–
Pull the motorcycle up onto the center stand at the grab handles.
–
Stand to the left of the vehicle.
–
Hold the handlebar with your left hand and push the center stand onto the ground with
your right foot.
–
Put your entire weight on arm 1 of the center stand while pulling the vehicle up at the
left grab handle until the center stand folds out all the way.
S00307-10
13.2
Removing the vehicle from the center stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–
Always place the vehicle on a firm and even surface.
13
SERVICE WORK ON THE CHASSIS
–
Unlock the steering and move the vehicle forward with both hands on the handlebar.
–
While the vehicle tips off of the center stand, activate the front brake to stop the vehicle from rolling away.
–
Check that the center stand is folded all the way up.
–
Insert the ignition key in seat lock 1 and turn it clockwise by 45°.
–
Lift up the seat at the rear, pull it back, and lift off.
–
Remove the ignition key.
S00308-10
13.3
Removing the seat
S00241-10
96
13
SERVICE WORK ON THE CHASSIS
13.4
Mounting the seat
2
0
1
0
97
–
Hook catch 1 of the seat onto the fuel tank and lower the rear while pushing it forward.
–
Insert locking pin 2 into the lock housing and push down the rear of the seat until the
locking pin engages with a click.
–
Check that the seat is correctly mounted.
–
Check the chain for coarse dirt accumulation.
401677-10
13.5
Checking for chain dirt
»
If the chain is very dirty:
–
400678-01
Clean the chain. (
p. 98)
13
SERVICE WORK ON THE CHASSIS
13.6
Cleaning the chain
98
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.
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 (
400725-01
p. 201)
13
SERVICE WORK ON THE CHASSIS
13.7
Checking the chain tension
99
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in
the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain
or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine
sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it
if necessary.
–
Place the motorcycle onto the side stand.
–
Shift the transmission to idle
–
In the area in front of the chain guide, push the chain up and determine chain tension A.
.
Info
The upper part of the chain B must be taut.
Chain wear is not always even, so you should repeat this measurement at different chain positions.
401664-10
Chain tension
»
40… 45 mm (1.57… 1.77 in)
If the chain tension does not meet the specification:
–
Adjust the chain tension. (
p. 100)
13
SERVICE WORK ON THE CHASSIS
13.8
Adjusting the chain tension
100
Warning
Danger of accidents Danger caused by incorrect chain tension.
–
If the chain is too taut, the components of the secondary power transmission (chain, engine sprocket, rear sprocket, bearings in
the transmission and in the rear wheel) will be under additional load. In addition to premature wear, this can cause the chain
or the countershaft of the transmission to break in extreme cases. If the chain is too loose, however, it may fall off the engine
sprocket or rear sprocket and block the rear wheel or damage the engine. Ensure that the chain tension is correct and adjust it
if necessary.
Preparatory work
– Check the chain tension. (
p. 99)
13
SERVICE WORK ON THE CHASSIS
101
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
40… 45 mm (1.57… 1.77 in)
Turn adjusting screws 3 on the left and right so that the markings on the left and
right chain adjusters 4 are in the same position in relation to reference marks C.
The rear wheel is then correctly aligned.
Info
The upper part of the chain must be taut.
Chain wear is not always even, so you should check the setting at different chain
positions.
–
Tighten nuts 2.
–
Make sure that chain adjusters 4 are resting against adjusting screws 3.
–
S00242-10
Tighten nut 1.
Guideline
Nut, rear wheel spindle
M25x1.5
90 Nm
(66.4 lbf ft)
Info
Chain adjusters 4 can be turned through 180°.
Thread greased
13
SERVICE WORK ON THE CHASSIS
13.9
Checking the chain, rear sprocket and engine sprocket
102
Preparatory work
– Raise the vehicle with the center stand. (
p. 95)
Main work
– 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
13
SERVICE WORK ON THE CHASSIS
103
–
Shift the transmission to idle
–
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
»
If distance B is greater than the specified measurement:
–
0
272 mm (10.71 in)
Change the power set.
x
Info
401665-10
When the chain is replaced, the rear sprocket and engine sprocket
should also be changed.
New chains wear out faster on old, worn sprockets.
For safety reasons, the chain has no chain joint.
13
SERVICE WORK ON THE CHASSIS
–
Check the chain sliding guard for wear at the cutout.
»
If rivet 1 of the chain is no longer visible at the lower edge C of the recess of the
chain sliding guard:
–
–
104
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
Screw, chain sliding guard
S00338-10
–
Check the chain guide for wear.
»
If the chain guide is worn:
–
–
»
If the chain guide is loose:
–
401670-01
Change the chain guide.
x
Check the chain guide for tightness.
Tighten the chain guide.
M5
5 Nm (3.7 lbf ft)
13
SERVICE WORK ON THE CHASSIS
105
Guideline
Screw, chain guide
M6
Finishing work
– Remove the vehicle from the center stand. (
13.10
5 Nm
(3.7 lbf ft)
Loctite® 243™
p. 95)
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.
–
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 top edge of container
»
If the coolant level does not meet specifications:
–
S00270-10
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.
13
SERVICE WORK ON THE CHASSIS
13.11
Checking the steering head bearing play
106
Warning
Danger of accidents Unstable vehicle handling from incorrect steering head bearing play.
–
Adjust the steering head bearing play without delay. (Your authorized KTM workshop will be glad to help.)
Info
If the vehicle is operated for a lengthy period with play in the steering head bearing, the bearings and the bearing seats in the
frame can become damaged over time.
Preparatory work
– Raise the vehicle with the center stand. (
p. 95)
Main work
– Place a load on the rear of the vehicle.
The front wheel is not in contact with the ground.
–
Move the handlebar to the straight-ahead position. Move the fork legs back and forth in
the direction of travel.
Play should not be detectable on the steering head bearing.
»
400738-11
If there is no detectable play:
–
–
Adjust the steering head bearing play.
x
Move the handlebar to and fro over the entire steering range.
It must be possible to move the handlebar easily over the entire steering range. There
should be no detectable detent positions.
»
If detent positions are detected:
–
Adjust the steering head bearing play.
x
13
SERVICE WORK ON THE CHASSIS
–
13.12
107
Check the steering head bearing and adjust if necessary.
Removing the bottom triple clamp cover
–
Remove screws 1.
–
Plug out the horn.
–
Remove the triple clamp cover 2.
202248-12
13.13
Installing the bottom triple clamp cover
x
–
Position the triple clamp cover 1.
–
Plug in the horn.
–
Mount and tighten screws 2.
Guideline
Remaining chassis screws
202248-13
M6
10 Nm (7.4 lbf ft)
13
SERVICE WORK ON THE CHASSIS
13.14
Removing the front side cover
–
Remove screw 1.
–
Remove screws 2.
–
Remove side cover 3.
–
Repeat the operation on the opposite side.
307815-10
307816-10
108
13
SERVICE WORK ON THE CHASSIS
13.15
Installing the front side cover
109
–
Position the side cover in the A area under the tank cover.
–
Attach catch 1 and bracket 2 of the side cover to the fuel tank and position the side
cover.
307817-10
307818-10
13
SERVICE WORK ON THE CHASSIS
–
110
Mount and tighten screw 3.
Guideline
Screw, cover part
M5x12
3.5 Nm
(2.58 lbf ft)
M5x12
3.5 Nm
(2.58 lbf ft)
307815-11
–
Mount and tighten screws 4.
Guideline
Screw, cover part
–
Repeat the operation on the opposite side.
307816-11
13.16
Removing the mask spoiler
x
Preparatory work
– Remove the seat. (
p. 96)
–
Remove the front side cover. (
–
Remove the tank cover. (
p. 108)
p. 116)
13
SERVICE WORK ON THE CHASSIS
Main work
– Remove screw 1.
307823-10
–
Remove screw 2.
–
Loosen holding lug 3 from the inside cover.
307824-10
307825-10
111
13
SERVICE WORK ON THE CHASSIS
–
Remove the mask spoiler laterally from the supports.
–
Pull the mask spoiler upward from bracket 4.
–
Detach connector 5.
–
Remove the mask spoiler with the turn signal.
–
Repeat the operation on the opposite side.
307828-10
307826-10
307827-10
112
13
SERVICE WORK ON THE CHASSIS
13.17
Installing the mask spoiler
x
Main work
– Plug in connector 1.
307827-11
–
Position the mask spoiler in bracket 2.
Info
Ensure that the turn signal cable is placed correctly.
307826-11
113
13
SERVICE WORK ON THE CHASSIS
114
–
Press the mask spoiler laterally into the supports.
–
Position holding lug 3 in the drill hole.
–
Mount and tighten screw 4.
307828-11
307825-10
Guideline
Screw, mask spoiler
307824-11
M5x17
3.5 Nm
(2.58 lbf ft)
13
SERVICE WORK ON THE CHASSIS
–
115
Mount and tighten screw 5.
Guideline
Screw, mask spoiler
–
M5x17
Repeat the operation on the opposite side.
307823-11
Finishing work
– Install the tank cover. (
13.18
p. 118)
–
Install the front side cover. (
–
Mount the seat. (
p. 109)
p. 97)
Removing the front fender
–
Remove holder 1 from the front fender.
–
Remove screws 2.
–
Remove the fender in a forward direction.
