KTM 450 RALLY Factory Replica 2019 Enduro Bike Owner Manual

KTM 450 RALLY Factory Replica 2019 Enduro Bike Owner Manual

OWNER'S MANUAL 2019 450 RALLY Factory Replica

Art. no. 3213863en

DEAR KTM CUSTOMER

DEAR KTM CUSTOMER Congratulations on your decision to purchase a KTM motorcycle. You are now the owner of a state-of-the-art sports vehicle that will continue giving you pleasure for a long time if you maintain it properly.

We wish you good and safe riding at all times!

Enter the serial numbers of your vehicle below.

Vehicle identification number ( p. 13)

Dealer's stamp

Engine number ( p. 13) Key number ( p. 13)

The Owner's Manual contained the latest information for this model series at the time of going to print. Slight deviations resulting from continuing development and design of the motorcycles can, however, not be completely excluded.

All specifications are non-binding. KTM Sportmotorcycle GmbH specifically reserves the right to modify or delete technical specifications, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery options, deviations from figures and descriptions, misprints, and other errors. The models portrayed partly contain special equipment that does not belong to the regular scope of supply.

© 2018 KTM Sportmotorcycle GmbH, 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.

ISO 9001(12 100 6061) KTM applies quality assurance processes that lead to the highest possible product quality as defined in the ISO 9001 international quality management standard.

Issued by: TÜV Management Service KTM Sportmotorcycle GmbH Stallhofnerstraße 3 5230 Mattighofen, Austria This document is valid for the following models: 450 RALLY Factory Replica (F9399S8)

*3213863en*

3213863en 10/2018

TABLE OF CONTENTS

TABLE OF CONTENTS

1

2

3

4

5

6

MEANS OF REPRESENTATION ...................... 5 1.1

1.2

Symbols used .................................... 5 Formats used..................................... 5

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

SAFETY ADVICE............................................ 6 Use definition – intended use.............. 6 Safety advice..................................... 6 Degrees of risk and symbols ................ 6 Tampering warning............................. 6

Safe operation ................................... 7 Protective clothing ............................. 7

Work rules......................................... 8 Environment...................................... 8 Owner's Manual ................................. 8

IMPORTANT NOTES...................................... 9 3.1

3.2

3.3

3.4

3.5

3.6

Manufacturer and implied warranty...... 9 Fuel, auxiliary substances ................... 9 Spare parts, accessories ..................... 9 Service ............................................. 9 Figures ............................................. 9 Customer service................................ 9

VIEW OF VEHICLE ...................................... 11 4.1

4.2

View of vehicle, front left .................. 11

View of vehicle, rear right side........... 12

SERIAL NUMBERS ..................................... 13 5.1

5.2

5.3

5.4

5.5

5.6

Vehicle identification number............ 13 Type label ....................................... 13 Engine number ................................ 13 Key number..................................... 13

Fork part number ............................. 14 Shock absorber article number .......... 14

CONTROLS................................................. 15 6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.8

6.9

6.10

6.11

6.12

6.13

6.14

6.15

6.16

6.17

6.18

Clutch lever..................................... 15 Hand brake lever.............................. 15 Throttle grip .................................... 15 Kill switch....................................... 15

Light switch .................................... 16 Turn signal switch............................ 16 Horn button..................................... 16 Electric starter button....................... 16

Emergency OFF switch ..................... 17 Overview of indicator lamps .............. 17 Fuel pump switch ............................ 17

Fuel tank ........................................ 18 Opening fuel tank filler caps ............. 18

Closing fuel tank filler caps............... 19

Cold start button.............................. 20 Idle speed adjusting screw................ 20

Shift lever ....................................... 21 Foot brake lever ............................... 21

7

8

9

6.19

6.20

6.21

6.22

6.23

Side stand....................................... 21

Steering lock ................................... 22 Tool set........................................... 22

Locking the steering......................... 23 Unlocking the steering...................... 23

COMBINATION INSTRUMENT ..................... 24 7.1

7.2

7.3

7.4

7.5

7.6

7.7

7.8

7.9

7.10

7.11

7.12

7.13

7.14

7.15

7.16

7.17

7.18

7.19

7.20

7.21

7.22

7.23

7.24

Combination instrument overview ...... 24 Activation and test ........................... 24 Setting kilometers or miles................ 24

Adjusting combination instrument function .......................................... 25

Setting clock ................................... 26 Viewing the lap time......................... 26

Display mode SPEED (speed)............ 27 Display mode SPEED/H (operating hours) ............................................. 27 Setup menu .................................... 27

Adjusting the unit of measurement .... 28

Display mode SPEED/CLK (time) ....... 29 Setting the clock.............................. 29 Display mode SPEED/LAP (lap time) .............................................. 29

Viewing the lap time......................... 30 Display mode SPEED/ODO (odometer) ...................................... 30

Display mode SPEED/TR1 (trip master 1) ........................................ 31 Display mode SPEED/TR2 (trip master 2) ........................................ 31 Setting TR2 (trip master 2)............... 31

Display mode SPEED/A1 (average speed 1) ......................................... 32 Display mode SPEED/A2 (average speed 2) ......................................... 32

Display mode SPEED/S1 (stop watch 1) ......................................... 33 Display mode SPEED/S2 (stop watch 2) ......................................... 33

Table of functions ............................ 34

Table of conditions and menu activation ........................................ 35

PREPARING FOR USE................................. 36 8.1

8.2

Advice on preparing for first use ........ 36

Running in the engine ...................... 37

RIDING INSTRUCTIONS.............................. 38 9.1

9.2

9.3

9.4

9.5

9.6

Checks and maintenance when preparing for use.............................. 38 Starting........................................... 38

Starting off...................................... 39 Shifting, riding ................................ 39

Braking ........................................... 40 Stopping, parking............................. 40

2

TABLE OF CONTENTS

9.7

9.8

Transporting .................................... 41 Refueling ........................................ 41

10 SERVICE SCHEDULE .................................. 43 10.1

10.2

Service schedule.............................. 43

Service work (as additional order) ...... 44

11 TUNING THE CHASSIS ............................... 45 11.1

11.2

11.3

Checking basic chassis setting with rider's weight................................... 45 Compression damping of the shock absorber.......................................... 45 Adjusting the low-speed compression damping of the shock absorber.......................................... 45

11.4

11.5

11.6

11.7

11.8

Adjusting the high-speed compression damping of the shock absorber.......................................... 46

Adjusting the rebound damping of the shock absorber........................... 47 Measuring the unloaded rear wheel sag ................................................. 47

Checking static sag of the shock absorber.......................................... 48 Checking riding sag of the shock absorber.......................................... 48

11.9

Adjusting the spring preload of the shock absorber ............................. 49

11.10 Adjusting the riding sag ................ 50

11.11 Checking the basic setting of the fork ................................................ 51 11.12 Adjusting the compression damping of the fork ....................................... 51 11.13 Adjusting the rebound damping of the fork........................................... 51

11.14 Handlebar position........................... 52 11.15 Adjusting the handlebar position .... 52

12 SERVICE WORK ON THE CHASSIS............... 55 12.1

12.2

12.3

12.4

Raising the motorcycle with a lift stand .............................................. 55 Removing motorcycle from lift stand .............................................. 55 Bleeding the fork legs....................... 55

Cleaning the dust boots of the fork legs ................................................ 56 Removing fork protector.................... 56 12.5

12.6

12.7

12.8

Installing the fork protector............... 57 Removing fork legs

Installing the fork legs

....................... 57

.................. 58 12.9

Removing lower triple clamp .......... 58

12.10 Installing the lower triple clamp ..... 60

12.11 Checking steering head bearing play ................................................ 62 12.12 Adjusting steering head bearing play ............................................ 62

12.13 Greasing the steering head bearing ........................................ 64 12.14 Removing shock absorber .............. 64

12.15 Installing the shock absorber

12.20 Removing air filter

box

12.22 Installing the air filter

12.26 Removing front left fuel tank

......... 65

12.16 Removing front fender ...................... 66 12.17 Installing the front fender ................. 66

12.18 Removing the seat ........................... 67 12.19 Mounting the seat ............................ 67 ........................ 67

12.21 Cleaning the air filter and air filter ............................................. 68

................... 69 12.23 Removing main silencer.................... 69

12.24 Installing the main silencer............... 70 12.25 Changing the glass fiber yarn filling of the main silencer ...................... 70

......... 71

12.27 Removing front right fuel tank

12.28 Installing the front left fuel tank

....... 72

.... 73

12.29 Installing the front right fuel tank ............................................ 74

12.30 Checking the chain for dirt accumulation................................... 75 12.31 Cleaning the chain ........................... 75

12.32 Checking chain tension..................... 76 12.33 Adjusting the chain tension............... 76

12.34 Checking chain, rear sprocket, engine sprocket, and chain guide ...... 77

12.35 Checking frame ............................ 79

12.36 Checking swingarm ....................... 80 12.37 Checking throttle cable routing.......... 80

12.38 Checking the rubber grip .................. 81 12.39 Adjusting the basic position of the clutch lever ..................................... 81 12.40 Checking/correcting the fluid level of the hydraulic clutch ......................... 81

12.41 Changing the hydraulic clutch fluid ............................................ 83

12.42 Removing side cover......................... 84

12.43 Mounting side cover ......................... 85

12.44 Removing front fairing ...................... 86 12.45 Mounting front fairing....................... 86 12.46 Removing engine guard .................... 86

12.47 Installing the engine guard ............... 87

13 BRAKE SYSTEM ......................................... 88 13.1

13.2

13.3

13.4

13.5

13.6

13.7

Adjusting the basic position of the hand brake lever .............................. 88 Checking brake discs........................ 88

Checking front brake fluid level ......... 89 Adding front brake fluid ................ 89

Checking the front brake linings ........ 90

Changing front brake linings .......... 91

Checking the free travel of the foot brake lever ...................................... 93

3

TABLE OF CONTENTS

13.8

Adjusting the free travel of the foot brake lever ................................... 94 13.9

Checking rear brake fluid level .......... 94

13.10 Adding rear brake fluid ................. 95

13.11 Checking the rear brake linings ......... 96 13.12 Changing rear brake linings ........... 96

14 WHEELS, TIRES ......................................... 99 14.1

14.2

14.3

14.4

14.5

14.6

14.7

14.8

Removing front wheel Installing the front wheel ................... 99 .............. 99

Removing rear wheel ................... 100

Installing the rear wheel .............. 102

Checking rear hub damping rubber pieces ....................................... 103 Checking tire condition................... 103

Checking tire pressure .................... 104

Checking spoke tension .................. 105

15 ELECTRICAL SYSTEM ............................... 106 15.1

15.2

15.3

15.4

15.5

Removing 12-V battery ............... 106 Installing the 12-V battery ........... 106

Charging the 12-V battery ........... 107

Changing the main fuse.................. 108

Changing the fuses of individual power consumers ........................... 109

16 COOLING SYSTEM .................................... 111 16.1

16.2

16.3

16.4

16.5

Cooling system .............................. 111 Checking the antifreeze and coolant level .................................. 111

Checking the coolant level .............. 112 Draining the coolant ................... 112

Refilling coolant ......................... 113

17 TUNING THE ENGINE............................... 114 17.1

17.2

17.3

17.4

17.5

Checking throttle cable play............ 114 Adjusting throttle cable play ........ 114

Adjusting the idle speed .............. 115

Checking basic position of the shift lever ............................................. 116 Adjusting the basic position of the shift lever .................................. 116

18 SERVICE WORK ON THE ENGINE .............. 117 18.1

18.2

18.3

Checking the engine oil level........... 117 Changing the engine oil and oil filter, cleaning the oil screens ...... 117

Adding engine oil........................... 121

19 CLEANING, CARE ..................................... 122 19.1

19.2

Cleaning the motorcycle ................. 122

Checks and maintenance steps for winter operation............................. 123

20 STORAGE................................................. 124 20.1

20.2

Storage ......................................... 124

Preparing for use after storage......... 125

21 TROUBLESHOOTING ................................ 126

22 BLINK CODE ............................................ 129

23 TECHNICAL DATA..................................... 130 23.1

23.2

23.3

23.3.1

23.3.2

23.3.3

23.4

23.5

23.6

23.7

23.8

23.9

Engine .......................................... 130

Engine tightening torques ............... 131

Capacities ..................................... 132 Engine oil ................................. 132 Coolant ..................................... 132

Fuel ......................................... 133 Chassis ......................................... 133

Electrical system............................ 134 Tires ............................................. 134 Fork.............................................. 134

Shock absorber .............................. 135

Chassis tightening torques .............. 136

24 WIRING DIAGRAM .................................... 138 24.1

24.2

24.3

24.4

Page 1 of 10 ................................. 138

Page 2 of 10 ................................. 140

Page 3 of 10 ................................. 142

Page 4 of 10 ................................. 144

24.5

24.6

24.7

24.8

Page 5 of 10 ................................. 146

Page 6 of 10 ................................. 148

Page 7 of 10 ................................. 150

Page 8 of 10 ................................. 152

24.9

Page 9 of 10 ................................. 154

24.10 Page 10 of 10 ............................... 156

25 SUBSTANCES .......................................... 158

26 AUXILIARY SUBSTANCES ......................... 160

27 STANDARDS ............................................ 161

28 INDEX OF SPECIAL TERMS ....................... 162

29 LIST OF ABBREVIATIONS.......................... 163

30 LIST OF SYMBOLS.................................... 164 30.1

30.2

30.3

Red symbols.................................. 164 Yellow and orange symbols.............. 164 Green and blue symbols.................. 164

INDEX ............................................................. 165

4

MEANS OF REPRESENTATION 1 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!

Your motorcycle will be optimally cared for there by specially trained experts using the special tools required.

Indicates a page reference (more information is provided on the specified page).

Indicates information with more details or tips.

Indicates the result of a testing step.

Indicates a voltage measurement.

Indicates a current measurement.

Indicates the end of an activity, including potential reworking.

1.2

Formats used

The typographical formats used in this document are explained below.

Proprietary name

Indicates a proprietary name.

Name ® Brand™ Underlined terms

Indicates a protected name.

Indicates a brand available on the open market.

Refer to technical details of the vehicle or indicate technical terms, which are explained in the glossary.

5

2 SAFETY ADVICE 2.1

Use definition

intended use

KTM sport motorcycles are designed and built to withstand the normal stresses and strains of racing. The motor cycles comply with the currently valid regulations and categories of the top international motorsport organizations.

Info

The motorcycle is authorized for public road traffic in the homologated (reduced) version only.

In the derestricted version, the motorcycle must be used only on closed off properties remote from public road traffic.

This motorcycle is designed for use in offroad endurance competition and not primarily for use in motocross.

2.2

Safety advice

A number of safety instructions need to be followed to operate the product described safely. Therefore read this instruction and all further instructions included carefully. The safety instructions are highlighted in the text and are referred to at the relevant passages.

Info

Various information and warning labels are attached in prominent locations on the product described. Do not remove any information or warning labels. If they are missing, you or others may not recognize dangers and may therefore be injured.

2.3

Degrees of risk and symbols Danger

Identifies a danger that will immediately and invariably lead to fatal or serious permanent injury if the appropriate measures are not taken.

Warning

Identifies a danger that is likely to lead to fatal or serious injury if the appropriate measures are not taken.

Caution

Identifies a danger that may lead to minor injuries if the appropriate measures are not taken.

Note

Identifies a danger that will lead to considerable machine and material damage if the appropriate measures are not taken.

Note

Indicates a danger that will lead to environmental damage if the appropriate measures are not taken.

2.4

Tampering warning

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or the causing thereof:

6

SAFETY ADVICE 2

1 The removal or rendering inoperative by any person other than for purposes of servicing, repair, or replace ment, 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: 1 Removal or puncturing of the main silencers, 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 parts of the vehicle, or parts of the exhaust system or intake system, with parts other than those specified by the manufacturer.

2.5

Safe operation Danger Danger of accidents

  A rider who is not fit to ride poses a danger to him or herself and others.

– Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

– Do not operate the vehicle if you are physically or mentally impaired.

Danger Danger of poisoning

  Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

– Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

Warning Danger of burns

  Some vehicle components become very hot when the vehicle is operated.

– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

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.