Info
Pay attention to the brake lines.
S00323-10
3.5 Nm
(2.58 lbf ft)
13
SERVICE WORK ON THE CHASSIS
13.19
Installing the front fender
116
x
–
Position the fender.
Info
Pay attention to where the brake lines are placed.
–
Mount and tighten screws 1.
Guideline
Screw, fender
S00323-11
13.20
–
M5x12
Mount holder 2 with the brake line on the fender.
Removing the tank cover
Preparatory work
– Remove the seat. (
–
Main work
– Remove screw 1.
–
307819-10
p. 96)
Remove the front side cover. (
Remove screw 2.
p. 108)
3.5 Nm
(2.58 lbf ft)
13
SERVICE WORK ON THE CHASSIS
–
Remove screw 3.
–
Remove screw 4.
–
Remove screw 5.
–
Raise the tank cover at the rear and remove it in a forward direction.
307820-10
307821-10
307822-10
117
13
SERVICE WORK ON THE CHASSIS
13.21
Installing the tank cover
118
Main work
– Position the tank cover.
Info
Note the sealing lip.
–
Mount and tighten screw 1.
Guideline
Screw, cover part
M5x12
3.5 Nm
(2.58 lbf ft)
M6
6 Nm (4.4 lbf ft)
M5x12
3.5 Nm
(2.58 lbf ft)
307821-11
–
Mount and tighten screw 2.
Guideline
Screw, cover part
–
Mount and tighten screw 3.
Guideline
Screw, cover part
307820-11
13
SERVICE WORK ON THE CHASSIS
–
119
Mount and tighten screw 4.
Guideline
Screw, cover part
–
M6
6 Nm (4.4 lbf ft)
M5x12
3.5 Nm
(2.58 lbf ft)
Mount and tighten screw 5.
Guideline
Screw, cover part
307819-11
Finishing work
– Install the front side cover. (
13.22
p. 109)
–
Mount the seat. (
–
Remove screws 1 and wind shield 2.
p. 97)
Removing the wind shield
S00259-10
13
SERVICE WORK ON THE CHASSIS
13.23
Installing the wind shield
–
Position wind shield 1.
–
Mount and tighten screws 2.
120
Guideline
Screw, wind shield
S00259-11
M5
3.5 Nm
(2.58 lbf ft)
14
BRAKE SYSTEM
14.1
ABS/antilock brake system
121
The ABS unit 1, which consists of a hydraulic unit, ABS control unit, and return pump, is
installed under the seat. A wheel speed sensor 2 is located at the front and rear wheels.
3
0
0
2
Warning
Danger of accidents Functional limitations of the ABS
–
The rear wheel may only be spun with the front brake applied (burn out) if the
ABS is switched off.
–
If the vehicle has been modified, such as shortened or lengthened spring deflections, different rim diameters, different tires, the wrong tire air pressure, different brake linings, etc., the ABS will not function optimally. Optimal functioning of the ABS is only ensured if the brake system only contains spare parts and
tires that have been approved and/or recommended by KTM.
–
Service work and repairs must be performed properly. (Your authorized KTM
workshop will be glad to help.)
The ABS is a safety system that prevents locking of the wheels when driving straight ahead
without the influence of lateral forces.
Warning
1
0
Danger of accidents Vehicle rollover
–
0
2
It is not always possible to prevent vehicle rollover in extreme riding situations
(e. g. luggage loaded with a high center of gravity, varying road surfaces, steep
descents, full braking without disengaging the gear). Adapt your riding style to
the road conditions and your riding ability.
ABS has two operating modes: the "Road" and "Offroad" ABS modes.
In the "Road" ABS mode, the brakes are also applied to the rear wheel when the front brake
is applied. ABS can intervene on both wheels.
401662-01
14
BRAKE SYSTEM
122
In the "Offroad" ABS mode, the front brake slows the front wheel. The rear brake slows the
rear wheel. There is no ABS intervention on the rear wheel. The ABS lamp 3 flashes slowly
to remind you that the "Offroad" ABS mode is enabled.
Info
In the "Offroad" ABS mode, the rear wheel may block and there is a risk of falling.
The ABS operates with two independent brake circuits (front and rear brakes). When the
ABS control unit detects a locking tendency in a wheel, ABS begins regulating the brake
pressure. The regulating process causes a slight pulsing of the hand and foot brake levers.
ABS lamp 3 must light up after the ignition is switched on and go out after starting off.
If it does not go out after starting off or if it is lit while riding, this indicates a fault in the
ABS system. In this case, the ABS is no longer enabled and the wheels may lock during
braking. The brake system itself stays functional; only ABS control is not available.
The ABS lamp may also light up if the rotating speeds of the front and rear wheels differ
greatly under extreme riding conditions, for example when making wheelies or if the rear
wheel spins. This causes the ABS to switch off.
To 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 lamp goes out when you start
off.
In the "MTC/ABS" menu, ABS can be switched off manually.
Info
After the ignition is switched back on, ABS is enabled again.
14.2
Checking the brake discs
Warning
Danger of accidents Reduced braking efficiency due to worn brake disc(s).
–
Change the worn brake disc(s) without delay. (Your authorized KTM workshop will be glad to help.)
14
BRAKE SYSTEM
123
–
Check the thickness of the front and rear brake discs at multiple points on each brake
disc to ensure it is at least thickness A.
Info
Wear will reduce the thickness of the brake disc at the contact surface 1 of the
brake linings.
Brake discs - wear limit
400618-10
»
Front
4 mm (0.16 in)
Rear
4.5 mm (0.177 in)
If the brake disc thickness is less than the specified value.
–
–
Check the front and rear brake discs for damage, cracking, and deformation.
»
If the brake disc exhibits damage, cracking, or deformation:
–
14.3
Change the brake disc.
Change the brake disc.
Checking the brake fluid level of the front brake
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–
Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
glad to help.)
14
BRAKE SYSTEM
124
–
–
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 MINA:
–
Add front brake fluid.
x(
p. 124)
S00269-10
14.4
Adding front brake fluid
x
Warning
Danger of accidents Failure of the brake system.
–
If the brake fluid level falls below the MIN mark, this indicates a leakage in the brake system or worn-out brake linings. Check
the brake system and do not continue riding. (Your authorized KTM workshop will be glad to help.)
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–
Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
glad to help.)
14
BRAKE SYSTEM
125
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake
fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Preparatory work
– Check the front brake linings. (
p. 126)
Main work
– Move the brake fluid reservoir mounted on the handlebar to a horizontal position.
–
Remove screws 1.
–
Remove cover 2 with membrane 3.
–
Add brake fluid to the MAX mark A.
Brake fluid DOT 4 / DOT 5.1 (
S00272-10
p. 197)
–
Position cover 2 with membrane 3.
–
Mount and tighten screws 1.
Info
Clean up overflowed or spilt brake fluid immediately with water.
14
BRAKE SYSTEM
14.5
Checking the front brake linings
126
Warning
Danger of accidents Reduced braking efficiency caused by worn brake linings.
–
Change worn brake linings immediately. (Your authorized KTM workshop will be glad to help.)
Note
Danger of accidents Reduced braking efficiency caused by damaged brake discs.
–
If the brake linings are not changed in time, the steel brake lining carriers grind on the brake disc. The braking effect is greatly
reduced and the brake discs are destroyed. Check the brake linings regularly.
–
Check all brake linings on both brake calipers to ensure they have minimum thickness A.
≥ 1 mm (≥ 0.04 in)
Minimum thickness
»
If the minimum thickness is less than specified:
–
–
»
S00305-10
14.6
Change the front brake linings.
x
Check all brake linings on both brake calipers for damage and cracking.
If there is damage or cracking:
–
Change the front brake linings.
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.)
14
BRAKE SYSTEM
127
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.)
Preparatory work
– Raise the vehicle with the center stand. (
p. 95)
Main work
– Check the brake fluid level in the brake fluid reservoir 1.
»
If the fluid level reaches the MIN marking A:
–
Add rear brake fluid.
x(
p. 127)
S00273-10
14.7
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.)
14
BRAKE SYSTEM
128
Warning
Skin irritation Brake fluid can cause skin irritation on contact.
–
Avoid contact with skin and eyes, and keep out of the reach of children.
–
Wear suitable protective clothing and goggles.
–
If brake fluid comes into contact with the eyes, flush the eyes thoroughly with water and consult a physician immediately.
Warning
Danger of accidents Reduced braking efficiency due to old brake fluid.
–
Change the brake fluid of the front and rear brake according to the service schedule. (Your authorized KTM workshop will be
glad to help.)
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Never use DOT 5 brake fluid! It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake
fluid.
Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!
Use only clean brake fluid from a sealed container.
Preparatory work
– Raise the vehicle with the center stand. (
–
Check the rear brake linings. (
p. 129)
p. 95)
14
BRAKE SYSTEM
129
Main work
– Remove screw cap 1 with membrane 2.
–
Add brake fluid to the MAX mark A.
Brake fluid DOT 4 / DOT 5.1 (
–
p. 197)
Mount and tighten screw cap 1 with membrane 2.
Info
Clean up overflowed or spilt brake fluid immediately with water.
S00274-10
14.8
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.
14
BRAKE SYSTEM
130
–
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 there is wear or tearing:
–
S00292-10
Change the rear brake linings.
Check the brake linings for damage and cracking.
Change the rear brake linings.
x
15
WHEELS, TIRES
15.1
Removing the front wheel
131
x
Preparatory work
– Raise the vehicle with the center stand. (
p. 95)
Main work
– Place a load on the rear of the vehicle.
The front wheel is not in contact with the ground.
–
Remove screw 1 and pull wheel speed sensor 2 out of the hole.
–
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.
S00313-10
Info
Do not pull the hand brake lever when the brake caliper has been removed.
S00314-10
15
WHEELS, TIRES
132
–
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.
–
S00315-10
–
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.
Info
Do not pull the hand brake lever when the front wheel is removed.
–
S00316-10
Remove spacers 6.
15
WHEELS, TIRES
15.2
Installing the front wheel
133
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:
–
–
Change the wheel bearing.
x
Clean and grease the shaft seal rings 1 and contact surface A of the spacers.
Long-life grease (
p. 202)
S00316-11
–
Insert the wide spacer 2 on the left in the direction of travel.
Info
The arrow B indicates the direction of travel of the front wheel.
The ABS sensor wheel is on the left-hand side when looking in the direction of
travel.
–
S00339-10
Insert the narrow spacer on the right in the direction of travel.
15
WHEELS, TIRES
134
Warning
Danger of accidents Reduced braking efficiency due to oil or grease on the
brake discs.
–
S00317-10
Always keep the brake discs free of oil and grease, and clean them with
brake cleaner when necessary.
–
Clean screw 3 and wheel spindle 4.
–
Lift the front wheel into the fork, position it, and insert the wheel spindle.
–
Mount and tighten screw 3.
Guideline
Screw, front wheel spindle
–
M25x1.5
45 Nm
(33.2 lbf ft)
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.
The brake calipers straighten.
–
Tighten screws 5 on both brake calipers.
Guideline
Screw, front brake caliper
S00314-11
–
M10
Remove the fixation of the hand brake lever.
45 Nm
(33.2 lbf ft)
Loctite® 243™
15
WHEELS, TIRES
135
–
Insert wheel speed sensor 6 into the hole and position it.
–
Mount and tighten screw 7.
Guideline
Remaining chassis screws
M6
–
Remove the vehicle from the center stand. (
–
Pull the front brake and compress the fork forcefully a few times.
–
Tighten screws 8.
10 Nm (7.4 lbf ft)
p. 95)
S00313-11
The fork legs straighten.
Guideline
Screw, fork stub
M8
S00315-11
15.3
Removing the rear wheel
x
Preparatory work
– Raise the vehicle with the center stand. (
p. 95)
15 Nm
(11.1 lbf ft)
15
WHEELS, TIRES
136
Main work
– Press the brake caliper by hand on to the brake disc in order to press back the brake
pistons.
S00275-10
–
Remove screw 1 and pull wheel speed sensor 2 out of the hole.
–
Remove nut 3. Remove chain adjuster 4.
S00277-10
S00276-10
15
WHEELS, TIRES
137
–
Pull out wheel spindle 5 only far enough to allow the rear wheel to be pushed forward.
–
Push the rear wheel forward as far as possible. Take the chain off of the rear sprocket
and place it on chain sprocket guard 6.
Warning
Danger of accidents Reduced braking effect caused by damaged brake discs.
–
S00286-10
–
Always lay the wheel down in such a way that the brake discs are not damaged.
Holding the rear wheel, withdraw the wheel spindle. Take the rear wheel out of the
swing arm.
Info
Do not operate the foot brake when the rear wheel is removed.
–
15.4
Installing the rear wheel
Remove the spacer 7.
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.
–
Check the rear hub rubber dampers.
x(
p. 139)
15
WHEELS, TIRES
138
–
Check the wheel bearing for damage and wear.
»
If the wheel bearing is damaged or worn:
–
–
Change the wheel bearing.
Long-life grease (
–
S00287-10
p. 202)
Clean and grease the thread of the wheel spindle and nut.
Long-life grease (
S00285-10
x
Clean and grease shaft seal ring 1 and contact surface A of the spacer.
p. 202)
–
Mount the rubber dampers and rear sprocket carrier in the rear wheel.
–
Place the rear wheel in the swingarm and bring the brake disc on the brake caliper into
contact.
–
Mount wheel spindle 2 but do not push it in all the way.
–
Push the rear wheel as far forward as possible and place the chain on the rear sprocket.
15
WHEELS, TIRES
139
–
Push the wheel spindle in all the way and mount chain adjuster 4 and nut 5.
Info
Mount chain adjusters 3 and 4 in the same position.
–
Push the rear wheel forward so that the chain adjusters are in contact with the tensioning screws, and tighten nut 5.
Guideline
In order for the rear wheel to be correctly aligned, the markings on the left and right
chain adjusters must be in the same position relative to the reference marks B.
S00288-10
Nut, rear wheel spindle
–
M25x1.5
90 Nm
(66.4 lbf ft)
Thread greased
Insert wheel speed sensor 6 into the hole. Mount and tighten screw 7.
Guideline
Remaining chassis screws
–
M6
10 Nm (7.4 lbf ft)
Operate the foot brake lever repeatedly until the brake linings are in contact with the
brake disc and there is a pressure point.
S00289-10
15.5
Checking the rear hub rubber dampers
x
Info
The engine power is transmitted from the rear sprocket to the rear wheel via 6 rubber dampers. The rubber dampers wear out during operation. If the rubber dampers are not changed in time, the rear sprocket carrier and the rear hub will be damaged.
15
WHEELS, TIRES
140
Preparatory work
– Raise the vehicle with the center stand. (
–
Remove the rear wheel.
x(
p. 95)
p. 135)
Main work
– Check the rubber dampers 1 of the rear hub for damage and wear.
»
If the rubber dampers of the rear hub are damaged or worn:
–
Change all rubber dampers in the rear hub.
S00290-10
–
Lay the rear wheel on a workbench with the rear sprocket facing upwards and insert the
wheel spindle in the hub.
–
Check the rear sprocket play A.
Info
Measure the play on the outside of the rear sprocket.
Play in rubber dampers, rear wheel
S00291-10
»
≤ 5 mm (≤ 0.2 in)
If clearance A larger than the specified value:
–
Change all rubber dampers in the rear hub.
Finishing work
– Install the rear wheel.
x(
p. 137)
15
WHEELS, TIRES
15.6
Checking the tire condition
141
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 an impact on the braking and riding response of the vehicle.
Worn tires have a negative effect on vehicle handling, especially on wet surfaces.
15
WHEELS, TIRES
142
–
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:
–
15.7
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.
15
WHEELS, TIRES
143
–
Remove the dust cap.
–
Check the tire air pressure when the tires are cold.
Tire air pressure, solo/with passenger/full payload
»
15.8
–
2.4 bar (35 psi)
Rear: with cold tires
2.9 bar (42 psi)
If the tire pressure does not meet specifications:
–
400695-01
Front: with cold tires
Correct the tire pressure.
Mount the dust cap.
Checking spoke tension
Warning
Danger of accidents Instable handling due to incorrect spoke tension.
–
Ensure that the spoke tension is correct. (Your authorized KTM workshop will be glad to help.)
Info
A loose spoke can easily cause lateral or radial runout on the wheel. More spokes loosen in a short period.
If the spokes are too tight, they can break due to local overload.
Check the spoke tension regularly, especially on a new motorcycle.
15
WHEELS, TIRES
144
–
Strike each spoke briefly using a screwdriver blade.
Info
The frequency of the sound is a function of the spoke length and spoke diameter.
If spokes of the same length and diameter vibrate with a different tone, this is
an indication that the spoke tensions differ.
You should hear a high note.
400694-01
»
If the spoke tension differs:
–
Correct the spoke tension.
x
16
ELECTRICAL SYSTEM
16.1
daytime running light
145
The daytime running light/parking light is integrated in the main headlight.
The daytime running light can be switched on when visibility conditions are good. Activate
the daytime running light in the combination instrument. Control is provided by the brightness sensor in the combination instrument. When visibility conditions are good, the low
beam is switched off and the daytime running light is switched on. It is four times brighter
than the parking light. When the daytime running light is switched off, it serves as a parking light.
Info
S00381-01
16.2
Removing the battery
Note the legal regulations regarding the daytime running light.
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 sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–
Never operate the vehicle with a discharged battery or without a battery.
16
ELECTRICAL SYSTEM
146
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 96)
Main work
– Pull locking mechanism 1 in the direction of the arrow.
–
Fold open cover 2.
–
Disconnect negative cable 3 of the battery.
–
Disconnect the positive cable 4 of the battery.
–
Take the battery and battery case 5 out of the battery compartment.
S00302-10
S00303-10
16
ELECTRICAL SYSTEM
16.3
Installing the battery
147
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 sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
Caution
Danger of accidents If the vehicle is operated with a discharged battery or without a battery, electronic components and safety
equipment may be damaged.
–
Never operate the vehicle with a discharged battery or without a battery.
Main work
– Insert the battery into battery case 1.
Info
The even side of the battery case must be opposite the poles.
–
Insert the battery and battery case into the battery compartment.
–
Connect both positive cables 2.