2.6

Protective clothing Warning Risk of injury

  Missing or poor protective clothing presents an increased safety risk.

– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

In the interest of your own safety, KTM recommends that you only operate the vehicle while wearing suitable pro tective clothing.

7

2 SAFETY ADVICE 2.7

Work rules

Special tools are necessary for certain tasks. The tools are not a component of the vehicle, but can be ordered using the number in parentheses. Example: bearing puller (15112017000) During assembly, use new parts to replace parts which cannot be reused (e.g. self-locking screws and nuts, seals, sealing rings, O-rings, pins, and lock washers).

In the case of certain screws, a screw adhesive (e.g.

Loctite ®

) is required. Observe the manufacturer's instruc tions.

After disassembly, clean the parts that are to be reused and check them for damage and wear. Change damaged or worn parts.

After completing a repair or service work, check the operating safety of the vehicle.

2.8

Environment

If you use your motorcycle responsibly, you can ensure that problems and conflicts do not occur. To protect the future of the motorcycle sport, make sure that you use your motorcycle legally, be environmentally aware, and respect the rights of others.

When disposing of used oil, other operating and auxiliary fluids, and used components, comply with the laws and regulations of the respective country.

Because motorcycles are not subject to the EU regulations governing the disposal of used vehicles, there are no legal regulations that pertain to the disposal of an end-of-life motorcycle. Your authorized KTM dealer will be glad to assist you.

2.9

Owner's Manual

It is important that you read this Owner's Manual carefully and completely before making your first trip. The Own er's Manual contains useful information and many tips on how to operate, handle, and service 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 must be handed over to the new owner if the vehicle is sold.

The Owner's Manual is also available for download from your authorized KTM dealer and on the KTM website.

International KTM Website: http://www.ktm.com

8

IMPORTANT NOTES 3 3.1

Manufacturer and implied warranty

The work specified in the service schedule may only be performed in an authorized KTM workshop and must be recorded in both the Service & Warranty Booklet and in the by the manufacturer warranty.

in the Service & Warranty Booklet.

KTM Dealer.net

, otherwise any warranty claim will be void. Damage or secondary damage caused by tampering with and/or conversions on the vehicle are not covered Additional information on the manufacturer or manufacturer warranty and the procedures involved can be found

3.2

Fuel, auxiliary substances Note Environmental hazard

  Improper handling of fuel is a danger to the environment.

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

Use fuels and auxiliary substances in accordance with the Owner's Manual and specification.

3.3

Spare parts, accessories

For your own safety, only use spare parts and accessory products that are approved and/or recommended by KTM and have them installed by an authorized KTM workshop. KTM accepts no liability for other products and any resulting damage or loss.

Certain spare parts and accessory products are specified in parentheses in the descriptions. Your authorized KTM dealer will be glad to advise you.

The current

KTM PowerParts

for your vehicle can be found on the KTM website.

International KTM Website: http://www.ktm.com

3.4

Service

A prerequisite for perfect operation and prevention of premature wear is that the service, care, and tuning work on the engine and chassis is properly carried out as described in the Owner's Manual. Incorrect adjustment and tuning of the engine and chassis can lead to damage and breakage of components.

Use of the vehicle under difficult conditions, such as on sand or on wet and muddy surfaces, can lead to consid erably more rapid wear of components such as the drive train, brake system, or suspension components. For this reason, it may be necessary to inspect or replace parts before the next scheduled service.

It is imperative that you adhere to the stipulated run-in times and service intervals. If you observe these exactly, you will ensure a much longer service life for your motorcycle.

3.5

Figures

The figures contained in the manual may depict special equipment.

In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.

3.6

Customer service

Your authorized KTM dealer will be happy to answer any questions you may have on your vehicle and KTM.

9

3 IMPORTANT NOTES

A list of authorized KTM dealers can be found on the KTM website.

International KTM Website: http://www.ktm.com

10

4.1

View of vehicle, front left VIEW OF VEHICLE 4

A00454-10 1 2 3 4

Clutch lever ( p. 15)

Seat release strap

Side stand ( p. 21) Shift lever ( p. 21)

11

4 VIEW OF VEHICLE 4.2

View of vehicle, rear right side

1 2 2 2 2 3 4 5 6

Fuel pump switch ( p. 17)

Kill switch (

Light switch (

p. 15)

p. 16) Turn signal switch ( Horn button ( p. 16) p. 16) Electric starter button (

Combination instrument

Throttle grip (

Foot brake lever (

p. 15)

p. 21)

p. 16)

A00455-10

12

SERIAL NUMBERS 5 5.1

Vehicle identification number

The vehicle identification number head on the right.

1 is embossed in the steering

5.2

Type label

401945-10 The type label 1 is located on the steering head on the left.

5.3

Engine number

A00441-10 The engine number 1 is stamped on the left side of the engine under the engine sprocket.

5.4

Key number

401949-10 The key number connector.

1 for the steering lock is stamped onto the key 402247-10

13

5 SERIAL NUMBERS 5.5

Fork part number

The fork part number stub.

1 is stamped on the inner side of the fork

5.6

401947-10

Shock absorber article number

The shock absorber article number 1 is located on the left side of the shock absorber compensating tank.

H03307-10

14

6.1

Clutch lever

The clutch lever 1 is fitted on the left side of the handlebar.

The clutch is hydraulically operated and self-adjusting.

CONTROLS 6 6.2

Hand brake lever

L03000-10 The hand brake lever 1 is fitted on the right side of the handle bar.

The hand brake lever operates the front brake.

6.3

Throttle grip

L03001-10 The throttle grip 1 is fitted on the right side of the handlebar.

6.4

Kill switch

L03002-10 A00447-10 The kill switch 1 is fitted on the left side of the handlebar.

Possible states

• Kill switch • Kill switch in basic position pressed engine will not start.

– – In this position, the ignition circuit is closed, and the engine can be started.

In this position, the ignition circuit is interrupted, a running engine stops, and a non-running

15

6 CONTROLS 6.5

6.6

6.7

Light switch

Light switch 1 is fitted on the left side of the handlebar.

Possible states

Low beam on tion. In this position, the low beam and tail light are switched on.

– Light switch is in the central posi High beam on switched on.

– Light switch is turned to the left.

In this position, the high beam and tail light are A00447-11

Turn signal switch

A00448-10 The turn signal switch bar.

1 is fitted on the left side of the handle-

Possible states

Turn signal off position.

– Turn signal switch is in the central Turn signal, left, on left.

– Turn signal switch turned to the Turn signal, right, on the right.

– Turn signal switch turned to

Horn button

The horn button 1 is fitted on the left side of the handlebar.

Possible states

• Horn button • Horn button tion.

in neutral position pressed – The horn is operated in this posi-

6.8

A00447-12

Electric starter button

The electric starter button handlebar.

1 is fitted on the right side of the

Possible states

• Electric starter button • Electric starter button starter motor is actuated.

in basic position is pressed – In this position, the A00449-10

16

CONTROLS 6 6.9

6.10

6.11

Emergency OFF switch

The emergency OFF switch handlebar.

1 is fitted on the right side of the

Possible states

Ignition off – In this position, the ignition circuit is interrupted, a running engine stops, and a non-running engine will not start.

Ignition on – In this position, the ignition circuit is closed and the engine can be started.

A00449-11

Overview of indicator lamps

A00402-10

Possible states

Left fuel level warning lamp lights up orange reserve mark.

– The fuel level of the two front fuel tanks has reached the The oil pressure warning lamp lights up red pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the pro cess, and switch off the engine.

– The oil Turn signal indicator lamp flashes green signal is switched on.

– The turn Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle elec tronics. Come safely to a halt, and contact an autho rized KTM workshop.

The high beam indicator lamp lights up blue high beam is switched on.

– The Right fuel level warning lamp lights up orange mark.

– The fuel level of the rear fuel tank has reached the reserve

Fuel pump switch

A00450-10 The fuel pump switch bar.

1 is fitted on the left side of the handle-

Possible states

FRONT – In this position, the fuel pump of the two front fuel tanks is active. Only the front fuel tanks empty out.

REAR – In this position, the fuel pump of the rear fuel tank is active. Only the rear tank empties out.

The fuel pump switch controls the fuel pumps of both front fuel tanks and the rear fuel tank.

17

6 CONTROLS 6.12

Fuel tank

This model has three separate fuel tanks controlled by a fuel pump switch. Two fuel tanks are located in front of the seat and one fuel tank is located beneath the seat.

The right fuel tank is filled via fuel tank filler cap fuel tank is filled via fuel tank filler cap 2 .

1 and the left L03011-10 The rear fuel tank is filled via fuel tank filler cap 3 .

6.13

L03012-10

Opening fuel tank filler caps

– – – – –

Danger Fire hazard

  Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

Switch off the engine for refueling.

Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

If any fuel is spilled, wipe it off immediately.

Observe the specifications for refueling.

– – – – – – –

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

Avoid skin, eye and clothing contact with fuel.

Immediately consult a doctor if you swallow fuel.

Do not inhale fuel vapors.

In case of skin contact, rinse the affected area with plenty of water.

Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

Change your clothing in case of fuel spills on them.

Keep fuels correctly in a suitable canister, and out of the reach of children.

Note Environmental hazard

  Improper handling of fuel is a danger to the environment.

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

18

– Turn fuel tank filler caps and lift off.

1 , 2 and 3 counterclockwise

CONTROLS 6 6.14

L03013-10

Closing fuel tank filler caps

– Mount fuel tank filler caps 1 , 2 , and 3 wise until the fuel tanks are tightly closed.

and turn clock-

Info

Route fuel tank breather hoses 4 without kinks.

L03014-10

19

6 CONTROLS 6.15

Cold start button

The cold start button 1 is fitted to the bottom of the throttle valve body.

The electronic fuel injection system extends the injection time if the engine is cold and the ambient temperature is low. To help the engine burn the increased fuel quantity, it must be supplied with additional oxygen by pushing the cold start button.

After briefly opening up the throttle and then releasing the throttle grip again, or turning the throttle grip towards the front, the cold start button returns to its original position.

Info

Check whether the cold start button has returned to its basic position.

Possible states

• The cold start button is activated – pushed in all the way.

• The cold start button is deactivated The cold start button is – The cold start button is in its basic position.

6.16

A00408-10

Idle speed adjusting screw

The idle setting of the throttle valve body substantially influences the vehicle’s starting behavior, a stable idle speed, and the vehi cle’s response when the throttle is opened.

An engine with a correctly set idle speed is easier to start than an engine with the idle speed set incorrectly.

The idle speed is adjusted using the idle speed adjusting screw 1 clockwise.

.

Increase the idle speed by turning the idle speed adjusting screw Decrease the idle speed by turning the idle speed adjusting screw counterclockwise.

A00407-10

20

6.17

Shift lever

The shift lever 1 is mounted on the left side of the engine.

CONTROLS 6

401950-10 The gear positions can be seen in the photograph.

The neutral or idle position is between the first and second gears.

6.18

Foot brake lever

401950-11 Foot brake lever 1 is located in front of the right footrest.

The rear brake is engaged with the foot brake lever.

6.19

Side stand

401956-10 The side stand 1 is located on the left of the vehicle.

401943-10

21

6 CONTROLS

The side stand is used for parking the motorcycle.

Info

When you are riding, side stand secured with rubber strap 2 .

1 must be folded up and

6.20

Steering lock

401944-10 Steering lock 1 is fitted on the left side of the steering head.

The steering lock is used to lock the steering. Steering, and there fore riding, is no longer possible.

6.21

Tool set

A00443-10 The tool set is located under seat 1 .

The tool set is stowed in compartment 2 .

A00442-10

22

CONTROLS 6 6.22

Locking the steering Note Danger of damage

  The parked vehicle can roll away or fall over.

– Park the vehicle on a firm and level surface.

– – – Park vehicle.

Turn handlebar as far as possible to the right.

Insert steering lock key in steering lock, turn it to the left, press it in, and turn it to the right. Remove steering lock key.

Steering is no longer possible.

Info

Never leave the steering lock key in the steering lock.

400732-01

6.23

Unlocking the steering

– Insert steering lock key in steering lock, turn it to the left, pull it out, and turn it to the right. Remove steering lock key.

The handlebar can now be moved again.

Info

Never leave the steering lock key in the steering lock.

400731-01

23

7 COMBINATION INSTRUMENT 7.1

Combination instrument overview

– – Press the button Press the button to control different functions.

to control different functions.

Info

When the vehicle is delivered, only the

SPEED/ODO

display modes are activated.

SPEED/H

and

7.2

Activation and test

A00403-10

Activating combination instrument

The combination instrument is activated when one of the buttons is pressed or an impulse comes from the wheel speed sensor.

Display test

To enable you to check that the display is functioning properly, all display segments light up briefly.

400313-01

WS (wheel size)

After the display function check, the wheel circumference displayed briefly.

WS

is

Info

The number 2205 equals the circumference of the 21" front wheel with standard tires.

The display then changes to the last selected mode.

400314-01

7.3

Setting kilometers or miles Info

If you change the unit, the value The values

TR1

,

TR2

,

A1

,

A2

and

ODO S1

is retained and converted accordingly.

are cleared when the unit of measure is changed.

400329-01

Condition

The motorcycle is stationary.

– Repeatedly press the button bottom right of the display.

Press the button briefly until for 2 – 3 seconds.

H

appears at the – The Setup menu is displayed and the active functions are shown.

– Repeatedly press the button

Adjusting the Km/h

– Press the button .

briefly until

Km/h

/

Mph

flashes.

Adjusting the Mph

– Press the button .

24

COMBINATION INSTRUMENT 7

– Wait 3 – 5 seconds The settings are stored.

Info

If no button is actuated for 10-12 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the Setup menu is closed.

7.4

Adjusting combination instrument function Info

When the vehicle is delivered, only the

SPEED/H

and

SPEED/ODO

display modes are activated.

400318-01

Condition

The motorcycle is stationary.

– – Repeatedly press the button bottom right of the display.

Press the button briefly until for 2 – 3 seconds.

H

appears at the The Setup menu is displayed and the active functions are shown.

Info

If no button is pressed for 10-12 seconds, the settings are automatically stored.

If no button is pressed for 20 seconds, or if no impulse comes from the wheel speed sensor, the settings are automatically saved and the Setup menu is closed.

– Repeatedly press the button tion flashes.

briefly until the desired func The selected function flashes.

Activating the function

– Press the button .

The symbol continues to appear in the display and the next function appears.

Deactivating a function

– Press the button .

The symbol disappears in the display and the next function appears.

25

7 COMBINATION INSTRUMENT 7.5

Setting clock

400330-01 – –

Condition

The motorcycle is stationary.

– – – Repeatedly press the button bottom right of the display.

Press the button briefly until for 2 – 3 seconds.

The hour display flashes.

Adjust hour display with the button Wait 3 – 5 seconds

CLK

appears at the and/or button .

The next segment of the display flashes and can be set.

You can set the following segments in the same way as the hours by pressing the button and the button .

Info

The seconds can only be set to zero.

If no button is actuated for 15-20 seconds or there is no signal from the wheel speed sensor, then the settings are automatically stored and the Setup menu is closed.

7.6

Viewing the lap time Info

This function can only be opened if lap times have actually been timed.

400321-01 – –

Condition

The motorcycle is stationary.

– – – Repeatedly press the button bottom right of the display.

Briefly press the button .

briefly until

LAP

appears at the

LAP 1

appears on the left side of the display.

The laps 1 – 10 can be viewed with the button .

Press and hold the button times.

for 3 – 5 seconds to clear the lap Briefly press the button .

Next display mode

Info

When an impulse is received from the wheel speed sen sor, the left side of the display changes back to the

SPEED

mode.

26

COMBINATION INSTRUMENT 7 7.7

7.8

7.9

Display mode SPEED (speed)

400317-02 – Repeatedly press the button the left side of the display.

briefly until

SPEED

appears on The current speed is displayed in the The current speed can be displayed in

SPEED Km/h

display mode.

or

Mph

.

Info

Make the setting according to the country.

When an impulse comes from the front wheel, the left side of the display changes to the

SPEED

mode and the current speed is shown.

Display mode SPEED/H (operating hours) Condition

• The motorcycle is stationary.