Guideline
602677-10
Screw, battery terminal
M6
4.5 Nm
(3.32 lbf ft)
16
ELECTRICAL SYSTEM
–
148
Connect both negative cables 3.
Guideline
Screw, battery terminal
–
M6
4.5 Nm
(3.32 lbf ft)
Fold down cover 4 and let it lock by pushing down lightly.
S00304-10
Finishing work
– Mount the seat. (
–
16.4
Recharging the battery
p. 97)
Set the time and date.
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 sparks and open flames away from the battery. Only charge in well-ventilated rooms.
–
In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least 15
minutes and contact a physician.
16
ELECTRICAL SYSTEM
149
Warning
Environmental hazard The battery contains elements that are harmful to the environment.
–
Do not discard batteries with the household waste. Dispose of faulty batteries in an environmentally compatible manner. Give
the battery to your authorized KTM dealer or dispose of it at a collection point for used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–
Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.
Info
Even when there is no load on the battery, it discharges steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid recharging with a high charging current shortens the battery's service life.
If the charging current, charging voltage, and charging time are exceeded, electrolyte escapes through the safety valves. This
reduces the battery capacity.
If the battery is depleted from starting the vehicle repeatedly, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will become over-discharged and sulfate, destroying the battery.
The battery is maintenance-free, i.e., the acid level does not have to be checked.
If the battery is not charged using the KTM battery charger, the battery must be removed for charging. Otherwise, overvoltage may
damage electronic components. Charge the battery according to the instructions on the battery housing.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 96)
16
ELECTRICAL SYSTEM
150
Main work
– Pull locking mechanism 1 in the direction of the arrow.
–
Fold open cover 2.
–
Disconnect the negative cable 3 of the battery to avoid damage to the motorcycle's
electronics.
–
Connect the battery charger to the battery. Switch on the battery charger.
S00302-10
602677-11
Battery charger (58429074000)
You can also use the battery charger to test the open-circuit voltage and start potential
of the battery, and to test the alternator. With this device, you cannot overcharge the
battery.
Info
602678-01
Charge the battery with a maximum of 10% of the capacity specified on the battery housing.
16
ELECTRICAL SYSTEM
–
151
Switch off and disconnect the battery charger after charging.
Guideline
The charging current, charging voltage, and charging time must not be exceeded.
Charge the battery regularly when the
motorcycle is not in use
–
3 months
Connect both negative cables 3.
Guideline
Screw, battery terminal
M6
602677-11
–
Fold down cover 4 and let it lock by pushing down lightly.
S00304-10
Finishing work
– Mount the seat. (
–
p. 97)
Set the time and date.
4.5 Nm
(3.32 lbf ft)
16
ELECTRICAL SYSTEM
16.5
Changing the main fuse
152
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.
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
p. 96)
Main work
– Remove screws 1.
–
Raise rear fairing 2 slightly.
–
Remove protection caps 3.
S00332-10
S00311-10
16
ELECTRICAL SYSTEM
–
153
Remove the faulty main fuse 4.
Info
A defective fuse is indicated by a burned-out fuse wire A.
A reserve fuse 5 is located in the starter relay.
The main fuse protects all power consumers of the vehicle.
–
Install a new main fuse.
Fuse (58011109130) (
S00312-10
p. 190)
–
Check that the electrical equipment is functioning properly.
–
Mount protection covers.
Tip
Insert a new spare fuse into the starter relay to have it available when needed.
–
Position rear fairing 2.
–
Mount and tighten screws 1.
Guideline
Screw, cover part
M5x12
S00332-10
Finishing work
– Mount the seat. (
–
p. 97)
Set the time and date.
3.5 Nm
(2.58 lbf ft)
16
ELECTRICAL SYSTEM
16.6
Changing the fuses in the fuse box
154
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. 96)
Main work
– Open fuse box cover 1.
S00322-10
16
ELECTRICAL SYSTEM
–
155
Check the fuses.
Info
A defective fuse is indicated by a burned-out fuse wire A.
–
Remove the defective fuse.
Guideline
Fuse res - 10 A - spare fuses
Fuse 1 - 10 A - power supply for control units and components
S00321-10
Fuse 2 - 10 A - socket (ACC1)
Fuse 3 - 25 A - ABS hydraulic unit
Fuse 4 - 40 A - ABS return pump
Fuse 5 - not used
–
Use spare fuses with the correct rating only.
Fuse (58011109110) (
p. 189)
Fuse (58011109125) (
p. 190)
Fuse (58011109140) (
p. 190)
Tip
Insert a spare fuse so that it is available if needed.
–
Check that the power consumer is functioning properly.
–
Close the fuse box cover.
Finishing work
– Mount the seat. (
p. 97)
16
ELECTRICAL SYSTEM
16.7
Removing the headlight mask with the headlight
156
Preparatory work
– Switch off all power consumers and switch off the engine.
–
Remove the seat. (
–
Remove the front side cover. (
–
Remove the tank cover. (
–
Remove the mask spoiler.
–
Remove the wind shield. (
p. 96)
p. 108)
p. 116)
x(
p. 110)
p. 119)
Main work
– Remove screws 1.
–
Remove the headlight mask forward.
–
Disconnect plug 2.
–
Place the headlight mask onto a soft cloth so that the headlight is not damaged.
S00293-10
S00294-10
16
ELECTRICAL SYSTEM
16.8
Refitting the headlight mask with the headlight
157
Main work
– Connect connector 1 of the headlight.
–
Check that the lighting is functioning properly.
–
Position the headlight mask.
–
Mount and tighten screws 2.
S00294-11
Guideline
Remaining chassis screws
M6
S00293-11
Finishing work
– Install the wind shield. (
–
Install the mask spoiler.
p. 120)
x(
–
Install the tank cover. (
–
Install the front side cover. (
p. 113)
p. 118)
–
Mount the seat. (
–
Check the headlight setting. (
p. 109)
p. 97)
p. 161)
10 Nm (7.4 lbf ft)
16
ELECTRICAL SYSTEM
16.9
Changing the low beam bulb
158
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.
–
Remove the seat. (
–
Remove the front side cover. (
–
Remove the tank cover. (
–
Remove the mask spoiler.
p. 96)
p. 108)
p. 116)
x(
p. 110)
–
Remove the wind shield. (
–
Remove the headlight mask with the headlight. (
p. 119)
p. 156)
Main work
– Push headlight bulb 1 lightly into the bulb socket, turn it all the way counterclockwise,
and pull it out.
–
S00297-10
Disconnect plug 2.
16
ELECTRICAL SYSTEM
–
159
Plug connector 2 into the new headlight bulb.
Low beam (H11/socket PGJ19-2) (
–
p. 190)
Position headlight bulb 1 into the bulb socket and turn it all the way clockwise.
The headlight bulb is locked into the bulb socket.
S00298-10
Finishing work
– Refit the headlight mask with the headlight. (
16.10
–
Install the wind shield. (
–
Install the mask spoiler.
p. 157)
p. 120)
x(
–
Install the tank cover. (
–
Install the front side cover. (
p. 113)
p. 118)
–
Mount the seat. (
–
Check the headlight setting. (
p. 109)
p. 97)
p. 161)
Changing the high beam bulb
Note
Damage to reflector Reduced brightness.
–
Grease on the lamp will evaporate due to the heat and be deposited on the reflector. Clean the lamp and keep it free of grease before
mounting.
Preparatory work
– Switch off all power consumers and switch off the engine.
16
ELECTRICAL SYSTEM
160
–
Remove the seat. (
–
Remove the front side cover. (
–
Remove the tank cover. (
–
Remove the mask spoiler.
p. 96)
p. 108)
p. 116)
x(
p. 110)
–
Remove the wind shield. (
–
Remove the headlight mask with the headlight. (
p. 119)
p. 156)
Main work
– Push headlight bulb 1 lightly into the bulb socket, turn it all the way counterclockwise,
and pull it out.
–
Disconnect plug 2.
–
Plug connector 2 into the new headlight bulb.
S00295-10
High beam (H11/socket PGJ19-2) (
–
p. 190)
Position headlight bulb 1 into the bulb socket and turn it all the way clockwise.
The headlight bulb is locked into the bulb socket.
S00296-10
Finishing work
– Refit the headlight mask with the headlight. (
–
Install the wind shield. (
p. 120)
p. 157)
16
16.11
ELECTRICAL SYSTEM
161
–
Install the mask spoiler.
–
Install the tank cover. (
–
Install the front side cover. (
–
Mount the seat. (
–
Check the headlight setting. (
–
Park the vehicle on a horizontal surface in front of a light-colored wall and make a mark
at the height of the center of the low beam headlight.
–
Make another mark at a distance B under the first mark.
x(
p. 113)
p. 118)
p. 109)
p. 97)
p. 161)
Checking the headlight setting
Guideline
Distance B
–
5 cm (2 in)
Position the vehicle perpendicular to the wall at a distance A from the wall and switch
on the low beam.
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 baggage and a passenger if
applicable.
»
If the boundary between light and dark does not meet specifications:
–
Adjust the headlight range. (
p. 162)
16
ELECTRICAL SYSTEM
16.12
Adjusting the headlight range
162
Preparatory work
– Check the headlight setting. (
–
p. 161)
Remove the bottom triple clamp cover. (
p. 107)
Main work
– Turn adjusting screw 1 to adjust the headlight range.
Info
Turn clockwise to increase the headlight range; turn counterclockwise to reduce
the headlight range.
If you have a payload, you may have to correct the headlight range.
S00301-10
–
Set the headlight to marking B.
Guideline
The light-dark boundary must lie exactly on the lower mark B when the motorcycle
is ready to operate with the rider mounted along with any luggage and a passenger if
applicable.
400726-11
Finishing work
– Install the bottom triple clamp cover.
x(
p. 107)
17
COOLING SYSTEM
17.1
Checking the coolant level in the compensating tank
163
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
The radiator is completely full.
–
Park the motorcycle on a horizontal surface.
–
Check the coolant level in the compensating tank 1.
The coolant level must be between MIN and MAX.
»
If there is no coolant in the compensating tank:
–
Check the cooling system for leaks.
x
Info
Do not start up the motorcycle!
S00324-10
–
»
Add coolant/bleed the cooling system.
x
If the coolant in the compensating tank is not at the required level, but the tank is
not empty:
17
COOLING SYSTEM
164
–
17.2
Correct the coolant level in the compensating tank. (
p. 164)
Correcting the coolant level in the compensating tank
Warning
Danger of scalding During motorcycle operation, the coolant gets very hot and is under pressure.
–
Do not remove the radiator cap, radiator hoses or other cooling system components when the engine is hot. Allow the engine
and cooling system to cool down. In case of scalding, rinse immediately with lukewarm water.
Warning
Danger of poisoning Coolant is poisonous and a health hazard.
–
Coolant must not come into contact with the skin, eyes, or clothing. If contact occurs with the eyes, rinse with water immediately and contact a physician. Immediately clean contaminated areas on the skin with soap and water. If coolant is swallowed,
contact a physician immediately. Change clothing that is contaminated with coolant. Keep coolant out of reach of children.
Condition
The engine is cold.
The radiator is completely full.
Preparatory work
– Check the coolant level in the compensating tank. (
–
Remove the front side cover. (
p. 108)
Info
Only disassemble the right-hand side.
p. 163)
17
COOLING SYSTEM
165
Main work
– Remove cover 1 of the compensating tank.
S00325-10
–
Add coolant until the coolant reaches the specified level.
Guideline
The coolant level must be between MIN and MAX.
Alternative 1
Coolant (
p. 197)
Alternative 2
Coolant (mixed ready to use) (
S00326-01
–
p. 197)
Mount the cover of the compensating tank.
Finishing work
– Install the front side cover. (
p. 109)
18
ENGINE TUNING
18.1
"Drive Mode"
166
Possible states
• Sport – Homologated performance with very direct response; the traction control allows
greater slip on the rear wheel
• Street – Homologated performance with very direct response; the traction control
allows normal slip on the rear wheel
• RAIN – Reduced homologated performance for better ridability; the traction control
allows normal slip on the rear wheel
• Offroad – Reduced homologated performance for better ridability; the traction control
allows high slip on the rear wheel
401829-01
Various vehicle tunings can be selected in the "Drive Mode" menu. You can choose from
"SPORT", "STREET", "RAIN" and "OFFROAD".
The drive mode selected last is displayed on the right in the segment display.
Info
The drive mode selection has no influence on the ABS.
18.2
MTC/motorcycle traction control
The traction control lowers the tightening torque in case of loss of traction in the rear
wheel. Depending on the traction control setting, a slight slip on the rear wheel may be
desirable. Example: Offroad.
Info
When traction control is switched off, the rear wheel may spin during high acceleration and on surfaces with low grip.
After the ignition is switched back on, traction control is enabled again.
401837-01
Traction control is controlled via the "Drive Mode" ( p. 166) menu on the combination
instrument. Traction control can be switched off in the "MTC/ABS" menu.
18
ENGINE TUNING
167
Info
When traction control is active, the TC lamp flashes.
When traction control is switched off, the TC lamp is lit.
19
SERVICE WORK ON THE ENGINE
19.1
Checking the engine oil level
168
Info
Oil consumption depends on the riding style and the operating conditions.
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
Main work
– Check the engine oil level in the engine oil level viewer.
Info
After switching off the engine, wait one minute before checking the level.
The engine oil level should be in the upper area B of the engine oil level viewer.
»
401696-11
When the engine oil level is in area A of the engine oil level viewer:
–
»
When the engine oil level is in area B of the engine oil level viewer:
–
»
Do not add engine oil.
Engine oil can be added.
When the engine oil level is in area C of the engine oil level viewer:
–
Add engine oil. (
p. 173)
19
SERVICE WORK ON THE ENGINE
19.2
Changing the engine oil and filter, cleaning the oil screens
169
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.
Preparatory work
– Remove the engine guard.
x
Main work
– Stand the motorcycle on its side stand on a horizontal surface.
S00333-10
–
Place a suitable container under the engine.
–
Remove oil drain plugs 1 with the magnet, O-rings, and oil screen.
19
SERVICE WORK ON THE ENGINE
–
Remove screws 2. Remove the oil filter cover 3 with the O-ring.
–
Pull oil filter 4 out of the oil filter housing.
S00334-10
Circlip pliers reverse (51012011000)
–
Completely drain the engine oil.
–
Thoroughly clean the parts and sealing surface.
–
Insert oil filter 4.
–
Lubricate the O-ring of the oil filter cover. Mount the oil filter cover 3.
S00335-10
S00336-10
170
19
SERVICE WORK ON THE ENGINE
–
171
Mount and tighten screws 2.
Guideline
Remaining engine screws
M5
6 Nm (4.4 lbf ft)
S00334-11
–
Thoroughly clean magnet A and oil screen B of the oil drain plugs.
100773-12
–
Mount and tighten oil drain plugs 1 with the magnet, O-rings, and oil screen.
Guideline
Oil drain plug
S00333-10
M20x1.5
20 Nm
(14.8 lbf ft)
19
SERVICE WORK ON THE ENGINE
–
The oil must be added in two steps.
Engine oil
–
S00330-11
3.60 l (3.8 qt.)
Outside
temperature:
≥ 0 °C (≥ 32 °F)
Engine oil
(SAE 10W/50)
( p. 198)
Outside
temperature:
< 0 °C (< 32 °F)
Engine oil (SAE
5W/40) ( p. 198)
Outside
temperature:
≥ 0 °C (≥ 32 °F)
Engine oil
(SAE 10W/50)
( p. 198)
Outside
temperature:
< 0 °C (< 32 °F)
Engine oil (SAE
5W/40) ( p. 198)
Remove screw plug 5 and fill in engine oil.
Engine oil (1st
quantity) approx.
–
172
3.0 l (3.2 qt.)
Mount screw plug 5.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in
unconsciousness and/or death.
–
–
When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
Start the engine and check that it is oil-tight.
19
SERVICE WORK ON THE ENGINE
173
–
Remove the screw plug and add the remaining engine oil to the upper marking A on
the engine oil level viewer.
–
Mount the screw plug.
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in
unconsciousness and/or death.
–
S00329-10
–
When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
Start the engine and check that it is oil-tight.
Finishing work
– Check the engine oil level. (
–
19.3
Install the engine guard.
p. 168)
x
Adding engine oil
Info
Too little engine oil or poor-quality engine oil results in premature wear to the engine.
The engine may be damaged if the engine oil level is too high.
Condition
The engine is at operating temperature.
Preparatory work
– Stand the motorcycle upright on a horizontal surface.
–
Check the engine oil level. (
p. 168)
19
SERVICE WORK ON THE ENGINE
174
Main work
– Remove screw plug 1.
S00330-10
–
Add engine oil to the upper marking A on the engine oil level viewer.
Condition
Outside temperature: ≥ 0 °C (≥ 32 °F)
Engine oil (SAE 10W/50) (
p. 198)
Condition
Outside temperature: < 0 °C (< 32 °F)
Engine oil (SAE 5W/40) (
S00329-10
p. 198)
Info
In order to achieve optimal engine performance, it is not advisable to mix different engine oils.
KTM recommends changing the engine oil.
–
Mount the screw plug.
19
SERVICE WORK ON THE ENGINE
175
Danger
Danger of poisoning Exhaust gases are toxic and inhaling them may result in
unconsciousness and/or death.
–
–
When running the engine, always make sure there is sufficient ventilation,
and do not start or run the engine in an enclosed space without an effective
exhaust extraction system.
Start the engine and check that it is oil-tight.
Finishing work
– Check the engine oil level. (
p. 168)
20
CLEANING, CARE
20.1
Cleaning motorcycle
176
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 brush.
Motorcycle cleaner (
p. 202)
Info
401061-01
Use warm water containing normal motorcycle cleaner and a soft sponge.
Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with
water first.
If the vehicle was operated in road salt, clean it with cold water. Warm water
would enhance the corrosive effects of salt.
20
CLEANING, CARE
177
–
After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.
–
Remove the closure of the exhaust system.
Warning
Danger of accidents Reduced braking efficiency due to a wet or dirty brake system.
–
–
Clean or dry a dirty or wet brake system by riding and braking gently.
After cleaning, ride the vehicle a short distance until the engine warms up.
Info
The heat produced causes water at inaccessible locations in the engine and on
the brake system to evaporate.