– Repeatedly press the button bottom right of the display.

briefly until

H

appears at the In display mode

H

, the service hours of the motor are displayed.

The service hour counter stores the total traveling time.

400316-01

Info

The service hour counter is necessary for ensuring that service work is carried out at the right intervals.

If the combination instrument is in

H

display mode when starting off, it automatically changes to the

ODO

display mode.

The

H

display mode is suppressed during the journey.

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

The display changes to the setup menu for the combination instrument functions.

Next display mode No function No function

Setup menu Condition

• The motorcycle is stationary.

– – Repeatedly press the button bottom right of the display.

Press the button briefly until for 2 – 3 seconds.

H

The Setup menu displays the active functions.

appears at the 400344-01

27

7 COMBINATION INSTRUMENT 7.10

Info

Repeatedly press the button briefly until the desired function is reached.

If no button is pressed for 20 seconds, the settings are automatically stored.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Wait 3 – 5 sec onds Wait 10 – 12 seconds Activates the flashing display and changes to the next display No function Deactivates the flashing display and changes to the next display No function Changes to the next display without changes Setup menu starts, stores the settings, and changes to

H

or

ODO

.

Adjusting the unit of measurement

– –

Condition

• The motorcycle is stationary.

– Repeatedly press the button bottom right of the display.

Press the button briefly until for 2 – 3 seconds.

H

Repeatedly press the button briefly until appears at the

Km/h

/

Mph

flashes.

In measurement unit mode, you can change the unit of measure ment.

400329-01

Info

If no button is pressed for 5 seconds, the settings are auto matically stored.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Wait 3 – 5 sec onds Wait 10 – 12 seconds Starts selection, activates

Km/h

display No function Activates

Mph

display No function Changes to the next display, changes from selection to the Setup menu Stores and closes the Setup menu

28

COMBINATION INSTRUMENT 7 7.11

7.12

7.13

Display mode SPEED/CLK (time)

– Repeatedly press the button bottom right of the display.

briefly until The time is shown in display mode

CLK

.

CLK

appears at the 400319-01 Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

The display changes to the Setup menu of the clock.

Next display mode No function No function

Setting the clock

400319-01

Condition

• The motorcycle is stationary.

– Repeatedly press the button bottom right of the display.

– Press the button briefly until for 2 – 3 seconds.

CLK

appears at the Increases the value Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Wait 3 – 5 sec onds Wait 10 – 12 seconds Increases the value Reduces the value Reduces the value Changes to the next value Closes the SETUP menu

Display mode SPEED/LAP (lap time)

– Repeatedly press the button bottom right of the display.

briefly until

LAP

appears at the In the

LAP

stop watch.

display mode, up to 10 lap times can be timed with the 400320-01

Info

If the lap time continues running after the button pressed, 9 memory locations are occupied.

Lap 10 must be timed using the button .

is

29

7 COMBINATION INSTRUMENT 7.14

7.15

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

The stop watch and the lap time are reset.

Next display mode Stops the clock.

Starts the stop watch or stop the current lap time measurement, stores it and the stop watch starts the next lap.

Viewing the lap time

400321-01

Condition

• The motorcycle is stationary.

– Repeatedly press the button bottom right of the display.

– Briefly press the button .

briefly until

LAP

appears at the The stop watch and the lap time are reset.

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Select a lap from 1 No function – 10 View the next lap time.

Display mode SPEED/ODO (odometer)

– Repeatedly press the button bottom right of the display.

briefly until

ODO

appears at the The total traveled distance is shown in display mode

ODO

.

400317-01 Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

No function Next display mode No function No function

30

COMBINATION INSTRUMENT 7 7.16

7.17

7.18

Display mode SPEED/TR1 (trip master 1)

– Repeatedly press the button top right of the display.

briefly until

TR1

appears at the

TR1 TR1

(trip master 1) runs constantly and counts up to 999.9.

You can use it to measure trips or the distance between refueling stops.

is coupled with

A1

(average speed 1) and

S1

(stop watch 1).

400323-01

Info

If 999.9 is exceeded, the values of automatically reset to 0.0.

TR1

,

A1

and

S1

are Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Displays of

TR1

,

A1

and

S1

are reset to 0.0.

Next display mode No function No function

Display mode SPEED/TR2 (trip master 2)

– Repeatedly press the button top right of the display.

briefly until

TR2

appears at the

TR2

(trip master 2) runs constantly and counts up to 999.9.

400324-01 Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Clears the values

TR2

and

A2

.

Next display mode Reduces value of

TR2

.

Reduces value of

TR2

.

Setting TR2 (trip master 2) Condition

• The motorcycle is stationary.

– – Repeatedly press the button top right of the display.

Press the button briefly until for 2 – 3 seconds until

TR2 TR2

appears at the flashes.

The displayed value can be set manually with the button the button . This is a very practical function when riding using the road book.

and 400324-01

31

7 COMBINATION INSTRUMENT 7.19

7.20

Info

The

TR2

value can also be corrected manually during the journey with the button and the button .

If 999.9 is exceeded, the value of

TR2

is automatically reset to 0.0.

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Wait 10 – 12 seconds Increases value of

TR2

.

Increases value of

TR2

.

Reduces value of

TR2

.

Reduces value of

TR2

.

Saves and closes the Setup menu

Display mode SPEED/A1 (average speed 1)

– Repeatedly press the button top right of the display.

briefly until

A1

appears at the

A1

(average speed 1) shows the average speed calculated using

TR1

(trip master 1) and

S1

(stop watch 1).

The calculation of this value is activated by the first impulse of the wheel speed sensor and ends 3 seconds after the last impulse.

400325-01 Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Displays of

TR1

,

A1

and

S1

are reset to 0.0.

Next display mode No function No function

Display mode SPEED/A2 (average speed 2)

– Repeatedly press the button top right of the display.

briefly until

A2

appears at the

A2

(average speed 2) shows the average speed on the basis of the current speed if the stop watch

S2

(stop watch 2) is running.

Info

The displayed value can differ from the actual average speed if

S2

was not stopped after the ride.

400326-01 Briefly press the button .

Next display mode

32

COMBINATION INSTRUMENT 7 7.21

7.22

Press the but ton for 2 – 3 seconds.

Press the but ton for 2 – 3 seconds.

Briefly press the button .

No function No function No function

Display mode SPEED/S1 (stop watch 1)

– Repeatedly press the button top right of the display.

briefly until

S1

appears at the

S1

(Stop watch 1) shows the riding time based on sensor.

TR1

and contin ues running as soon as an impulse arrives from the wheel speed The calculation of this value starts with the first impulse from the wheel speed sensor and ends 3 seconds after the last impulse.

400327-01 Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

Displays of

TR1

,

A1

and

S1

are reset to 0.0.

Next display mode No function No function

Display mode SPEED/S2 (stop watch 2)

– Repeatedly press the button top right of the display.

briefly until

S2

appears at the

S2

If (Stop watch 2) is a manual stop watch.

S2

is running in the background, the display

S2

flashes.

400328-01 Press the but ton for 2 – 3 seconds.

Briefly press the button .

Press the but ton for 2 – 3 seconds.

Briefly press the button .

The displays of

S2

and

A2

are set to 0,0.

Next display mode No function Starts or stops

S2

.

33

7 COMBINATION INSTRUMENT 7.23

Display Table of functions

Display mode

SPEED/H

(oper ating hours) Setup menu Adjusting the unit of mea surement

Press the but ton for 2

3 seconds.

The display changes to the setup menu for the combination instrument functions.

No function No function

Briefly press the button .

Next display mode Activates the flashing display and changes to the next dis play Starts selec tion, acti vates

Km/h

display

Press the but ton for 2

3 seconds.

No function

Briefly press the button .

No function

Wait 3

5 sec onds Wait 10

12 seconds

No function No function Deactivates the flashing display and changes to the next dis play Activates

Mph

display Changes to the next dis play without changes Setup menu starts, stores the settings, and changes to

H

or

ODO

.

Changes to the next dis play, changes from selec tion to the Setup menu Stores and closes the Setup menu No function Display mode

SPEED/CLK

(time) Setting the clock Display mode

SPEED/LAP

(lap time) The display changes to the Setup menu of the clock.

Increases the value Next display mode Increases the value No function Reduces the value The stop watch and the lap time are reset.

Viewing the lap time The stop watch and the lap time are reset.

No function Display mode

SPEED/ODO

(odometer) Display mode

SPEED/TR1

(trip master 1) Displays of

TR1 S1

,

A1

to 0.0.

and are reset Next display mode Select a lap from 1 Next display mode Next display mode – 10 Stops the clock.

No function No function No function Reduces the value Changes to the next value Starts the stop watch or stop the cur rent lap time measure ment, stores it and the stop watch starts the next lap.

View the next lap time.

No function No function Closes the SETUP menu

34

COMBINATION INSTRUMENT 7 Display

Display mode

SPEED/TR2

(trip master 2) Setting

TR2

(trip master 2)

Press the but ton for 2

3 seconds.

Clears the values

TR2

and

A2

.

Increases value of

TR2

.

Briefly press the button .

Next display mode Increases value of

TR2

.

Press the but ton for 2

3 seconds.

Reduces value of

TR2

.

Briefly press the button .

Reduces value of

TR2

Reduces value of

TR2

.

Reduces value of

TR2

.

.

Wait 3

5 sec onds Wait 10

12 seconds

Saves and closes the Setup menu Display mode

SPEED/A1

(aver age speed 1) Displays of

TR1

,

A1

and

S1

are reset to 0.0.

No function Display mode

SPEED/A2

(aver age speed 2) Display mode

SPEED/S1

(stop watch 1) Display mode

SPEED/S2

watch 2) (stop Displays of

TR1 S1

,

A1

are reset to 0.0.

and The displays of

S2

and

A2

are set to 0,0.

Next display mode Next display mode Next display mode Next display mode No function No function No function No function No function No function No function Starts or stops

S2

.

7.24

Display Table of conditions and menu activation

Display mode

SPEED/H

(operating hours) Setup menu Adjusting the unit of measurement Setting the clock Display mode

SPEED/LAP

(lap time) Viewing the lap time Display mode

SPEED/TR1

(trip master 1) Display mode

SPEED/TR2

(trip master 2) Setting

TR2

(trip master 2) Display mode

SPEED/A1

(average speed 1) Display mode

SPEED/A2

(average speed 2) Display mode

SPEED/S1

(stop watch 1) Display mode

SPEED/S2

(stop watch 2)

The motorcycle is stationary.

• • • • • •

Menu can be acti vated

• • • • • • •

35

8 PREPARING FOR USE 8.1

Advice on preparing for first use

– –

Danger Danger of accidents

  A rider who is not fit to ride poses a danger to him or herself and others.

Do not operate the vehicle if you are not fit to ride due to alcohol, drugs or medication.

Do not operate the vehicle if you are physically or mentally impaired.

Warning Risk of injury

  Missing or poor protective clothing presents an increased safety risk.

– Wear appropriate protective clothing such as helmet, boots, gloves as well as trousers and a jacket with protectors on all rides.

– Always wear protective clothing that is in good condition and meets the legal regulations.

Warning Danger of crashing

  Different tire tread patterns on the front and rear wheel impair the handling charac teristic.

Different tire tread patterns can make the vehicle significantly more difficult to control.

– Make sure that only tires with a similar tire tread pattern are fitted to the front and rear wheel.

Warning Danger of accidents

  An unadapted riding style impairs the handling characteristic.

– Adapt your riding speed to the road conditions and your riding ability.

Warning Danger of accidents

  The vehicle is not designed to carry passengers.

– Do not ride with a passenger.

Warning Danger of accidents

  The brake system fails in the event of overheating.

If the foot brake lever is not released, the brake linings drag continuously.

– Take your foot off the foot brake lever when you are not braking.

Warning Danger of accidents

  Total weight and axle loads influence the handling characteristic.

– Do not exceed the maximum permissible overall weight or the axle loads.

– –

Warning Risk of misappropriation

  People who act without authorization endanger themselves and others.

Do not leave the vehicle unattended if the engine is running.

Protect the vehicle against access by unauthorized persons.

Info

When using your motorcycle, remember that others may feel disturbed by excessive noise.

– – – – – Make sure that the pre-sales inspection work has been carried out by an authorized KTM workshop.

You receive a delivery certificate and the Service & Manufacturer Warranty Booklet at vehicle handover.

Before riding for the first time, read the entire Owner's Manual carefully.

Get to know the controls.

Adjust basic position of the clutch lever. ( p. 81)

Adjust basic position of the hand brake lever. ( p. 88)

36

PREPARING FOR USE 8

– – – Adjust the free travel of the foot brake lever.

Set basic position of shift lever.

( p. 116)

( p. 94)

Get used to the handling characteristic of the motorcycle on a suitable terrain before undertaking a more chal lenging trip.

– – – –

Info

Offroad, you should be accompanied by another person on another vehicle so that you can help each other.

Try also to ride as slowly as possible and in a standing position to get a better feel for the motorcycle.

Do not make any off-road trips that exceed your ability and experience.

Hold the handlebar firmly with both hands and keep your feet on the footrests when riding.

If you carry luggage, make sure you secure it firmly as close as possible to the center of the vehicle and ensure even weight distribution between the front and rear wheels.

Info

Motorcycles react sensitively to any changes of weight distribution.

– – Do not exceed the maximum permissible weight and the maximum permissible axle loads.

Guideline Maximum permissible overall weight 335 kg (739 lb.) Maximum permissible front axle load Maximum permissible rear axle load 161.5 kg (356 lb.) 173.5 kg (382.5 lb.)

Run in the engine. ( p. 37)

8.2

Running in the engine

During the running-in phase, do not exceed the specified engine speed and engine performance.

Guideline Maximum engine speed During the first operating hour Maximum engine performance During the first 3 operating hours 7,000 rpm ≤ 75 % – Avoid fully opening the throttle!

37

9 RIDING INSTRUCTIONS 9.1

Checks and maintenance when preparing for use Info

Before every trip, check the condition of the vehicle and ensure that it is safe to operate.

The vehicle must be in perfect technical condition when used.

– – – – – – – – – – – – – – – – – – – – –

Check the engine oil level. (

Check the electrical system.

Check front brake fluid level. (

Check rear brake fluid level. (

p. 117)

p. 89)

p. 94)

Check the front brake linings. (

Check the rear brake linings. (

p. 90)

p. 96)

Check that the brake system is functioning properly.

Check the coolant level. ( p. 112)

Check the chain for dirt accumulation. ( p. 75)

Check chain, rear sprocket, engine sprocket, and chain guide. (

Check chain tension. (

Check tire condition. (

p. 76)

p. 103)

Check tire pressure. ( p. 104)

Check the spoke tension. ( p. 105)

Clean the dust boots of the fork legs. (

Bleed the fork legs. ( p. 55)

p. 56)

p. 77)

Check the air filter.

Check the fuel filter.

Check the settings of all controls and ensure that they can be operated smoothly.

Check all screws, nuts, and hose clamps regularly for tightness.

Check the fuel reserves.

9.2

Starting

– –

Danger Danger of poisoning

  Exhaust gases are toxic and inhaling them may result in unconsciousness and death.

Always make sure there is sufficient ventilation when running the engine.

Use effective exhaust extraction when starting or running the engine in an enclosed space.

Note Engine damage

  High revving speed with a cold engine negatively impacts the lifespan of the engine.

– Always run the engine warm at a low speed.

– – Take the motorcycle off side stand stand with rubber strap 2 .

1 and secure the side Shift transmission into neutral.

401944-10

38

RIDING INSTRUCTIONS 9

400733-01

Condition

Ambient temperature: < 20 °C (< 68 °F) – Push cold start button in all the way.

– Press the electric starter button.

Info

Press the electric starter button for at most 5 seconds.

Wait for a least 5 seconds before trying again.

At temperatures below 15 °C (60 °F), several attempts at starting may be necessary to warm-up the lithium-ion battery and thereby increase the starting power.

When starting, the

FI

warning lamp lights up briefly as a function check.

9.3

Starting off Info

When you are riding, the side stand must be folded up and secured with the rubber strap.

– Pull the clutch lever, shift into first gear, release the clutch lever slowly and at the same time open the throt tle carefully.