–
Push back the protection caps of the handlebar controls to allow any water that has
penetrated to evaporate.
–
After the motorcycle has cooled off, lubricate all moving parts and bearings.
–
Clean the chain. (
–
Treat bare metal parts (except for brake discs and exhaust system) with corrosion
inhibitor.
p. 98)
Cleaning and preserving materials for metal, rubber and plastic (
–
Treat the painted parts with a mild paint polish.
High-luster polish for paint (
–
p. 201)
p. 202)
Treat the 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)
–
Oil the ignition/steering lock, tank lock, and seat lock.
20
CLEANING, CARE
178
Universal oil spray (
20.2
p. 203)
Checks and maintenance steps for winter operation
Info
If you use the motorcycle in winter, you must expect salt on the roads. You should therefore take precautions against aggressive
road salt.
If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of
salt.
–
Clean the motorcycle. (
–
Clean the brakes.
p. 176)
Info
After EVERY trip on salted roads, thoroughly wash the brake calipers and brake
linings with cold water and dry carefully. This should be done after the parts are
cooled down and while they are installed.
After riding on salted roads, thoroughly wash the motorcycle with cold water and
dry it well.
401060-01
–
Treat the engine, the swingarm, and all other bare or galvanized parts (except brake
discs) with a wax-based corrosion inhibitor.
Info
Corrosion inhibitor must not come into contact with the brake discs. This would
severely lower the braking effect.
–
Clean the chain. (
p. 98)
21
STORAGE
21.1
Storage
179
Info
If you plan to garage the motorcycle for a longer period, perform the following steps or have them performed.
Before storing the motorcycle, check all parts for function and wear. If service, repairs or replacements are necessary, you should
do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the
new season.
–
When refueling for the last time before taking the motorcycle out of service, add fuel
additive.
Fuel additive (
401058-01
p. 201)
–
Clean the motorcycle. (
–
Change the engine oil and filter, clean the oil screens.
–
Check the coolant fill level and antifreeze.
–
Check the tire air pressure. (
–
Remove the battery.
p. 176)
x(
x(
p. 169)
x
p. 142)
p. 145)
Guideline
Storage temperature of battery without
direct sunshine
0… 35 °C (32… 95 °F)
–
Recharge the battery.
–
Store the vehicle in a dry location that is not subject to large fluctuations in temperature.
–
Raise the vehicle with the center stand. (
–
Cover the vehicle with a tarp or similar cover that is permeable to air.
x(
p. 148)
p. 95)
21
STORAGE
180
Info
Do not use non-porous materials since they prevent humidity from escaping,
thus causing corrosion.
Avoid running the engine for a short time only. Since the engine cannot warm
up properly, the water vapor produced during combustion condenses and causes
valves and the exhaust system to rust.
21.2
Preparing for use after storage
–
Remove the vehicle from the center stand. (
–
Recharge the battery.
–
Install the battery.
p. 95)
x ( p. 148)
x ( p. 147)
Info
If the battery was disconnected, the time and date must be set.
401059-01
–
Refuel. (
–
Perform checks and maintenance measures when preparing for use. (
–
Take a test ride.
p. 81)
p. 71)
22
TROUBLESHOOTING
181
Faults
Possible cause
Action
Combination instrument shows nothing
on the display
Fuse 1 blown
–
Engine does not crank when the electric starter button is pressed
Change the fuses in the fuse box. (
p. 154)
Main fuse burned out
–
Change the main fuse. (
Battery discharged
–
Recharge the battery.
–
Check the quiescent current.
Ignition/steering lock is faulty
–
Check the ignition/steering lock.
Emergency OFF switch is off
–
Press the emergency OFF switch to the position ON .
Operating error
–
Carry out the start procedure. (
Battery discharged
–
Recharge the battery.
–
Check the quiescent current.
–
Read out the fault memory using the KTM diagnostics tool.
Safety start system is faulty
p. 152)
x(
x(
p. 148)
x
x
p. 72)
p. 148)
x
x
Engine turns only if the clutch lever is
drawn
Engine turns although a gear is
engaged
ICU is not enabled
–
Activate the ICU.
CAN bus communication error
–
Read out the fault memory using the KTM diagnostics tool.
Fault in EFI control unit.
–
Read out the fault memory using the KTM diagnostics tool.
Fault in MCU control unit.
–
The vehicle is in gear
–
Shift the transmission to idle
Safety start system is faulty
–
Read out the fault memory using the KTM diagnostics tool.
Safety start system is faulty
–
x
x
x
Read out the fault memory using the KTM diagnostics tool. x
.
x
Read out the fault memory using the KTM diagnostics tool. x
22
TROUBLESHOOTING
182
Faults
Possible cause
Action
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
Engine dies during the trip
Fuel quality is insufficient
–
Add suitable fuel.
Lack of fuel
–
Refuel. (
Defect in fuel injection system
–
Read out the fault memory using the KTM diagnostics tool.
p. 81)
The engine warning lamp lights
up/flashes
Defect in fuel injection system
–
x
Read out the fault memory using the KTM diagnostics tool. x
The ABS warning lamp lights up
ABS fuse is blown
–
Change the fuses in the fuse box. (
Wheel speeds of front and rear wheels
differ greatly
–
Stop, switch off the ignition, start again.
Malfunction in ABS
–
Read out the fault memory using the KTM diagnostics tool.
Engine oil level too high
–
Check the engine oil level. (
Engine oil too thin (low viscosity)
–
Change the engine oil and filter, clean the oil
screens.
( p. 169)
A power consumer is connected to the
socket/ACC1.
–
Disconnect the power consumer from the
socket/ACC1.
The hazard warning flasher is switched
on
–
Battery is not charged by alternator
–
Ignition not switched off when vehicle
was parked
–
p. 154)
x
High oil consumption
p. 168)
x
The battery is discharged
–
–
Recharge the battery.
x ( p. 148)
Recharge the battery. x ( p. 148)
Check the charging voltage. x
Recharge the battery. x ( p. 148)
Switch off the hazard warning flasher.
23
TECHNICAL DATA
23.1
Engine
183
Design
2-cylinder 4-stroke Otto engine, 75° V arrangement, water-cooled
Displacement
1,195 cm³ (72.92 cu in)
Stroke
69 mm (2.72 in)
Bore
105 mm (4.13 in)
Compression ratio
12.5:1
Idle speed
1,300… 1,500 rpm
Control
DOHC, 4 valves per cylinder, chain-driven
Valve - valve stem diameter
Intake
42 mm (1.65 in)
Exhaust
34 mm (1.34 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 upper compression (rectangular) ring, 1 lower compression ring,
1 oil scraper ring
Engine lubrication
Dry sump lubrication system with three rotor pumps
Primary transmission
40:76
Clutch
Antihopping clutch in oil bath/hydraulically operated
Transmission
6-speed claw gears
Transmission ratio
23
TECHNICAL DATA
184
1st gear
12:35
2nd gear
15:32
3rd gear
18:30
4th gear
20:27
5th gear
24:27
6th gear
27:26
Mixture preparation
Electronically controlled fuel injection
Ignition system
Contactless controlled fully electronic ignition with digital ignition
adjustment
Alternator
12 V, 450 W
Spark plug
Inside spark plug
NGK LKAR9BI9
Outside spark plug
NGK LMAR7A-9
Electrode gap, spark plug
0.8… 0.9 mm (0.031… 0.035 in)
Cooling
Water cooling, permanent circulation of coolant by water pump
Cold start device
Electric starter
23.2
Engine tightening torques
Screw, retaining bracket, valve cover,
rear
EJOT Altracs M6x10
10 Nm (7.4 lbf ft)
–
Hose clip, intake flange
M4
1.5 Nm (1.11 lbf ft)
–
Remaining engine screws
M5
6 Nm (4.4 lbf ft)
–
Screw, bearing retainer
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, bearing shell retaining bracket
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, engine oil level viewer
M5
4 Nm (3 lbf ft)
–
23
TECHNICAL DATA
185
Screw, gear sensor
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, pulse generator
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Bleeder screw, water pump cover
M6
10 Nm (7.4 lbf ft)
–
Freewheel ring bolt
M6 – 10.9
15 Nm (11.1 lbf ft)
Loctite® 648™
Nut, cylinder head
M6
9 Nm (6.6 lbf ft)
–
Plug, vacuum connection
M6
5 Nm (3.7 lbf ft)
Loctite® 243™
Remaining engine screws
M6
10 Nm (7.4 lbf ft)
–
Screw, camshaft bearing support
M6 – 10.9
10 Nm (7.4 lbf ft)
–
Screw, clutch cover
M6
10 Nm (7.4 lbf ft)
–
Screw, clutch spring
M6
12 Nm (8.9 lbf ft)
–
Screw, coolant connection on cylinder
head
M6
10 Nm (7.4 lbf ft)
–
Screw, damping plate
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, engine case
M6x60
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6x80
10 Nm (7.4 lbf ft)
–
Screw, engine case
M6x90
10 Nm (7.4 lbf ft)
–
Screw, freewheel holder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, locking lever
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, oil pump cover
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
18 Nm (13.3 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)
–
23
TECHNICAL DATA
186
Screw, water pump cover
M6
10 Nm (7.4 lbf ft)
–
Screw, water pump wheel
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Stud, chain shaft
M6
8 Nm (5.9 lbf ft)
–
Vacuum connection
M6
2.5 Nm (1.84 lbf ft)
Loctite® 243™
Nozzle 100
M6x0.75
4 Nm (3 lbf ft)
Loctite® 243™
Oil nozzle
M6x0.75
4 Nm (3 lbf ft)
Loctite® 243™
Plug, crankshaft retainer
M8
15 Nm (11.1 lbf ft)
–
Screw, camshaft bearing support
M8 – 10.9
Step 1
10 Nm (7.4 lbf ft)
Step 2
18 Nm (13.3 lbf ft)
–
Screw, engine case
M8
18 Nm (13.3 lbf ft)
–
Screw, engine console
M8
20 Nm (14.8 lbf ft)
Loctite® 243™
Screw, timing chain guide rail
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Screw, timing chain tensioning rail
M8
15 Nm (11.1 lbf ft)
Loctite® 243™
Stud, exhaust flange
M8
10 Nm (7.4 lbf ft)
–
Oil pressure sensor
M10x1
10 Nm (7.4 lbf ft)
–
Plug, cam lever axis
M10x1
15 Nm (11.1 lbf ft)
–
Plug, clutch lubrication
M10x1
12 Nm (8.9 lbf ft)
–
Screw, conrod bearing
M10x1
Step 1
25 Nm (18.4 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
–
Screw, timing chain tensioner release
M10x1
10 Nm (7.4 lbf ft)
–
23
TECHNICAL DATA
187
Spark plug
M10x1
15 Nm (11.1 lbf ft)
–
Cylinder head screw
M11x1.5
Tightening sequence:
Using a crisscross pattern
Step 1
15 Nm (11.1 lbf ft)
Step 2
30 Nm (22.1 lbf ft)
Step 3
90°
Step 4
90°
Lubricated with engine oil
Coolant temperature sensor
M12x1.5
12 Nm (8.9 lbf ft)
–
Rotor screw
M12x1.5
90 Nm (66.4 lbf ft)
–
Spark plug
M12x1.5
15 Nm (11.1 lbf ft)
–
Nut of engine sprocket
M20x1.5
100 Nm (73.8 lbf ft)
Loctite® 243™
Oil drain plug
M20x1.5
20 Nm (14.8 lbf ft)
–
Nut, inner clutch hub
M22x1.5
130 Nm (95.9 lbf ft)
Loctite® 243™
Plug, timing-chain tensioner
M24x1.5
25 Nm (18.4 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
3.60 l (3.8 qt.)