9.4

Shifting, riding Warning Danger of accidents

  If you change down at high engine speed, the rear wheel blocks and the engine races.

– Do not change into a low gear at high engine speed.

Info

If unusual noises occur while riding, stop immediately, switch off the engine and contact an authorized KTM workshop.

First gear is used for starting off and for steep inclines.

– – – – – – Shift into a higher gear when conditions allow (incline, road situation, etc.). To do so, release the throttle while simultaneously pulling the clutch lever, shift into the next gear, release the clutch lever and open the throttle.

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.

Always open the throttle only as much as the engine can handle sumption.

– abrupt throttle opening increases fuel con To shift down, apply the brakes and close the throttle at the same time.

Pull the clutch lever and shift into a lower gear, release the clutch lever slowly, and either open the throttle or shift again.

Switch off the engine if running at idle speed or stationary for a long time.

Guideline ≥ 2 min

39

9 RIDING INSTRUCTIONS

– – Avoid frequent and longer slipping of the clutch. This heats the engine oil, the engine, and the cooling sys tem.

Ride at a low engine speed instead of at a high engine speed with a slipping clutch.

9.5

Braking Warning Danger of accidents

  Excessively forceful application of the brakes blocks the wheels.

– Adjust application of the brakes to the respective riding situation and riding surface conditions.

Warning Danger of accidents

  A spongy pressure point on the front or rear brake reduces braking efficiency.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Moisture and dirt impair the brake system.

– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

– – – On sandy, wet or slippery surfaces, use the rear brake.

Braking should always be completed before you go into a bend. Change down to a lower gear appropriate to your road speed.

On long downhill stretches, use the braking effect of the engine. To do so, shift back one or two gears, but do not overrev the engine. You will need to apply the brakes far less often and the brake system will not overheat.

9.6

Stopping, parking

– –

Warning Risk of misappropriation

  People who act without authorization endanger themselves and others.

Do not leave the vehicle unattended if the engine is running.

Protect the vehicle against access by unauthorized persons.

Warning Danger of burns

  Some vehicle components become very hot when the vehicle is operated.

– Do not touch any parts such as the exhaust system, radiator, engine, shock absorber, or brake system before the vehicle parts have cooled down.

– Let the vehicle parts cool down before you perform any work on the vehicle.

– –

Note Material damage

  The vehicle may be damaged by incorrect procedure when parking.

Significant damage may be caused if the vehicle rolls away or falls over.

The components for parking the vehicle are designed only for the weight of the vehicle.

Park the vehicle on a firm and level surface.

Ensure that nobody sits on the vehicle when the vehicle is parked on a stand.

40

RIDING INSTRUCTIONS 9

– –

Note Fire hazard

  Hot vehicle components pose a fire hazard and explosion risk.

Do not park the vehicle near to materials which are highly flammable or explosive.

Allow the vehicle to cool down before covering it.

– – – – Apply the brakes on the motorcycle.

Shift transmission into neutral.

Press the kill switch while the engine is idling until the engine stops.

Park the motorcycle on firm ground.

9.7

Transporting Note Danger of damage

  The parked vehicle can roll away or fall over.

– Park the vehicle on a firm and level surface.

Note Fire hazard

  Hot vehicle components pose a fire hazard and explosion risk.

– Do not park the vehicle near to materials which are highly flammable or explosive.

– Allow the vehicle to cool down before covering it.

– – Switch off the engine.

Use tension belts or other suitable devices to secure the motorcycle against falling over or rolling away.

401475-01

9.8

Refueling

– – – – –

Danger Fire hazard

  Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

Switch off the engine for refueling.

Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

If any fuel is spilled, wipe it off immediately.

Observe the specifications for refueling.

41

9 RIDING INSTRUCTIONS

– – – – – –

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

Avoid skin, eye and clothing contact with fuel.

Immediately consult a doctor if you swallow fuel.

Do not inhale fuel vapors.

In case of skin contact, rinse the affected area with plenty of water.

Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

Change your clothing in case of fuel spills on them.

Note Material damage

  Inadequate fuel quality causes the fuel filter to quickly become clogged.

In some countries and regions, the available fuel quality and cleanliness may not be sufficient. This will result in problems with the fuel system.

– Refuel only with clean fuel that meets the specified standards. (Your authorized KTM workshop will be glad to help.)

Note Environmental hazard

  Improper handling of fuel is a danger to the environment.

– Do not allow fuel to enter the groundwater, the soil, or the sewage system.

– – – – Switch off the engine.

Open fuel tank filler caps. ( p. 18)

Fill the fuel tank with fuel up to measurement A .

Guideline Measurement of A 45 mm (1.77 in) Front left fuel tank, approx.

Super unleaded (ROZ 95/RON

95/PON 91) ( p. 159)

Front right fuel tank, approx.

Super unleaded (ROZ 95/RON

95/PON 91) ( p. 159)

Rear fuel tank, approx.

Super unleaded (ROZ 95/RON

95/PON 91) ( p. 159)

Total fuel tank capacity, approx.

Super unleaded (ROZ 95/RON

95/PON 91) ( p. 159)

Close fuel tank filler caps. ( p. 19)

8.0 l (2.11 US gal) 8.0 l (2.11 US gal) 14.0 l (3.7 US gal) 30.0 l (7.93 US gal) M01572-10

42

SERVICE SCHEDULE 10 10.1

Service schedule

Read out fault memory using the KTM diagnostics tool.

Check that the electrical equipment is functioning properly.

Check and charge the 12-V battery.

Check the front brake linings. (

Check the rear brake linings. (

Check brake discs. ( p. 88)

Check the brake lines for damage and leakage.

Check rear brake fluid level. (

Check the free travel of the foot brake lever. (

Check frame and link fork.

Check link fork bearing.

Check the heim joints at the top of the shock absorber.

Check the shock absorber linkage.

Conduct a minor fork service.

Conduct a major fork service.

Check tire condition. (

Check tire pressure. (

Check the wheel hubs.

Check the rim run-out.

Check chain tension. (

p. 103)

p. 104)

Check the wheel bearing for play.

Check the spoke tension. ( p. 105)

Check chain, rear sprocket, engine sprocket, and chain guide. (

p. 76)

Lubricate all moving parts (e.g., hand lever, chain, ...) and check for smooth operation.

Check/correct the fluid level of the hydraulic clutch. (

Check front brake fluid level. (

Check the valve clearance.

p. 90)

p. 96)

p. 94)

p. 89)

Check the free travel on the hand brake lever.

Check steering head bearing play. ( p. 62)

p. 93)

p. 81)

Every 30 operating hours Every 20 operating hours Every 10 operating hours/after every race Once after 1 operating hour

○ ○ ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

p. 77)

○ ○ ○ ○ ○ ○ ○ ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Check the clutch and damping elements in the clutch basket.

Change engine oil and oil filter and clean the oil screens.

Change the absorbing elements in the outer clutch hub.

Check all hoses (e.g. fuel, cooling, bleeder, drainage, etc.) and sleeves for cracking, leaks, and incorrect routing.

Check the antifreeze and coolant level. (

Check the cables for damage and routing without sharp bends.

Check that the cables are undamaged, routed without sharp bends and set correctly.

Clean the air filter and air filter box.

Clean the fuel filter of the fuel tank.

p. 111)

Change the glass fiber yarn filling of the main silencer.

(

( p. 117)

p. 70)

○ ○ ○ ○ ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

43

10 SERVICE SCHEDULE

○ ● Check the screws and nuts for tightness.

Check the fuel pressure.

Adjust the idle speed.

( p. 115)

Check that the radiator fan is functioning properly.

Every 30 operating hours Every 20 operating hours Every 10 operating hours/after every race Once after 1 operating hour

○ ○ ● ● ● ● ● ● ● ● ● ● ● ● 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.

Make the service entry in let.

KTM Dealer.net

and in the Service & Manufacturer Warranty Book ○ ○ ○ ● ● ● ● ● ● ● ● ● One-time interval Periodic interval

10.2

Service work (as additional order)

○ ● Change the front brake fluid.

Change the rear brake fluid.

Change the hydraulic clutch fluid.

Grease the steering head bearing.

Service the shock absorber.

Check/measure the cylinder.

(

( p. 83)

p. 64)

Change the spark plug and spark plug connector.

Change the piston.

Check the cylinder head.

Change the valves, valve springs and valve spring seats.

Check the camshaft and rocker arm.

Change the connecting rod, conrod bearing and crank pin.

Change the shaft seal rings of the water pump.

Check the transmission and shift mechanism.

Check oil pressure control valve.

Change the suction pump.

Check the pressure pump and lubrication system.

Replace the timing chain.

Check the timing assembly.

Change all engine bearings.

One-time interval Periodic interval

after every race Annually Every 100 operating hours Every 50 operating hours Every 40 operating hours Once after 20 operating hours

○ ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

44

TUNING THE CHASSIS 11 11.1

Checking basic chassis setting with rider's weight Info

When adjusting the basic chassis setting, first adjust the shock absorber and then the fork.

– – – – For optimal motorcycle riding characteristics and to avoid damage to forks, shock absorbers, swingarm and frame, the basic settings of the suspension components must match the rider's weight.

As delivered, KTM offroad motorcycles are adjusted for an average rider's weight (with full protective clothing).

Guideline Standard rider weight 75 … 85 kg (165 … 187 lb.) If the rider's weight is above or below this range, the basic set ting of the suspension components must be adjusted accord ingly.

Small weight differences can be compensated by adjusting the spring preload, but in the case of large weight differences, the springs must be replaced.

401030-01

11.2

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 on the landing after a jump: the rear wheel suspension com presses quickly.

The low-speed setting, for example, has an effect when riding over long ground swells: the rear wheel suspension compresses slowly.

These two ranges can be adjusted separately, although the transition between high-speed and low-speed is grad ual. Thus, modifications in the high-speed range affect the compression damping in the low-speed range and vice versa.

11.3

Adjusting the low-speed compression damping of the shock absorber Caution Risk of injury

  Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info

The effect of the low-speed setting can be seen in the slow to normal compression of the shock absorber.

Preparatory work

Remove the seat. (

p. 67)

Remove tool set compartment.

45

11 TUNING THE CHASSIS

A00469-10

Main work

– Turn adjusting screw click.

– 1 clockwise up to the last perceptible Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Guideline Low-speed compression damping Comfort Standard Sport 24 clicks 20 clicks 16 clicks

Info

Turn clockwise to increase damping; turn counterclock wise to reduce damping.

Finishing work

Mount the seat. (

p. 67)

Mount tool set compartment.

11.4

Adjusting the high-speed compression damping of the shock absorber Caution Risk of injury

  Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info

The effect of the high-speed setting can be seen in fast compression of the shock absorber.

A00469-11

Preparatory work

Remove the seat. (

p. 67)

Remove tool set compartment.

Main work

– Turn adjusting screw 1 clockwise all the way.

Turn counterclockwise by the number of turns corresponding to the shock absorber type.

Guideline High-speed compression damping Comfort 45 clicks Standard Sport 40 clicks 30 clicks

Info

Turn clockwise to increase damping; turn counterclock wise to reduce damping.

Finishing work

Mount the seat. ( p. 67)

46

TUNING THE CHASSIS 11

– Mount tool set compartment.

11.5

Adjusting the rebound damping of the shock absorber Caution Risk of injury

  Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.) L03020-10 – – Turn adjusting screw click.

1 clockwise up to the last perceptible Turn counterclockwise by the number of clicks corresponding to the shock absorber type.

Guideline Rebound damping Comfort Standard Sport 24 clicks 20 clicks 16 clicks

Info

Turn clockwise to increase damping; turn counterclock wise to reduce damping.

11.6

Measuring the unloaded rear wheel sag Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Measure the vertical distance between the rear axle and a fixed point such as a marking on the side cover.

– Note down the value as dimension A .

400988-10

Finishing work

Remove motorcycle from the lift stand. ( p. 55)

47

11 TUNING THE CHASSIS 11.7

Checking static sag of the shock absorber

Condition

The fuel tanks are half full.

– – – Measure distance Hold the motorcycle perpendicular with the aid of an assistant.

Measure the distance between the rear axle and the fixed point again.

A

of rear wheel unloaded. (

Note down the value as dimension B .

p. 47)

Info

The static sag is the difference between measurements A and B .

Check static sag.

Static sag 40 mm (1.57 in) » If the static sag is less or more than the specified value: –

(

Adjust the spring preload of the shock absorber.

p. 49)

11.8

400989-10

Checking riding sag of the shock absorber

– –

Condition

The fuel tanks are half full.

– – Measure distance A

of rear wheel unloaded. ( p. 47)

With another person holding the motorcycle, the rider, wear ing full protective clothing, sits on the seat in a normal sitting position (feet on footrests) and bounces up and down a few times.

The rear wheel suspension levels out.

Another person now measures the distance between the rear axle and the fixed point.

Note down the value as dimension C .

Info

The riding sag is the difference between measurements A and C .

Check riding sag.

Riding sag 105 mm (4.13 in) » If the riding sag differs from the specified measurement: – Adjust the riding sag.

( p. 50)

400990-10

48

TUNING THE CHASSIS 11 11.9

Adjusting the spring preload of the shock absorber Caution Risk of injury

  Parts of the shock absorber will move around if the shock absorber is detached incorrectly.

The shock absorber is filled with highly compressed nitrogen.

– Please follow the description provided. (Your authorized KTM workshop will be glad to help.)

Info

Before changing the spring preload, make a note of the present setting, e.g., by measuring the spring length.

– – – –

Preparatory work

Raise the motorcycle with a lift stand. (

– Fold out the side stand and secure it.

Remove the seat. ( p. 67)

– Take out the tool set compartment.

Remove main silencer. (

Remove shock absorber.

p. 69)

( p. 64)

p. 55)

After removing the shock absorber, clean it thoroughly.

Main work

– Loosen screw – sion.

1 .

Turn adjusting ring 2 until the spring is no longer under ten Hook wrench (T106S) Measure the overall spring length while the spring is not under tension.

Tighten the spring by turning adjusting ring measurement A .

2 to specified Guideline Spring preload Standard 11 mm 402405-10

Info

Depending on the static sag and/or the riding sag, it may be necessary to increase or decrease the spring preload.

– Tighten screw 1 .

Guideline Screw, shock absorber adjusting ring M5

Finishing work

– Install the shock absorber.

– – –

Install the main silencer. (

Mount tool set compartment.

Mount the seat. ( p. 67)

( p. 65)

p. 70)

5 Nm (3.7 lbf ft)

49

11 TUNING THE CHASSIS

Remove motorcycle from the lift stand. ( p. 55)

11.10

Adjusting the riding sag

B00292-10 – – – – –

Preparatory work

Raise the motorcycle with a lift stand. (

– Fold out the side stand and secure it.

Remove the seat. ( p. 67)

Take out the tool set compartment.

Remove main silencer. (

Remove shock absorber.

p. 69)

( p. 64)

p. 55)

After removing the shock absorber, clean it thoroughly.

Main work

– Choose and mount a suitable spring.

Guideline Spring rate Weight of rider: ( ≤ 143 lb.) ≤ 65 kg 48 N/mm (274 lb/in) 51 N/mm (291 lb/in) Weight of rider: 65 … 75 kg (143 … 165 lb.) Weight of rider: 75 … 85 kg (165 … 187 lb.) Weight of rider: 85 … 95 kg (187 … 209 lb.) Weight of rider: ( ≥ 209 lb.) ≥ 95 kg 54 N/mm (308 lb/in) 57 N/mm (325 lb/in) 60 N/mm (343 lb/in)

Info

The spring rate is shown on the outside of the spring.

Smaller weight differences can be compensated by changing the spring preload.

– – – – – –

Finishing work

– Install the shock absorber.

Install the main silencer. (

Mount tool set compartment.

Mount the seat. ( p. 67)

( p. 65)

p. 70)

Remove motorcycle from the lift stand. (

Check static sag of the shock absorber. ( Check riding sag of the shock absorber. (

p. 55)

p. 48) p. 48)

Adjust the rebound damping of the shock absorber. ( p. 47)

50

TUNING THE CHASSIS 11 11.11

Checking the basic setting of the fork Info

For various reasons, no exact riding sag can be determined for the forks.

– – As with the shock absorber, small differences in the rider's weight can be compensated by the spring preload.

However, if the fork is often overloaded (hard end stop on com pression), harder springs must be fit to avoid damage to the fork and frame.

401000-01

11.12

Adjusting the compression damping of the fork Info

The hydraulic compression damping determines the fork suspension behavior.

A00451-10 – Turn adjusting screws 1 clockwise all the way.

Info

Adjusting screws 1 are located at the top end of the fork legs.

Make the same adjustment on both fork legs.

– Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline Compression damping Standard 15 clicks

Info

Turn clockwise to increase damping; turn counterclock wise to reduce damping.

11.13

Adjusting the rebound damping of the fork Info

The hydraulic rebound damping determines the fork suspension behavior.

51

11 TUNING THE CHASSIS 11.14

Handlebar position

402496-10 – – Take off protection caps 1 .

Turn adjusting screws 2 clockwise all the way.

Info

Adjusting screws 2 are located at the bottom end of the fork legs.

Make the same adjustment on both fork legs.

Turn counterclockwise by the number of clicks corresponding to the fork type.

Guideline Rebound damping Standard 15 clicks –

Info

Turn clockwise to increase damping; turn counterclock wise to reduce damping.

Mount protection caps 1 .

The holes on the handlebar holders are placed at a distance of from the center.

A Distance A between holes 3.5 mm (0.138 in) The handlebar supports can be turned by 180°. In this way, the handlebar can be mounted in the position that is most comfortable for the rider.

The handlebar supports can also be mounted at two different heights (with and without a spacer).

11.15

L03166-10

Adjusting the handlebar position Warning Danger of accidents

  A repaired handlebar poses a safety risk.

If the handlebar is bent or straightened, the material becomes fatigued. The handlebar may break as a result.

– Change the handlebar if the handlebar is damaged or bent.

52

TUNING THE CHASSIS 11

L03167-10 – – – Remove four screws 1 .

Take off handlebar clamps elastomers 4 .

2 with rubber washers 3 and Fix handlebar onto instrument support with cable ties.

– – – –

Info

Cover the components to protect them against damage.

Do not kink the cables and lines.

Take out lower shells 5 .

Remove clamp bar 7 with rubber cones 6 .

Remove two screws 8 . Take off handlebar supports.

Place handlebar supports in required position. Mount and tighten two screws 8 .

Guideline Screw, handle bar support M10 40 Nm (29.5 lbf ft)

Loctite ® 243™ Condition

Spacer 9 fitted: Use an M10x35 screw.

Condition

without spacer 9 : Use an M10x25 screw.

Info

Position left and right handlebar supports evenly.

– – – Insert conical rubber pieces 6 and clamping bar 7 .

Fit lower shells 5 .

Position handlebar.

Info

Make sure the cables and wiring are positioned cor rectly.

Position handlebar clamps elastomers 4 .

2 with rubber washers 3 and Elastomer kit, green - soft (SXS05125203) Elastomer kit, yellow - medium (standard) (SXS05125204) Elastomer kit, red - hard (SXS05125205)

Info

The elastomers are available in different versions.

– Mount and evenly tighten four screws 1 .

Guideline Screw, handlebar clamp M8 16 Nm (11.8 lbf ft)

53

11 TUNING THE CHASSIS Info

Make sure the installed gaps are even.

54

SERVICE WORK ON THE CHASSIS 12 12.1

Raising the motorcycle with a lift stand Note Danger of damage

  The parked vehicle can roll away or fall over.

– Park the vehicle on a firm and level surface.

– – Use the engine guard underneath the engine to raise the vehi cle.

Neither wheel is in contact with the ground.

Secure the motorcycle against falling over.

401942-01

12.2

Removing motorcycle from lift stand Note Danger of damage

  The parked vehicle can roll away or fall over.

– Park the vehicle on a firm and level surface.

– – – Remove motorcycle from the lift stand.

Remove lift stand.

To park the motorcycle, press side stand 1 with your foot and lean the motorcycle on it.

to the ground

Info

When you are riding, the side stand must be folded up and secured with the rubber strap.

401943-10

12.3

Bleeding the fork legs Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Release bleeder screws 1 .

Any excess pressure escapes from the interior of the fork.

Tighten the bleeder screws.

A00451-11

Finishing work

Remove motorcycle from the lift stand. ( p. 55)

55

12 SERVICE WORK ON THE CHASSIS 12.4

Cleaning the dust boots of the fork legs Preparatory work

Raise the motorcycle with a lift stand. (

Remove fork protector. ( p. 56)

p. 55)

Main work

– Push dust boots 1 of both fork legs downward.

Info

The dust boots remove dust and coarse dirt particles from the inside fork tubes. Over time, dirt can accumu late behind the dust boots. If this dirt is not removed, the oil seals behind can start to leak.

A00452-10 – –

Warning Danger of accidents

  Oil or grease on the brake discs reduces the braking effect.

Always keep the brake discs free of oil and grease.

Clean the brake discs with brake cleaner when nec essary.

– Clean and oil the dust boots and inner fork tubes of both fork legs.

Universal oil spray ( p. 160)

– – Press the dust boots back into the installation position.

Remove excess oil.

Finishing work

Install the fork protector. (

p. 57)

Remove motorcycle from the lift stand. ( p. 55)

12.5

Removing fork protector

– – – Remove screws 1 and take off the clamp.

Remove screws fork protector.

2 on the left fork leg and take off the left Remove screws fork protector.

3 on the right fork leg and take off the right A00456-10

56

SERVICE WORK ON THE CHASSIS 12 12.6

Installing the fork protector

A00456-11 – – – Position fork protector on the right fork leg. Mount and tighten screws 1 .

Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) Position brake line, wiring harness, and clamp. Mount and tighten screws 2 .

Position fork protector on left fork leg. Mount and tighten screws 3 .

Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft)

12.7

Removing fork legs Preparatory work

Raise the motorcycle with a lift stand. (

– Remove front wheel.

( p. 99)

p. 55)

Main work

– Remove screws – side.

1 .

Allow the brake caliper and brake line to hang loosely to the A00467-10 – – Loosen screws 2 . Take out the right fork leg.

Loosen screws 3 . Take out the left fork leg.

A00468-10

57

12 SERVICE WORK ON THE CHASSIS 12.8

Installing the fork legs Main work

– Position fork legs.

Bleeder screws 1 are positioned toward the front.

Info

Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

A00451-11 A00468-11 – – Tighten screws 2 .

Guideline Screw, top triple clamp Tighten screws 3 .

Guideline Screw, bottom triple clamp M8 M8 17 Nm (12.5 lbf ft) 12 Nm (8.9 lbf ft) – Position brake caliper. Mount and tighten screws 4 .

Guideline Screw, front brake caliper M8 30 Nm (22.1 lbf ft)

Loctite ® 243™

A00467-11

Finishing work

– Install the front wheel.

( p. 99)

12.9

Removing lower triple clamp

– –

Preparatory work

Raise the motorcycle with a lift stand. (

– Remove front wheel.

( p. 99)

Remove fork legs.

(

Remove front fender. (

p. 57)

p. 66)

p. 55)

Main work

– Remove cable tie(s) 1 .

Allow the brake caliper and brake line to hang loosely to the side.

L03030-10

58

SERVICE WORK ON THE CHASSIS 12

– Remove screws 2 and take off the cable guide.

A00471-10 – – Remove screws 3 handlebar clamps.

and take off the retaining plate with the Remove screws 4 and take off steering damper 5 .

A00472-10 – Fix handlebar tie(s) 7 .

6 onto the instrument support with cable A00474-10 – – – – Secure lower triple clamp 8 against falling out.

Remove screw 9 .

Remove screw bk .

Remove upper triple clamp.

A00475-10 – – – Remove O-ring bk . Remove protective ring bl .

Take out the lower triple clamp with the steering stem.

Take out the upper steering head bearing.

A00473-10

59

12 SERVICE WORK ON THE CHASSIS 12.10

Installing the lower triple clamp

– –

Main work

– Clean the bearing and sealing elements, check for damage, and grease.

High viscosity grease ( p. 160)

– Insert the lower triple clamp with the steering stem. Mount upper steering head bearing.

Check whether upper steering head seal tioned.

1 is correctly posi Slide on protective ring 2 and O-ring 3 .

A00466-10 – – Position upper triple clamp.

Mount screw 4 , but do not tighten yet.

A00475-11 – Position fork legs.

Bleeder screws 5 are positioned toward the front.

Info

Grooves are milled into the side of the upper end of the fork legs. The second milled groove (from the top) must be flush with the upper edge of the upper triple clamp.

A00476-10 – Tighten screws 6 .

Guideline Screw, bottom triple clamp M8 12 Nm (8.9 lbf ft) A00468-12

60

SERVICE WORK ON THE CHASSIS 12

– Secure the brake line with cable tie 7 .

Guideline Screw, brake line holder on bottom triple clamp M5 2 Nm (1.5 lbf ft) L03038-10 A00476-13 – – Tighten screw 4 .

Guideline Screw, top steering head M20x1 Mount and tighten screw Guideline 8 .

Screw, top steering stem M8 – Tighten screws 9 .

Guideline Screw, top triple clamp M8 12 Nm (8.9 lbf ft) 20 Nm (14.8 lbf ft)

Loctite ® 243™

17 Nm (12.5 lbf ft) A00468-13 A00472-11 – – – Remove cable tie(s) and place handlebar onto handlebar clamp base.

Position steering damper and mount and tighten screws bk .

Guideline Screw, steering damper M6 15 Nm (11.1 lbf ft) Fit handlebar clamps, position the handlebar, and mount and tighten screws bl .

Guideline Screw, handlebar clamp M8 16 Nm (11.8 lbf ft)

Finishing work

– Check that the wiring harness, throttle cables, and brake and clutch lines can move freely and are routed correctly.

Install front fender. ( p. 66)

– Install the front wheel.

( p. 99)

Check steering head bearing play. ( p. 62)

Remove motorcycle from the lift stand. ( p. 55)

61

12 SERVICE WORK ON THE CHASSIS 12.11

Checking steering head bearing play Warning Danger of accidents

  Incorrect steering head bearing play impairs the handling characteristic and dam ages components.

– Correct incorrect steering head bearing play immediately. (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.

400738-11

Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Move the handlebar to the straight-ahead position. Move the fork legs to and fro in the direction of travel.

Play should not be detectable on the steering head bearing.

– » If there is detectable play: – Adjust steering head bearing play.

( p. 62)

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 steering head bearing play.

( p. 62)

Check steering head bearing and replace if required.

Finishing work

Remove motorcycle from the lift stand. ( p. 55)

12.12

Adjusting steering head bearing play Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Remove screws – Remove screws 1 and take off the handlebar clamps.

2 and take off steering damper 3 .

A00472-12

62

SERVICE WORK ON THE CHASSIS 12

– – – Fix handlebar onto instrument support with cable ties.

Loosen screws 4 .

Remove screw 5 .

A00476-11 – – Loosen and retighten screw 6 .

Guideline Screw, top steering head M20x1 12 Nm (8.9 lbf ft) Using a plastic hammer, tap lightly on the upper triple clamp to avoid stresses.

A00476-12 A00476-11 A00472-12 – – Tighten screws 4 .

Guideline Screw, top triple clamp M8 Mount and tighten screw 5 .

Guideline Screw, top steering stem M8 17 Nm (12.5 lbf ft) 20 Nm (14.8 lbf ft)

Loctite ® 243™

– – – Position steering damper screws 2 .

3 and mount and tighten Guideline Screw, steering damper M6 15 Nm (11.1 lbf ft) Remove cable tie(s) and place handlebar onto handlebar clamp base.

Fit retaining plate with handlebar clamps, position handlebar, and mount and tighten screws 1 .

Guideline Screw, handlebar clamp M8 16 Nm (11.8 lbf ft)

Finishing work

Check steering head bearing play. (

p. 62)

Remove motorcycle from the lift stand. ( p. 55)

63

12 SERVICE WORK ON THE CHASSIS 12.13

Greasing the steering head bearing

– – Remove lower triple clamp.

Install the lower triple clamp.

(

(

p. 58)

p. 60)

12.14

H02387-01

Removing shock absorber

– –

Preparatory work

Raise the motorcycle with a lift stand. (

– Fold out the side stand and secure it.

Remove the seat. ( p. 67)

Take out the tool set compartment.

Remove main silencer. ( p. 69)

Main work

– Remove screws 1 .

p. 55)

L03048-10 – Carefully lower rear fuel tank 2 .

L03049-10 – Remove screw 3 with the washer.

Info

Raise wheel slightly to make it easier to remove screw.

L03050-10

64

SERVICE WORK ON THE CHASSIS 12

– Remove screw 4 with the washer.

L03051-10 – Remove shock absorber toward top carefully.

12.15

L03052-10

Installing the shock absorber Main work

– Carefully position shock absorber into the vehicle from above.

L03053-10 – Mount and tighten screw 1 with the washer.

Guideline Screw con nection, shock absorber, top M10 45 Nm (33.2 lbf ft)

Loctite ® 243™

L03054-10 L03055-10 – Mount and tighten screw Guideline Screw connec tion, shock absorber, bot tom M10 2 with the washer.

45 Nm (33.2 lbf ft)

Loctite ® 243™ Info

Raise wheel slightly to be able to mount screw more easily.

65

12 SERVICE WORK ON THE CHASSIS

– Raise rear fuel tank 3 .

L03056-10 – Mount and tighten screws 4 .

Guideline Remaining screws, chassis M8 25 Nm (18.4 lbf ft) L03057-10 – –

Finishing work

Install the main silencer. (

– Mount tool set compartment.

p. 70)

Mount the seat. ( p. 67)

Remove motorcycle from the lift stand. ( p. 55)

12.16

Removing front fender

– Remove screws 1 and take off fender 2 .

12.17

A00480-10

Installing the front fender

– Position fender 1 and mount and tighten screws 2 .

Guideline Remaining screws, chassis M6 10 Nm (7.4 lbf ft) A00480-11

66

12.18

Removing the seat SERVICE WORK ON THE CHASSIS 12

– Pull on loop take it off.

1 . At the same time, lift the seat at the rear and

12.19

Mounting the seat

A00445-10 – – – Position the seat between the two front fuel tanks.

Insert locking pin 1 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.

L03062-10

12.20

Removing air filter Note Engine damage

  Unfiltered intake air has a negative effect on the service life of the engine.

Dust and dirt will enter the engine without an air filter.

– Never start to use the vehicle without an air filter.

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Preparatory work

Remove the seat. (

p. 67)

Take out the tool set compartment.

Main work

– Remove screws – 1 .

Remove air filter cover 2 .

A00477-10

67

12 SERVICE WORK ON THE CHASSIS

– Remove air filter 3 .

A00477-11

12.21

Cleaning the air filter and air filter box Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Do not clean the air filter with fuel or petroleum since these substances attack the foam.

L03065-10

Preparatory work

Remove the seat. (

p. 67)

Take out the tool set compartment.

– Remove air filter.

( p. 67)

Main work

– Wash the air filter thoroughly in special cleaning liquid and allow it to dry properly.

Air filter cleaner ( p. 160)

Info

Only press the air filter to dry it, never wring it out.

– Oil the dry air filter with a high-grade air filter oil.

Oil for foam air filter ( p. 160)

– – Clean the air filter box.

Check intake flange for damage and looseness.

Finishing work

– Install the air filter.

Mount the seat. (

(

p. 67)

p. 69)

Mount tool set compartment.

68

SERVICE WORK ON THE CHASSIS 12 12.22

Installing the air filter Main work

– Mount clean air filter 1 .

Info

The air filter must lie flush against the air filter box along the entire sealing surface.

If the air filter is not correctly mounted, dust and dirt can enter the engine and cause damage.

A00477-12 – – Position air filter cover 2 .

Mount and tighten screws 3 .

A00477-13

Finishing work

Mount the seat. (

p. 67)

Mount tool set compartment.

12.23

Removing main silencer Warning Danger of burns

  The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down before performing any work on the vehicle.

– – Detach springs 1 .

Spring hook (5030501700004) Remove screw 2 and take off the main silencer.

A00453-10

69

12 SERVICE WORK ON THE CHASSIS 12.24

Installing the main silencer

A00453-11 – – – Position main silencer. Mount screw yet.