Outside temperature: ≥ 0 °C
(≥ 32 °F)
Engine oil (SAE 10W/50)
( p. 198)
23
TECHNICAL DATA
Engine oil
23.3.2
3.60 l (3.8 qt.)
188
Outside temperature: < 0 °C
(< 32 °F)
Coolant
Coolant
2.40 l (2.54 qt.)
Coolant (
p. 197)
Coolant (mixed ready to use) (
23.3.3
p. 197)
Fuel
Total fuel tank capacity, approx.
Fuel reserve, approx.
23.4
Engine oil (SAE 5W/40)
( p. 198)
23 l (6.1 US gal)
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 4860 MXTA SPLIT
Shock absorber
WP Suspension 4618 BAVP DCC PA
Suspension travel
Front
220 mm (8.66 in)
Rear
220 mm (8.66 in)
Brake system
Front
Double disc brake with radially mounted four-pot brake calipers,
floating brake discs
Rear
Single disc brake with dual-piston brake caliper, floating brake
disc
23
TECHNICAL DATA
189
Brake discs - diameter
Front
320 mm (12.6 in)
Rear
267 mm (10.51 in)
Brake discs - wear limit
Front
4 mm (0.16 in)
Rear
4.5 mm (0.177 in)
Tire air pressure, solo/with passenger/full payload
Front: with cold tires
2.4 bar (35 psi)
Rear: with cold tires
2.9 bar (42 psi)
Secondary drive ratio
17:42
Chain
5/8 x 5/16” (525) X‑ring
Steering head angle
64°
Wheelbase
1,580 mm (62.2 in)
Seat height, unloaded
890 mm (35.04 in)
Ground clearance, unloaded
250 mm (9.84 in)
Weight without fuel, approx.
217 kg (478 lb.)
Maximum permissible front axle load
159 kg (351 lb.)
Maximum permissible rear axle load
281 kg (619 lb.)
Maximum permissible total weight
440 kg (970 lb.)
23.5
Electrical system
Battery
YTZ14S
Battery voltage: 12 V
Nominal capacity: 11.2 Ah
maintenance-free
Fuse
58011109110
10 A
23
TECHNICAL DATA
190
Fuse
58011109125
25 A
Fuse
58011109130
30 A
Fuse
58011109140
40 A
Low beam
H11/socket PGJ19-2
12 V
55 W
High beam
H11/socket PGJ19-2
12 V
55 W
Parking light
LED
Instrument lights and indicator lamps
LED
Turn signal
LED
Tail light
LED
Brake light
LED
License plate lamp
LED
23.6
Tires
Front tires
Rear tires
90/90 V 21 M/C (54V) TL
Continental ContiTrailATTACK 2
150/70 ZR 18 M/C 70W TL
Continental ContiTrailATTACK 2
Additional information is available in the Service section under:
http://www.ktm.com
23.7
Fork
Fork part number
14.18.8M.25
Fork
WP Suspension 4860 MXTA SPLIT
Compression damping
23
TECHNICAL DATA
191
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Full payload
7 clicks
Rebound damping
Comfort
17 clicks
Standard
12 clicks
Sport
7 clicks
Full payload
7 clicks
Spring preload - Preload Adjuster
Comfort
2 turns
Standard
5 turns
Sport
5 turns
Full payload
8 turns
Spring length with preload spacer(s)
475 mm (18.7 in)
Spring rate
Medium (standard)
5.5 N/mm (31.4 lb/in)
Fork length
915 mm (36.02 in)
Air chamber length
+0.98
95+25
−15 mm (3.74−0.59 in)
Fork oil per fork leg
720 ml (24.34 fl. oz.)
Fork oil (SAE 4) (48601166S1) (
p. 199)
23
TECHNICAL DATA
23.8
Shock absorber
192
Shock absorber part number
15.18.7M.25
Shock absorber
WP Suspension 4618 BAVP DCC PA
Compression damping, low-speed
Comfort
15 clicks
Standard
10 clicks
Sport
8 clicks
Full payload
8 clicks
Compression damping, high-speed
Comfort
1.5 turns
Standard
1.5 turns
Sport
1 turn
Full payload
1 turn
Rebound damping
Comfort
15 clicks
Standard
10 clicks
Sport
8 clicks
Full payload
8 clicks
Spring preload
Comfort
4 turns
Standard
4 turns
Sport
4 turns
Full payload
16 turns
Spring rate
23
TECHNICAL DATA
193
Medium (standard)
170 N/mm (971 lb/in)
Spring length
205 mm (8.07 in)
Gas pressure
10 bar (145 psi)
Riding sag
55 mm (2.17 in)
Static sag
25 mm (0.98 in)
Fitted length
406 mm (15.98 in)
Shock absorber oil (
23.9
p. 199)
SAE 2.5
Chassis tightening torques
Screw, combination switch, left
M4
2 Nm (1.5 lbf ft)
–
Screw, side stand switch
M4
2 Nm (1.5 lbf ft)
–
Remaining screws, chassis
M5
5 Nm (3.7 lbf ft)
–
Screw, brake line holder on swingarm
M5
5 Nm (3.7 lbf ft)
–
Screw, cable channel
M5
5 Nm (3.7 lbf ft)
–
Screw, cable guide, wheel speed sensor,
rear
M5
3 Nm (2.2 lbf ft)
–
Screw, chain sliding guard
M5
5 Nm (3.7 lbf ft)
–
Screw, combination switch, right
M5
3.5 Nm (2.58 lbf ft)
–
Screw, cover part
M5x12
3.5 Nm (2.58 lbf ft)
–
Screw, filler cap
M5
5 Nm (3.7 lbf ft)
–
Screw, foot brake lever stub
M5
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, fuel level indicator
M5
3 Nm (2.2 lbf ft)
–
Screw, heat guard on main silencer
M5
4 Nm (3 lbf ft)
–
Screw, wind shield
M5
3.5 Nm (2.58 lbf ft)
–
23
TECHNICAL DATA
Spoke nipple
194
M5
4… 6 Nm (3… 4.4 lbf ft)
–
Ground fitting on frame
M6
6 Nm (4.4 lbf ft)
–
Nut, ABS unit fixation
M6
8 Nm (5.9 lbf ft)
–
Remaining chassis nuts
M6
10 Nm (7.4 lbf ft)
–
Remaining chassis screws
M6
10 Nm (7.4 lbf ft)
–
Screw, battery terminal
M6
4.5 Nm (3.32 lbf ft)
–
Screw, brake line holder on bottom
triple clamp
M6
8 Nm (5.9 lbf ft)
Loctite® 243™
Screw, cable channel
M6
5 Nm (3.7 lbf ft)
–
Screw, chain guide
M6
5 Nm (3.7 lbf ft)
Loctite® 243™
Screw, clutch assembly
M6
5 Nm (3.7 lbf ft)
–
Screw, cooler retaining bracket
M6
7 Nm (5.2 lbf ft)
–
Screw, cover part
M6
6 Nm (4.4 lbf ft)
–
Screw, engine guard
M6
10 Nm (7.4 lbf ft)
–
Screw, foot brake cylinder
M6
10 Nm (7.4 lbf ft)
Loctite® 243™
Screw, front brake disc
M6
14 Nm (10.3 lbf ft)
Loctite® 243™
Screw, fuel pump
M6
6 Nm (4.4 lbf ft)
–
Screw, fuel tank
M6
10 Nm (7.4 lbf ft)
–
Screw, fuel tap
M6
6 Nm (4.4 lbf ft)
–
Screw, lower rear part
M6
6 Nm (4.4 lbf ft)
–
Screw, magnetic holder on side stand
M6
6 Nm (4.4 lbf ft)
Loctite® 243™
Screw, manifold holder
M6
12 Nm (8.9 lbf ft)
Loctite® 243™
Screw, rear brake disc
M6
14 Nm (10.3 lbf ft)
Loctite® 243™
Screw, voltage regulator
M6
6 Nm (4.4 lbf ft)
–
Screw, wheel speed sensor, front
M6
10 Nm (7.4 lbf ft)
–
23
TECHNICAL DATA
195
Screw, wheel speed sensor, rear
M6
10 Nm (7.4 lbf ft)
–
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
12 Nm (8.9 lbf ft)
–
Screw, exhaust clamp
M8
12 Nm (8.9 lbf ft)
–
Screw, foot brake lever
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, fork stub
M8
15 Nm (11.1 lbf ft)
–
Screw, front footrest bracket
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, handlebar clamp
M8
20 Nm (14.8 lbf ft)
–
Screw, ignition lock (tamper-proof
screw)
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, rear footrest bracket
M8
25 Nm (18.4 lbf ft)
Loctite® 243™
Screw, steering damper clamp
M8
12 Nm (8.9 lbf ft)
–
Screw, suitcase hook
M8
20 Nm (14.8 lbf ft)
–
Screw, top triple clamp
M8
15 Nm (11.1 lbf ft)
–
Engine carrying screw
M10
45 Nm (33.2 lbf ft)
–
Remaining chassis nuts
M10
45 Nm (33.2 lbf ft)
–
Remaining chassis screws
M10
45 Nm (33.2 lbf ft)
–
Screw, front brake caliper
M10
45 Nm (33.2 lbf ft)
Loctite® 243™
Screw, handlebar support
M10
40 Nm (29.5 lbf ft)
Loctite® 243™
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
25 Nm (18.4 lbf ft)
–
Nut, tire pressure sensor
M10x1
12 Nm (8.9 lbf ft)
–
23
TECHNICAL DATA
196
Screw, subframe
M10x1.25
45 Nm (33.2 lbf ft)
Loctite® 243™
Lambda sensor
M12x1.25
25 Nm (18.4 lbf ft)
–
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, socket
M18x1
4 Nm (3 lbf ft)
–
Nut, swingarm pivot
M19x1.5
130 Nm (95.9 lbf ft)
Thread greased
Screw, steering head, top
M22x1.5
50 Nm (36.9 lbf ft)
–
Nut, rear wheel spindle
M25x1.5
90 Nm (66.4 lbf ft)
Thread greased
Screw, front wheel spindle
M25x1.5
45 Nm (33.2 lbf ft)
–
Nut, steering head, top
M28x1.0
12 Nm (8.9 lbf ft)
–
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
205
INDEX
C
A
ABS . . . . . . . . . . . .
Accessories . . . . . . .
Antilock brake system
Auxiliary substances .
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121
. 14
121
. 14
B
Battery
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Brake discs
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Brake fluid
front brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
rear brake, adding . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Brake fluid level
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 123
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Brake linings
front brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . 126
rear brake, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-130
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Brakes, applying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Capacity
coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
engine oil . . . . . . . . . . . . . . . . . . . . . . . . . 172, 187-188
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82, 188
Center stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chain
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
checking for dirt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Chain tension
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Chassis number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Clutch
fluid level, checking/rectifying . . . . . . . . . . . . . . . . . . . 105
Clutch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Combination instrument . . . . . . . . . . . . . . . . . . . . . . . . . 39-56
"ABS" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Activation and test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