1 , but do not tighten Attach springs 2 .

Spring hook (5030501700004) Tighten screw 1 .

Guideline Remaining screws, chassis M8 25 Nm (18.4 lbf ft)

12.25

Changing the glass fiber yarn filling of the main silencer Warning Danger of burns

  The exhaust system gets very hot when the vehicle is driven.

– Allow the exhaust system to cool down before performing any work on the vehicle.

Info

Over a period, the fibers of the rock wool escape into the air, and the silencer "burns out".

Not only is the noise level higher, the performance characteristic changes.

A00405-10

Preparatory work

Remove main silencer. ( p. 69)

Main work

– Drill out all rivets on the main silencer and remove steel strips.

Carefully remove rivets in inward direction.

Info

Remove all remains of rivets from the inside of the main silencer.

– – – – – – – – – Take off silencer cap 1 and outer tube 2 .

Pull glass fiber yarn filling 3 off of inner tube 4 .

Clean the parts that need to be reinstalled and check for dam age.

Wind adhesive tape around the end of inner tube 4 .

Mount new glass fiber yarn filling 3 on inner tube 4 .

Remove adhesive tape from inner tube 4 .

Slide outer tube 2 over the glass fiber yarn filling 3 .

Insert silencer cap 1 into the outer tube.

Position steel bands and mount new rivets.

Finishing work

Install the main silencer. ( p. 70)

70

SERVICE WORK ON THE CHASSIS 12 12.26

Removing front left fuel tank

– – – – –

Danger Fire hazard

  Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

Switch off the engine for refueling.

Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

If any fuel is spilled, wipe it off immediately.

Observe the specifications for refueling.

– – – – – – –

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

Avoid skin, eye and clothing contact with fuel.

Immediately consult a doctor if you swallow fuel.

Do not inhale fuel vapors.

In case of skin contact, rinse the affected area with plenty of water.

Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

Change your clothing in case of fuel spills on them.

Keep fuels correctly in a suitable canister, and out of the reach of children.

A00478-10 – – –

Preparatory work

Remove the seat. (

p. 67)

Take out the tool set compartment.

Remove front fairing. ( Remove engine guard. (

Remove side cover. (

p. 86) p. 86)

p. 84)

Main work

– Clean plug-in connection compressed air.

1 of the fuel line thoroughly with –

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve!

Disconnect plug-in connection of the fuel line and remove it from the holder.

Info

Remaining fuel may flow out of the fuel hose.

– Mount wash cap set 2 from the separate enclosure.

Wash cap set (81212016100) S01076-10

71

12 SERVICE WORK ON THE CHASSIS

L03072-10 – Clean plug-in connection compressed air.

3 of the fuel line thoroughly with –

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve!

Disconnect plug-in connection of the fuel line.

– – – – –

Info

Remaining fuel may flow out of the fuel hose.

Mount wash cap set from the separate enclosure.

Wash cap set (81212016000) Disconnect plug-in connection 4 of the fuel pump.

Detach fuel tank breather hose 5 .

Remove screws 6 .

Take off the fuel tank.

Info

Set the fuel tank down in an upright position as other wise fuel can escape from the fuel tank breather at the fuel tank filler cap.

A00481-10

12.27

Removing front right fuel tank

– – – – –

Danger Fire hazard

  Fuel is highly flammable.

The fuel in the fuel tank expands when warm and can escape if overfilled.

Do not refuel the vehicle in the vicinity of open flames or lit cigarettes.

Switch off the engine for refueling.

Make sure that no fuel is spilled; particularly not on hot parts of the vehicle.

If any fuel is spilled, wipe it off immediately.

Observe the specifications for refueling.

– – – – – – –

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

Avoid skin, eye and clothing contact with fuel.

Immediately consult a doctor if you swallow fuel.

Do not inhale fuel vapors.

In case of skin contact, rinse the affected area with plenty of water.

Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

Change your clothing in case of fuel spills on them.

Keep fuels correctly in a suitable canister, and out of the reach of children.

Preparatory work

Remove the seat. (

p. 67)

Take out the tool set compartment.

Remove front fairing. ( p. 86)

72

SERVICE WORK ON THE CHASSIS 12

A00478-10 – –

Remove engine guard. (

Remove side cover. (

p. 86)

p. 84)

Main work

– Clean plug-in connection compressed air.

1 of the fuel line thoroughly with –

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve!

Disconnect plug-in connection of the fuel line and remove it from the holder.

Info

Remaining fuel may flow out of the fuel hose.

– Mount wash cap set 2 from the separate enclosure.

Wash cap set (81212016000) S01076-10 – – – Detach fuel tank breather hose 3 .

Remove screws 4 .

Take off the fuel tank.

Info

Set the fuel tank down in an upright position as other wise fuel can escape from the fuel tank breather at the fuel tank filler cap.

A00482-10

12.28

Installing the front left fuel tank

Main work

– Position fuel tank, and mount and tighten screws 1 .

Guideline Screw, front fuel tank M8 8 Nm (5.9 lbf ft) Mount fuel tank breather hose 2 .

A00481-11

73

12 SERVICE WORK ON THE CHASSIS

L03072-10 A00478-11 – – Remove wash cap set.

Clean plug-in connection compressed air.

3 of the fuel line thoroughly with – – – –

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve!

Lubricate the O-ring and join the plug-in connection of the fuel line.

Join the plug-in connector of fuel pump 4 .

Remove wash cap set.

Clean plug-in connection compressed air.

5 of the fuel line thoroughly with

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve!

– – Position fuel line in the holder.

Lubricate the O-ring and join the plug-in connection of the fuel line.

– –

Finishing work

Install the engine guard. (

Mount front fairing. (

p. 87)

p. 86)

Mount side cover. (

Mount tool set compartment.

Mount the seat. (

p. 85)

p. 67)

12.29

Installing the front right fuel tank

Main work

– Position fuel tank, and mount and tighten screws 1 .

Guideline Screw, front fuel tank M8 8 Nm (5.9 lbf ft) Mount fuel tank breather hose 2 .

A00482-11 A00478-12 – – Remove wash cap set.

Clean plug-in connection compressed air.

3 of the fuel line thoroughly with – –

Info

Under no circumstances should dirt enter into the fuel line. Dirt in the fuel line clogs the injection valve!

Position fuel line in the holder.

Lubricate the O-ring and join the plug-in connection of the fuel line.

74

SERVICE WORK ON THE CHASSIS 12 Finishing work

Install the engine guard. (

Mount front fairing. (

p. 87)

p. 86)

Mount side cover. ( p. 85)

– Mount tool set compartment.

Mount the seat. ( p. 67)

12.30

Checking the chain for dirt accumulation

– Check the chain for coarse dirt accumulation.

» If the chain is very dirty: –

Clean the chain. ( p. 75)

400678-01

12.31

Cleaning the chain Warning Danger of accidents

  Lubricants on the tires reduces the road grip.

– Remove lubricants from the tires using a suitable cleaning agent.

– –

Warning Danger of accidents

  Oil or grease on the brake discs reduces the braking effect.

Always keep the brake discs free of oil and grease.

Clean the brake discs with brake cleaner when necessary.

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

The service life of the chain depends largely on its maintenance.

Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Rinse off loose dirt with a soft jet of water.

– Remove old grease residue with chain cleaner.

Chain cleaner ( p. 160)

After drying, apply chain spray.

Off-road chain spray ( p. 160)

400725-01

75

12 SERVICE WORK ON THE CHASSIS Finishing work

Remove motorcycle from the lift stand. ( p. 55)

12.32

Checking chain tension

– –

Warning Danger of accidents

  Incorrect chain tension damages components and results in accidents.

If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.

If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.

Check the chain tension regularly.

Set the chain tension in accordance with the specification.

L02756-10

Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Push the chain upward at the end of the chain sliding guard to measure chain tension A .

Info

Top chain section 1 must be taut.

Chain wear is not always even, so you should repeat this measurement at different chain positions.

Chain tension 7 mm » If the chain tension does not meet the specification: –

Adjust the chain tension. ( p. 76)

Finishing work

Remove motorcycle from the lift stand. ( p. 55)

12.33

Adjusting the chain tension

– –

Warning Danger of accidents

  Incorrect chain tension damages components and results in accidents.

If the chain is tensioned too much, the chain, engine sprocket, rear sprocket, transmission and rear wheel bearings wear more quickly. Some components may break if overloaded.

If the chain is too loose, the chain may fall off the engine sprocket or the rear sprocket. As a result, the rear wheel locks or the engine will be damaged.

Check the chain tension regularly.

Set the chain tension in accordance with the specification.

Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

76

SERVICE WORK ON THE CHASSIS 12

A00446-10 –

Main work

– Loosen nut – Loosen nuts 1 .

2 .

Adjust the chain tension by turning adjusting screws and right.

3 left Guideline Chain tension 7 mm Turn adjusting screws 3 on the left and right so that the markings on the left and right chain adjusters are in the same position relative to reference marks A . The rear wheel is then correctly aligned.

– – –

Info

The top chain section must be taut.

Chain wear is not always even. Repeat this measure ment at different chain positions.

Tighten nuts 2 .

Make sure that chain adjusters adjusting screws 3 .

4 are fitted correctly on Tighten nut 1 .

Guideline Nut, rear wheel spin dle M25x1.5

90 Nm (66.4 lbf ft)

Info

The wide adjustment range of the chain adjusters enables different secondary ratios with the same chain length.

Chain adjusters 4 can be turned by 180°.

Finishing work

Remove motorcycle from the lift stand. ( p. 55)

12.34

Checking chain, rear sprocket, engine sprocket, and chain guide Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Shift transmission into neutral.

– Check rear sprocket and engine sprocket for wear.

» If the rear sprocket and engine sprocket are worn: – Change the drivetrain kit.

400227-01

Info

The engine sprocket, rear sprocket, and chain should always be replaced together.

77

12 SERVICE WORK ON THE CHASSIS 1 2 3 16 17 18

400987-10 – – Pull on the top section of the chain with the specified weight A .

Guideline Weight, chain wear measure ment 10 … 15 kg (22 … 33 lb.) Measure distance section.

B of 18 chain rollers in the lower chain

Info

Chain wear is not always even, so you should repeat this measurement at different chain positions.

Maximum distance B at the longest chain section 272 mm (10.71 in) » If distance B – is greater than the specified measurement: Change the drivetrain kit.

Info

When a new chain is mounted, the rear sprocket and engine sprocket should also be changed.

New chains wear out faster on old, worn sprock ets.

– – Check chain sliding guard for wear.

» If the lower edge of the chain pins is in line with, or below, the chain sliding guard: – Change the chain sliding guard.

Check that the chain sliding guard is firmly seated.

» If the chain sliding guard is loose: – Tighten chain sliding guard.

Guideline Screw, chain sliding guard M6 6 Nm (4.4 lbf ft)

Loctite ® 243™

L03081-10

78

SERVICE WORK ON THE CHASSIS 12

– – Check chain sliding piece for wear.

» If the lower edge of the chain pins is in line with or below the chain sliding piece: – Change the chain sliding piece.

Check that the chain sliding piece is firmly seated.

» If the chain sliding piece is loose: – Tighten the chain sliding piece.

Guideline Screw, chain slid ing piece M8 15 Nm (11.1 lbf ft) L03082-10 L03083-10 – Check chain guide for wear.

Info

Wear can be seen on the front of the chain guide.

– » If the chain guide is worn: – Change the chain guide.

Check that the chain guide is firmly seated.

» If the chain guide is loose: – Tighten the chain guide.

Guideline Remaining screws, chassis M6 Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Finishing work

Remove motorcycle from the lift stand. ( p. 55)

12.35

Checking frame

L03160-10 – Check frame for cracks and deformation.

» If the frame exhibits cracks or deformation due to a mechanical impact: – Change the frame.

Info

Always replace a frame that has been dam aged due to a mechanical impact. Repair of the frame is not authorized by KTM.

79

12 SERVICE WORK ON THE CHASSIS 12.36

Checking swingarm

– Check link fork for damage, cracking, and deformation.

» If the link fork shows signs of damage, cracking, or defor mation: – Change the link fork.

Info

Always replace a damaged link fork. Repairing the link fork is not authorized by KTM.

L03161-10

12.37

Checking throttle cable routing

– –

Preparatory work

Remove the seat. (

p. 67)

Take out the tool set compartment.

Remove front fairing. ( p. 86)

Remove engine guard. (

Remove side cover. (

p. 86)

p. 84)

Remove front right fuel tank.

( p. 72)

Main work

– Check throttle cable routing.

Both throttle cables must be routed side-by-side behind the handlebars and between the right fork leg and frame toward the throttle valve body.

» If the throttle cable routing is not as specified: – Correct the throttle cable routing.

A00479-10 – – – –

Finishing work

– Install the front right fuel tank.

Install the engine guard. (

(

p. 87)

Mount front fairing. (

Mount side cover. (

p. 86)

p. 85)

Mount tool set compartment.

Mount the seat. ( p. 67)

p. 74)

80

SERVICE WORK ON THE CHASSIS 12 12.38

Checking the rubber grip

– Check the rubber grips on the handlebar for damage, wear, and looseness.

» If a rubber grip is damaged, worn, or loose: – Change and secure the rubber grip.

Rubber grip adhesive (00062030051) ( p. 160)

12.39

401197-01

Adjusting the basic position of the clutch lever

– Adjust basic position of the clutch lever to your hand size by turning adjusting screw 1 .

L03085-10

Info

Turn the adjusting screw clockwise to increase the distance between the clutch lever and the handlebar.

Turn the adjusting screw counterclockwise to decrease the distance between the clutch lever and the handle bar.

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.

12.40

Checking/correcting the fluid level of the hydraulic clutch

– – – – –

Warning Skin irritation

  Brake fluid causes skin irritation.

– Keep brake fluid out of the reach of children.

Wear suitable protective clothing and safety glasses.

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

Consult a doctor immediately if brake fluid has been swallowed.

Rinse the affected area with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.

– If brake fluid spills on to your clothing, change the clothing.

Info

The fluid level rises with increasing wear of the clutch facing discs.

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

81

12 SERVICE WORK ON THE CHASSIS

– – Remove screw 1 .

Take off fuel pump controller 2 and hang to the side.

L03162-10 L03086-10 – – – – – Move the hydraulic clutch fluid reservoir mounted on the han dlebar to a horizontal position.

Remove screws 3 .

Take off cover 4 with membrane 5 .

Check fluid level.

Fluid level tainer rim A below con 4 mm (0.16 in) » If the level of the fluid does not meet specifications: – Correct the fluid level of the hydraulic clutch.

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

Position cover screws 3 .

4 with membrane 5 . Mount and tighten

Info

Clean up overflowed or spilled brake fluid immediately with water.

– – Position fuel pump controller 2 .

Mount and tighten screw 1 .

L03162-10

82

SERVICE WORK ON THE CHASSIS 12 12.41

Changing the hydraulic clutch fluid

– – – – – –

Warning Skin irritation

  Brake fluid causes skin irritation.

Keep brake fluid out of the reach of children.

Wear suitable protective clothing and safety glasses.

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

Consult a doctor immediately if brake fluid has been swallowed.

Rinse the affected area with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.

– If brake fluid spills on to your clothing, change the clothing.

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and clutch lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

– – Remove screw 1 .

Take off fuel pump controller 2 and hang to the side.

L03162-10 – – – Move the hydraulic clutch fluid reservoir mounted on the han dlebar to a horizontal position.

Remove screws 3 .

Take off cover 4 with membrane 5 .

L03087-10

83

12 SERVICE WORK ON THE CHASSIS

L03088-10 – – – – Disconnect plug-in connector 6 .

Disconnect plug-in connection 7 of the fuel line.

Fill bleeding syringe 8 with the appropriate hydraulic fluid.

Syringe (50329050000)

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

On the slave cylinder, remove bleeder screw bleeding syringe 8 .

9 and mount – – – – – Inject the liquid into the system until it escapes from open ings bk of the master cylinder without bubbles.

Now and then, extract fluid from the master cylinder reservoir to prevent overflow.

Remove bleeding syringe screw 9 .

8 . Mount and tighten bleeder Correct the fluid level of the hydraulic clutch.