"Clock/Date" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
"Distance" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
"Drive Mode" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49, 166
"DRL" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
"Favorites" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
"Fuel Cons" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INDEX
"General Info" . . . . . . . . . . . .
"Heat Grip" menu . . . . . . . . . .
"Heat Grips" . . . . . . . . . . . . .
Indicator lamps . . . . . . . . . .
"Language" . . . . . . . . . . . . . .
matrix display . . . . . . . . . . .
menu overview . . . . . . . . . . .
Message on the matrix display
"MTC" . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . .
"Pressure" . . . . . . . . . . . . . .
"Quick Shift" . . . . . . . . . . . . .
Segment display . . . . . . . . . .
service display . . . . . . . . . . .
"Set Favorites" . . . . . . . . . . . .
"Settings" . . . . . . . . . . . . . . .
shift warning light . . . . . . . . .
"Shift Light" . . . . . . . . . . . . .
"Temp" . . . . . . . . . . . . . . . .
"TPMS" . . . . . . . . . . . . . . . .
"Trip 1" . . . . . . . . . . . . . . . .
"Trip 2" . . . . . . . . . . . . . . . .
"Volume" . . . . . . . . . . . . . . .
"Warnings" . . . . . . . . . . . . . .
206
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.
. 46
. 48
. 56
. 41
. 51
. 40
. 50
. 42
. 49
. 39
. 53
. 56
. 40
. 44
. 47
. 47
. 43
. 55
. 52
. 46
. 45
. 45
. 53
. 48
compensating tank, correcting . . . . . . . . . . . . . . . . . . . 164
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E
Electric starter button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Emergency OFF switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine
running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine oil
adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Engine oil level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Engine sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Filler cap
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Combination switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Foot brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 63
Coolant level
compensating tank, checking . . . . . . . . . . . . . . . . . . . . 163
Footrests
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
INDEX
207
Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
compression damping, adjusting . . . . . . . . . . . . . . . . . . . 87
rebound, adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 89
Fork part number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Front fender, front
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Front wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fuel cocks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fuses
in fuse box, changing . . . . . . . . . . . . . . . . . . . . . . . . . 154
G
Grab handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
H
Hand brake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 60
Handlebar position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hazard warning flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hazard warning flasher switch . . . . . . . . . . . . . . . . . . . . . . . . 25
Headlight
daytime running light . . . . . . . . . . . . . . . . . . . . . . . . . 145
headlight range, adjusting . . . . . . . . . . . . . . . . . . . . . . 162
Headlight mask with headlight
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Headlight setting
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
High beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Horn button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
I
Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
immobilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
K
Key number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
L
Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Low beam bulb
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Luggage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Luggage rack plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
M
Main fuse
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Mask spoiler
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
INDEX
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Matrix display
menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
208
Rear sprocket
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Motorcycle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Rear wheel
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Motorcycle traction control . . . . . . . . . . . . . . . . . . . . . . . . . 166
MTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Refueling
fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
O
Rider footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil filter
changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Riding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
starting off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
S
Oil screens
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Owner's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Seat
mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
P
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Passenger footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Preparing for use
advice on first use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
after storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
checks and maintenance measures when preparing for use . 71
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
R
Rear hub rubber dampers
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Seat lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-86
Shift lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
basic position, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 65
basic position, checking . . . . . . . . . . . . . . . . . . . . . . . . 65
Shifting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
compression damping . . . . . . . . . . . . . . . . . . . . . . . . . . 90
compression damping, high-speed, adjusting . . . . . . . . . . 91
compression damping, low-speed, adjusting . . . . . . . . . . . 90
INDEX
rebound damping, adjusting . . . . . . . . . . . . . . . . . . . . . . 92
spring preload, adjusting . . . . . . . . . . . . . . . . . . . . . . . . 93
Shock absorber part number . . . . . . . . . . . . . . . . . . . . . . . . . 22
Side cover, front
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Side cover, front,
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Side stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Socket for electrical accessories . . . . . . . . . . . . . . . . . . . . . . 29
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spoke tension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Starting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Steering head bearing play
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Storage compartment
Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Suspension setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-94
Switch
on the left side of the handlebar . . . . . . . . . . . . . . . . . . . 24
on the right side of the handlebar . . . . . . . . . . . . . . . . . . 27
209
T
Tank cover
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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
183-196
. . . . 184
. . . . 190
. . . . 192
. . . . 190
Throttle grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tire air pressure
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Tire condition
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Tool set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Triple clamp cover, bottom
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181-182
Turn signal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Type label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INDEX
210
U
Use definition
...................................9
V
Vehicle
loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
raising with the center stand . . . . . . . . . . . . . . . . . . . . . 95
removing from the center stand . . . . . . . . . . . . . . . . . . . 95
View of vehicle
front left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
rear right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
W
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wind shield
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Winter operation
checks and maintenance steps . . . . . . . . . . . . . . . . . . . 178
Work rules
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
*3211956en*
3211956en
07/2013
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
Photo: Mitterbauer/KTM
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