Guideline Fluid level tainer rim A below con 4 mm (0.16 in) Position cover screws 3 .

4 with membrane 5 . Mount and tighten

Info

Clean up overflowed or spilled brake fluid immediately with water.

L03089-10 – – Position fuel pump controller 2 .

Mount and tighten screw 1 .

12.42

Removing side cover

L03162-10

Preparatory work

Remove the seat. ( p. 67)

84

SERVICE WORK ON THE CHASSIS 12 Main work

– Disconnect plug-in connectors – Remove screws 2 .

1 of the turn signals.

A00483-10 – – – Remove screws 3 .

Unlock quick releases 4 .

Carefully push the side cover to the rear and remove.

12.43

Mounting side cover

A00484-10 – – – Position side cover and slide it forward.

Lock quick releases 1 .

Mount and tighten screws 2 .

A00484-11

85

12 SERVICE WORK ON THE CHASSIS

– – Mount and tighten screws 3 .

Join plug-in connection 4 of the turn signals.

12.44

A00483-11

Removing front fairing

– – Unlock quick releases 1 .

Raise the front fairing, tilt forward and take off.

12.45

A00485-10

Mounting front fairing

– – Position front fairing.

Lock quick releases 1 .

12.46

A00485-10

Removing engine guard

– Remove screws 1 guard to the front.

with the washers. Take off the engine A00486-10

86

SERVICE WORK ON THE CHASSIS 12 12.47

Installing the engine guard

– – Position the engine guard.

Mount and tighten screws Guideline 1 with the washers.

Screw, engine guard M8 25 Nm (18.4 lbf ft) A00486-11

87

13 BRAKE SYSTEM 13.1

Adjusting the basic position of the hand brake lever

– Adjust basic position of the hand brake lever to your hand size by turning adjusting screw 1 .

A00487-10

Info

Turn the adjusting screw clockwise to increase the distance between the hand brake lever and the han dlebar.

Turn the adjusting screw counterclockwise to decrease the distance between the hand brake lever and the han dlebar.

The range of adjustment is limited.

Only turn the adjusting screw by hand, and do not use force.

Do not make any adjustments while riding.

13.2

Checking brake discs Warning Danger of accidents

  Worn-out brake discs reduce the braking effect.

– Make sure that worn-out brake discs are replaced immediately. (Your authorized KTM workshop will be glad to help.) 400257-10 – Check front and rear brake disc thickness at multiple points for the dimension A .

Info

Wear reduces the thickness of the brake disc around the contact surface of the brake linings.

– Brake discs - wear limit front rear 3.4 mm (0.134 in) 3.5 mm (0.138 in) » If the brake disc thickness is less than the specified value: – Change brake disc.

Check front and rear brake discs for damage, cracking, and deformation.

» If the brake disc exhibits damage, cracking, or deforma tion: – Change brake disc.

88

BRAKE SYSTEM 13 13.3

Checking front brake fluid level Warning Danger of accidents

  An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – – Move brake reservoir mounted on handlebar to a horizontal position.

Check brake fluid level in level viewer 1 .

» If the brake fluid level has dropped below the marking – Add front brake fluid.

( p. 89)

A :

13.4

A00488-10

Adding front brake fluid Warning Danger of accidents

  An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the specified marking or the specified value, the brake system is leaking or the brake linings are worn down.

– Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) – – – – – –

Warning Skin irritation

  Brake fluid causes skin irritation.

Keep brake fluid out of the reach of children.

Wear suitable protective clothing and safety glasses.

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

Consult a doctor immediately if brake fluid has been swallowed.

Rinse the affected area with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.

– If brake fluid spills on to your clothing, change the clothing.

Warning Danger of accidents

  Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

89

13 BRAKE SYSTEM Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

– – – Move brake reservoir mounted on handlebar to a horizontal position.

Remove screws 1 .

Take off cover 2 with membrane 3 .

A00489-10 – – – Add brake fluid to level A .

Guideline Dimension A 5 mm (0.2 in)

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

Position cover 2 with membrane 3 .

Mount and tighten screws 1 .

Info

Clean up overflowed or spilled brake fluid immediately with water.

13.5

A00490-10

Checking the front brake linings Warning Danger of accidents

  Worn-out brake linings reduce the braking effect.

– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

90

BRAKE SYSTEM 13 Warning Danger of accidents

  Damaged brake discs reduce the braking effect.

If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.

– Check the brake linings regularly.

– – Check the brake linings for minimum thickness A .

Minimum thickness A ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickness is less than specified: – Change front brake linings.

( p. 91)

Check the brake linings for damage and cracking.

» If damage or cracking is visible: – Change front brake linings.

( p. 91)

A00491-10

13.6

Changing front brake linings Warning Danger of accidents

  Incorrect servicing will cause the brake system to fail.

– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.) – – – – – –

Warning Skin irritation

  Brake fluid causes skin irritation.

Keep brake fluid out of the reach of children.

Wear suitable protective clothing and safety glasses.

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

Consult a doctor immediately if brake fluid has been swallowed.

Rinse the affected area with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.

– If brake fluid spills on to your clothing, change the clothing.

Warning Danger of accidents

  Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – –

Warning Danger of accidents

  Oil or grease on the brake discs reduces the braking effect.

Always keep the brake discs free of oil and grease.

Clean the brake discs with brake cleaner when necessary.

91

13 BRAKE SYSTEM Warning Danger of accidents

  Brake linings which have not been approved alter the braking efficiency.

Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

If brake linings are used that differ from the original equipment, compliance with the original homologa tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.

– Only use brake linings approved and recommended by KTM.

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

– – – Move brake reservoir mounted on handlebar to a horizontal position.

Remove screws 1 .

Take off cover 2 with membrane 3 .

A00489-10 A00492-10 – Press the brake caliper onto the brake disc by hand in order to push back the brake pistons. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.

– –

Info

Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

Remove cotter pin 4 .

Drive out pin linings.

5 with drift 6 toward rim and remove brake A00493-10

92

BRAKE SYSTEM 13

– – Clean brake caliper and brake caliper bracket.

Check that spring plate plate 8 7 in the brake caliper and sliding in the brake caliper bracket are seated properly.

L02781-10 – Insert new brake linings, insert pin pin 4 .

5 , and mount cotter A00492-11 – – Operate the hand brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point.

Add brake fluid up to level A .

Guideline Dimension A 5 mm (0.2 in) – –

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

Position cover 2 with membrane 3 .

Mount and tighten screws 1 .

Info

Clean up overflowed or spilled brake fluid immediately with water.

13.7

A00490-10

Checking the free travel of the foot brake lever Warning Danger of accidents

  The brake system fails in the event of overheating.

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

– Set the free travel on the foot brake lever in accordance with the specification.

93

13 BRAKE SYSTEM

A00494-10 – – – Detach the spring from the foot brake lever.

Move the foot brake lever back and forth between the end stop and the contact to the foot brake cylinder piston and check free travel A .

Guideline Free travel at the foot brake lever 3 … 5 mm (0.12 … 0.2 in) » If the free travel does not meet specifications: –

(

Adjust the free travel of the foot brake lever.

p. 94)

Attach the spring to the foot brake lever.

13.8

Adjusting the free travel of the foot brake lever Warning Danger of accidents

  The brake system fails in the event of overheating.

If there is no free travel on the foot brake lever, pressure builds up in the brake system on the rear brake.

– Set the free travel on the foot brake lever in accordance with the specification.

– – Loosen nut 1 and use screw 2 to adjust free travel A .

Guideline Free travel at the foot brake lever 3 … 5 mm (0.12 … 0.2 in) Hold screw 2 and tighten nut 1 .

Guideline Remaining nuts, chassis M6 10 Nm (7.4 lbf ft) A00494-11

13.9

Checking rear brake fluid level Warning Danger of accidents

  An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the worn down.

MIN

marking, the brake system is leaking or the brake linings are – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

94

BRAKE SYSTEM 13

– – Stand vehicle upright.

Check brake fluid level in level viewer 1 .

» If the brake fluid level has dropped below the marking – Add rear brake fluid.

( p. 95)

A :

13.10

A00495-10

Adding rear brake fluid Warning Danger of accidents

  An insufficient brake fluid level will cause the brake system to fail.

If the brake fluid level drops below the worn down.

MIN

marking, the brake system is leaking or the brake linings are – Check the brake system and do not continue riding until the problem is eliminated. (Your authorized KTM workshop will be glad to help.) – –

Warning Skin irritation

  Brake fluid causes skin irritation.

– Keep brake fluid out of the reach of children.

– Wear suitable protective clothing and safety glasses.

– Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

– Consult a doctor immediately if brake fluid has been swallowed.

Rinse the affected area with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.

– If brake fluid spills on to your clothing, change the clothing.

Warning Danger of accidents

  Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.)

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

95

13 BRAKE SYSTEM

A00496-10 – – – – Stand vehicle upright.

Remove screw cap 1 with the washer and membrane 2 .

Add brake fluid to the marking on the inside of the compensat ing tank.

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

Mount screw cap with washer and membrane.

Info

Clean up overflowed or spilled brake fluid immediately with water.

13.11

Checking the rear brake linings Warning Danger of accidents

  Worn-out brake linings reduce the braking effect.

– Ensure that worn-out brake linings are replaced immediately. (Your authorized KTM workshop will be glad to help.)

Warning Danger of accidents

  Damaged brake discs reduce the braking effect.

If the brake linings are not changed in time, the brake lining carriers grind against the brake disc. As a consequence, the braking effect is greatly reduced and the brake discs are destroyed.

– Check the brake linings regularly.

– – Check the brake linings for minimum thickness A .

Minimum thickness A ≥ 1 mm ( ≥ 0.04 in) » If the minimum thickness is less than specified: – Change rear brake linings.

( p. 96)

Check the brake linings for damage and cracking.

» If damage or cracking is visible: – Change rear brake linings.

( p. 96)

S03071-11

13.12

Changing rear brake linings Warning Danger of accidents

  Incorrect servicing will cause the brake system to fail.

– Ensure that service work and repairs are performed professionally. (Your authorized KTM workshop will be glad to help.)

96

BRAKE SYSTEM 13

– – – – – –

Warning Skin irritation

  Brake fluid causes skin irritation.

Keep brake fluid out of the reach of children.

Wear suitable protective clothing and safety glasses.

Do not allow brake fluid to come into contact with the skin, the eyes or clothing.

Consult a doctor immediately if brake fluid has been swallowed.

Rinse the affected area with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water immediately and consult a doctor if brake fluid comes into contact with the eyes.

– If brake fluid spills on to your clothing, change the clothing.

Warning Danger of accidents

  Old brake fluid reduces the braking effect.

– Make sure that brake fluid for the front and rear brake is changed in accordance with the service schedule. (Your authorized KTM workshop will be glad to help.) – –

Warning Danger of accidents

  Oil or grease on the brake discs reduces the braking effect.

Always keep the brake discs free of oil and grease.

Clean the brake discs with brake cleaner when necessary.

Warning Danger of accidents

  Brake linings which have not been approved alter the braking efficiency.

Not all brake linings are tested and approved for KTM motorcycles. The structure and friction coefficient of the brake linings, and thus their brake power, may vary greatly from that of original brake linings.

If brake linings are used that differ from the original equipment, compliance with the original homologa tion is not guaranteed. In this case, the vehicle no longer corresponds to its condition at delivery and the warranty shall be void.

– Only use brake linings approved and recommended by KTM.

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Never use DOT 5 brake fluid. It is silicone-based and purple in color. Oil seals and brake lines are not designed for DOT 5 brake fluid.

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint.

Only use clean brake fluid from a sealed container.

– – Stand vehicle upright.

Remove screw cap 1 with the washer and membrane 2 .

A00496-10

97

13 BRAKE SYSTEM

S03071-10 – Press brake caliper onto the brake disc by hand in order to push back the brake piston. Ensure that brake fluid does not flow out of the brake fluid reservoir; extract some if necessary.

Info

Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.

Remove cotter pin 3 .

– Drive out pin linings.

4 with drift 5 toward rim and remove brake S03070-10 – – Clean brake caliper and brake caliper bracket.

Check that spring plate plate 6 in the brake caliper and sliding 7 in brake caliper bracket are seated properly.

L02780-10 – Insert new brake linings pin.

8 , insert pin 4 , and mount cotter S03069-10 S03068-10 – – – Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point.

Correct brake fluid level to the marking on the inside of the compensating tank.

Brake fluid DOT 4 / DOT 5.1 ( p. 158)

Mount screw cap with washer and membrane.

Info

Clean up overflowed or spilled brake fluid immediately with water.

98

WHEELS, TIRES 14 14.1

Removing front wheel Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

Main work

– Press the brake caliper onto the brake disc by hand in order to push back the brake pistons.

Info

Make sure that you do not press the brake caliper against the spokes when pushing back the brake pistons.

A00492-12 A00497-10 – – – Loosen screws 1 .

Remove screw 2 .

Loosen screws 3 .

Warning Danger of accidents

  Damaged brake discs reduce the braking effect.

– Always lay the wheel down in such a way that the brake disc is not damaged.

– Hold front wheel and remove wheel spindle. Take the front wheel out of the fork.

Info

Do not actuate the hand brake lever when the front wheel is removed.

– Remove spacers 4 .

14.2

S01062-10

Installing the front wheel

– –

Warning Danger of accidents

  Oil or grease on the brake discs reduces the braking effect.

Always keep the brake discs free of oil and grease.

Clean the brake discs with brake cleaner when necessary.

99

14 WHEELS, TIRES 14.3

Removing rear wheel

H00935-10 A00497-11 – – Check wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn: – Change the wheel bearing.

Clean and grease shaft seal rings 1 contact surface of the wheel spindle.

and contact surfaces A of the spacers. Clean and grease the shaft seal rings and the

Long-life grease (

Insert the spacers.

p. 160)

– – – Position front wheel and insert wheel spindle 2 .

The brake linings are correctly positioned.

Mount and tighten screw 3 .

Guideline Screw, front wheel spindle M24x1.5

40 Nm (29.5 lbf ft) – – – –

Info

Ensure that the grip of the wheel spindle does not con tact with the right fork leg.

Operate the hand brake lever several times until the brake lin ings are seated correctly against the brake disc.

Remove motorcycle from the lift stand. ( p. 55)

Operate the front brake and compress the fork a few times firmly.

The fork legs straighten.

Tighten screws 4 and 5 .

Guideline Screw, fork stub M8 15 Nm (11.1 lbf ft)

Preparatory work

Raise the motorcycle with a lift stand. ( p. 55)

100

WHEELS, TIRES 14 Main work

– Press brake caliper onto the brake disc by hand in order to push back the brake piston.

– – – –

Info

Make sure that you do not press the brake caliper against the spokes when pushing back the brake piston.

Remove nut 1 .

Remove chain adjuster 2 .

Pull out wheel spindle to be pushed forward.

3 far enough to allow the rear wheel Push the rear wheel forward as far as possible. Remove chain from rear sprocket.

Info

Cover the components to protect them against damage.

S03063-10

Warning Danger of accidents

  Damaged brake discs reduce the braking effect.

– Always lay the wheel down in such a way that the brake disc is not damaged.

– Hold the rear wheel and remove wheel spindle rear wheel out of the link fork.

3 . Take the

Info

Do not operate the foot brake lever when the rear wheel is removed.

– Remove spacer 4 .

S03060-11 – Remove rear sprocket carrier 5 .

S03059-11

101

14 WHEELS, TIRES 14.4

Installing the rear wheel

– –

Warning Danger of accidents

  Oil or grease on the brake discs reduces the braking effect.

Always keep the brake discs free of oil and grease.

Clean the brake discs with brake cleaner when necessary.

– –

Main work

– Check rear hub damping rubber pieces.

(

Check wheel bearing for damage and wear.

» If the wheel bearing is damaged or worn: – Change the wheel bearing.

p. 103)

Clean and grease shaft seal ring the spacer.

1 and contact surface A of

Long-life grease (

Insert the spacer.

p. 160)

S03060-10 – – Clean and grease the spacers of the rear sprocket carrier.

Long-life grease ( p. 160)

Insert rear sprocket carrier 2 into the rear hub.

S03059-10 S03057-10 – – – – – – Position rear wheel and insert wheel spindle 3 .

The brake linings are correctly positioned.

Mount chain.

Position chain adjuster it yet.

4 . Mount nut 5 , but do not tighten Make sure that the chain adjusters are fitted correctly on the adjusting screws 6 .

Check chain tension. ( p. 76)

Tighten nut 5 .

Guideline Nut, rear wheel spin dle M25x1.5

90 Nm (66.4 lbf ft) –

Info

The wide adjustment range of the chain adjusters enables different secondary ratios with the same chain length.

Chain adjusters 4 can be turned by 180°.

Operate the foot brake lever repeatedly until the brake lin ings are in contact with the brake disc and there is a pressure point.

102

WHEELS, TIRES 14 Finishing work

Remove motorcycle from the lift stand. ( p. 55)

14.5

Checking rear hub damping rubber pieces Info

The engine power is transmitted from the rear sprocket to the rear wheel via the 6 damping rubber pieces.

They eventually wear out during operation. If the damping rubber pieces are not changed in time, the rear sprocket carrier and the rear hub will be damaged.

S03056-10 S03055-10 –

Preparatory work

Raise the motorcycle with a lift stand. (

– Remove rear wheel.

( p. 100)

p. 55)

Main work

– Check bearing 1 .

» If the bearing is damaged or worn: – Change the bearing.

Check damping rubber pieces and wear.

2 of the rear hub for damage » If the damping rubber pieces of the rear hub are damaged or worn: – Change all the damping rubber pieces of the rear hub.

Lay the rear wheel on a workbench with the rear sprocket fac ing upward and insert the wheel spindle in the hub.

To check the play A , hold the rear wheel tight and try to rotate the rear sprocket.

Info

Measure the play on the outside of the rear sprocket.

Play of damping rubber pieces on rear wheel ≤ 5 mm ( ≤ 0.2 in) » If clearance – A is larger than the specified value: Change all the damping rubber pieces of the rear hub.

Finishing work

– Install the rear wheel.

( p. 102)

Remove motorcycle from the lift stand. ( p. 55)

14.6

Checking tire condition Info

Only mount tires approved and/or recommended by KTM.

Other tires could have a negative effect on handling characteristics.

The type, condition, and pressure of the tires all have a major impact on the handling characteristic of the motorcycle.

The tires mounted on the front and rear wheels must have a similar profile.

Worn tires have a negative effect on handling characteristics, especially on wet surfaces.

103

14 WHEELS, TIRES

400602-10 H01144-01 – – Check front and rear tires for cuts, run-in objects, and other damage.

» If the tires have cuts, run-in objects, or other damage: – Change tires.

Check tread depth.

Info

Adhere to the legally required minimum tread depth.

– Minimum tread depth ≥ 2 mm ( ≥ 0.08 in) » If the tread depth is less than the minimum tread depth: – Change tires.

Check tire age.

Info

The tire date of manufacture is usually contained in the tire label and is indicated by the last four digits of the

DOT

number. The first two digits indicate the week of manufacture and the last two digits the year of manu facture.

KTM recommends that the tires be changed after 5 years at the latest, regardless of the actual state of wear.

» If the tires are more than 5 years old: – Change tires.

14.7

Checking tire pressure Info

Low tire pressure leads to abnormal wear and overheating of the tire.

Correct tire pressure ensures optimal riding comfort and maximum tire service life.

400695-01 – – – Remove protection cap.

Check tire pressure when the tires are cold.

Offroad tire pressure front rear 1.0 … 1.5 bar (15 … 22 psi) 1.0 … 1.5 bar (15 … 22 psi) Street tire pressure front rear 1.5 bar (22 psi) 1.5 bar (22 psi) » If the tire pressure does not meet specifications: – Correct the tire pressure.

Mount protection cap.

104

WHEELS, TIRES 14 14.8

Checking spoke tension Warning Danger of accidents

  Incorrectly tensioned spokes impair the handling characteristic and result in sec ondary damage.

The spokes break due to being overloaded if they are too tightly tensioned. If the tension in the spokes is too low, then lateral and radial run-out will form in the wheel. Other spokes will become looser as a result.

– Check spoke tension regularly, and in particular on a new vehicle. (Your authorized KTM workshop will be glad to help.) 400694-01 – Strike each spoke briefly using a screwdriver blade.

Info

The frequency of the sound depends on the spoke length and spoke diameter.

If you hear different tone frequencies from different spokes of equal length and diameter, this is an indica tion of different spoke tensions.

– You should hear a high note.

» If the spoke tension differs: – Correct the spoke tension.

Check the spoke torque.

Guideline Spoke nipple, front wheel M4.5

Spoke nipple, rear wheel M5 Torque wrench kit (58429094000) 5 … 6 Nm (3.7 … 4.4 lbf ft) 5 … 6 Nm (3.7 … 4.4 lbf ft)

105

15 ELECTRICAL SYSTEM 15.1

Removing 12-V battery

– – – –

Warning Risk of injury

  12 V batteries contain harmful substances.

Keep 12 V batteries out of the reach of children.

Keep sparks and open flames away from 12 V batteries.

Only charge 12 V batteries in well-ventilated rooms.

Maintain a minimum clearance from inflammable materials when charging 12 V batteries.

Minimum clearance 1 m (3 ft) – Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.

Minimum voltage before the start of the charge 9 V – Dispose of 12 V batteries with less than the minimum voltage correctly.

Preparatory work

– Switch off all power consumers and switch off the engine.

Remove the seat. ( p. 67)

– – –

Main work

– Disconnect negative cable – Disconnect positive cable 1 2 from the 12-V battery.

from the 12-V battery.

Remove screw 3 .

Detach holder 4 to the rear.

Lift out the 12-V battery.

15.2

A00500-10

Installing the 12-V battery

A00500-11 – – – –

Main work

– Insert the 12-V battery into the battery compartment.

Lithium-ion battery ( p. 134)

Attach holder 1 .

Mount and tighten screw 2 .

Connect positive cable 3 to the 12-V battery.

Guideline Nut, cable on 12-V battery M6 5 Nm (3.7 lbf ft) Connect negative cable 4 to the 12-V battery.

Guideline Nut, cable on 12-V battery M6 5 Nm (3.7 lbf ft)

Finishing work

Mount the seat. ( p. 67)

106

ELECTRICAL SYSTEM 15 15.3

Charging the 12-V battery

– – – –

Warning Risk of injury

  12 V batteries contain harmful substances.

Keep 12 V batteries out of the reach of children.

Keep sparks and open flames away from 12 V batteries.

Only charge 12 V batteries in well-ventilated rooms.

Maintain a minimum clearance from inflammable materials when charging 12 V batteries.

Minimum clearance 1 m (3 ft) – Do not charge deeply discharged 12 V batteries if the charge is already below the minimum voltage.

Minimum voltage before the start of the charge 9 V – Dispose of 12 V batteries with less than the minimum voltage correctly.

Note Environmental hazard

  12 V batteries contain environmentally hazardous materials.

– Do not dispose of 12 V batteries as household waste.

– Dispose of 12 V batteries at a collection point for used batteries.

Info

Even if there is no load on the 12-V battery, it discharges steadily each day.

The charging voltage of the 12-V battery must not exceed 14.4 V.

The charging level and the method of charging are very important for the service life of the 12-V battery.

If the charging current or charging voltage are exceeded, the 12-V battery will be irreparably damaged.

If the 12-V battery is depleted by repeated starting, the 12-V battery must be charged immediately.

If the 12-V battery is left in a discharged state for an extended period, it will become over-discharged and will be irreparably damaged.

The 12-V battery is maintenance-free.

M01573-01

Preparatory work

– Switch off all power consumers and switch off the engine.

Remove the seat. ( p. 67)

– Disconnect negative cable of the 12-V battery to avoid damage to the onboard electronics.

Main work

– Connect battery charger to the 12-V battery. Switch on battery charger.

Battery charger (79629974000) It is impossible to overcharge the 12-V battery using this device.

– –

Info

Only charge the 12-V battery with the specified battery charger.

This is the only way to ensure that a charging voltage of 14.4 V is not exceeded.

Switch off battery charger after charging and disconnect it from the 12-V battery.

Connect negative cable to the 12-V battery.

107

15 ELECTRICAL SYSTEM Finishing work

Mount the seat. ( p. 67)

15.4

Changing the main fuse

– –

Warning Fire hazard

  Incorrect fuses overload the electrical system.

Only use fuses with the required ampere value.

Do not bypass or repair fuses.

Info

The main fuse protects all power consumers of the vehicle. It is located in the starter relay housing under the seat.

Preparatory work

– Switch off all power consumers and switch off the engine.

Remove the seat. ( p. 67)

Main work

– Remove protection cap 1 .

Remove the faulty main fuse 2 .

S03086-10 S03053-10 – Fit a new main fuse.

Fuse (58011109130) ( p. 134)

Info

Replace a faulty fuse A reserve fuse 3 2 by an equivalent fuse only.

is located in the starter relay.

Check that the electrical equipment is functioning properly.

Tip

Insert the spare fuse so that it is available if needed.

– Attach the protection caps.

Finishing work

Mount the seat. ( p. 67)

108

ELECTRICAL SYSTEM 15 15.5

Changing the fuses of individual power consumers 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. 67)

Main work

– Push on locks 1 and remove fuse box cover 2 .

S03052-10 S03051-10 – Remove faulty fuse.

Guideline Fuse

1

- 10 A - ICO Speedocap, turn signal, instrument Fuse

2

- 10 A - road book Fuse

3

- 5 A - Iritrack Fuse

4

- 5 A - GPS Fuse

5

- 5 A - brake light, coolant temperature indicator lamp, oil pressure warning lamp, horn Fuse

6

- 15 A - high beam, low beam, position light, road book lighting, tail light Fuse

7

- 10 A - radiator fan Fuse

8

- 10 A - front fuel pump, rear fuel pump, diagnosis, EFI, lambda sensor, map switch, malfunction indicator lamp

Info

A faulty fuse has a burned-out fuse wire A .

– –

Warning Fire hazard

  Incorrect fuses overload the electrical sys tem.

Only use fuses with the required ampere value.

Do not bypass or repair fuses.

– – – Insert a spare fuse with the correct rating.

Fuse (58011109105) ( Fuse (58011109110) ( Fuse (58011109115) ( p. 134) p. 134) p. 134)

Check that the power consumer is functioning properly.

Close the fuse box cover.

109

15 ELECTRICAL SYSTEM Finishing work

Mount the seat. ( p. 67)

110

COOLING SYSTEM 16 16.1

16.2

Cooling system

A00498-10 Water pump 1 in the engine ensures forced circulation of the coolant.

The pressure resulting from the warming of the cooling system is regulated by a valve in radiator cap ing the vehicle at the specified coolant temperature will not result in a risk of malfunctions.

2 . This ensures that operat 120 °C (248 °F) Cooling is effected by the air stream.

The lower the speed, the less the cooling effect. Dirty cooling fins also reduce the cooling effect.

Additional cooling is provided by the radiator fan, which is acti vated at high temperature.

Checking the antifreeze and coolant level Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.

– In the event of scalding, rinse the area affected immediately with lukewarm water.

– – – – – –

Warning Danger of poisoning

  Coolant is toxic and a health hazard.

Keep coolant out of the reach of children.

Do not allow coolant to come into contact with the skin, the eyes and clothing.

Consult a doctor immediately if coolant is swallowed.

Rinse the affected area immediately with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

Change clothing if coolant spills onto your clothing.

400243-10

Condition

The engine is cold.

– – – Stand the motorcycle upright on a horizontal surface.

Remove the radiator cap.

Check the antifreeze in the coolant.

− 25 … − 45 °C ( − 13 … − 49 °F) – » If the antifreeze in the coolant does not match the speci fied value: – Correct the antifreeze in the coolant.

Check the coolant level in the radiator.

Coolant level radiator fins A above the 10 mm (0.39 in) » If the coolant level does not match the specified value: – Correct the coolant level.

111

16 COOLING SYSTEM

Coolant ( p. 158)

Mount the radiator cap.

16.3

Checking the coolant level Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.

– In the event of scalding, rinse the area affected immediately with lukewarm water.

– – – – – –

Warning Danger of poisoning

  Coolant is toxic and a health hazard.

Keep coolant out of the reach of children.

Do not allow coolant to come into contact with the skin, the eyes and clothing.

Consult a doctor immediately if coolant is swallowed.

Rinse the affected area immediately with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

Change clothing if coolant spills onto your clothing.

400243-10 –

Condition

The engine is cold.

– – – Stand the motorcycle upright on a horizontal surface.

Remove the radiator cap.

Check the coolant level in the radiator.

Coolant level radiator fins A above the 10 mm (0.39 in) » If the coolant level does not match the specified value: – Correct the coolant level.

Coolant ( p. 158)

Mount the radiator cap.

16.4

Draining the coolant Warning Danger of scalding

  During motorcycle operation, the coolant gets very hot and is under pressure.

– Do not open the radiator, the radiator hoses or other cooling system components if the engine or the cooling system are at operating temperature.

– Allow the cooling system and the engine to cool down before you open the radiator, the radiator hoses or other components of the cooling system.

– In the event of scalding, rinse the area affected immediately with lukewarm water.

112

COOLING SYSTEM 16

– – – – – –

Warning Danger of poisoning

  Coolant is toxic and a health hazard.

Keep coolant out of the reach of children.

Do not allow coolant to come into contact with the skin, the eyes and clothing.

Consult a doctor immediately if coolant is swallowed.

Rinse the affected area immediately with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

Change clothing if coolant spills onto your clothing.

Condition

The engine is cold.

– – – – – Position motorcycle upright.

Place an appropriate container under the water pump cover.

Remove screw 1 . Take off radiator cap Completely drain coolant.

2 .

Mount and tighten screw Guideline 1 with a new seal ring.

Screw, water pump cover M6 10 Nm (7.4 lbf ft) S03050-10

16.5

Refilling coolant

– – – – – –

Warning Danger of poisoning

  Coolant is toxic and a health hazard.

Keep coolant out of the reach of children.

Do not allow coolant to come into contact with the skin, the eyes and clothing.

Consult a doctor immediately if coolant is swallowed.

Rinse the affected area immediately with plenty of water in the event of contact with the skin.

Rinse eyes thoroughly with water and consult a doctor immediately if coolant gets into the eyes.

Change clothing if coolant spills onto your clothing.

S03049-10 – – – Make sure that screw 1 is tightened.

Stand the motorcycle upright.

Pour coolant in up to measurement A above the radiator fins.

Guideline Coolant level radiator fins A above the 10 mm (0.39 in) 1.0 l (1.1 qt.) – – –

Coolant ( p. 158)

Mount the radiator cap.

Take a short test ride.

Check the coolant level. ( p. 112)

113

17 TUNING THE ENGINE 17.1

Checking throttle cable play

400192-11 – – Check throttle grip for smooth operation.

Move the handlebar to the straight-ahead position. Turn the throttle grip back and forth slightly and determine the play in throttle cable A .

Throttle cable play 3 … 5 mm (0.12 … 0.2 in) » If the throttle cable play does not meet specifications: – Adjust throttle cable play.

( p. 114)

Danger Danger of poisoning

  Exhaust gases are toxic and inhal ing them may result in unconsciousness and death.

– Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

– Start the engine and let it run at idle speed. Move the handle bar to and fro over the entire steering range.

The idle speed must not change.

» If the idle speed changes: – Adjust throttle cable play.

( p. 114)

17.2

Adjusting throttle cable play Info

If the correct routing of the throttle cables has already been secured, the fuel tank does not need to be removed.

– – – –

Preparatory work

Remove the seat. (

p. 67)

Take out the tool set compartment.

Remove front fairing. ( Remove engine guard. ( p. 86) p. 86)

Remove side cover. ( p. 84)

Remove front right fuel tank.

Check throttle cable routing. (

( p. 72)

p. 80)

114

TUNING THE ENGINE 17

A00499-10 – – – – – – –

Main work

– Move the handlebar to the straight-ahead position.

– Push back sleeve 1 .

Loosen nut 2 .

Turn adjusting screw 3 in as far as possible.

Loosen nut 4 .

Push cold start button 6 all the way to the stop.

Turn adjusting screw 5 so that the cold start button moves to the basic position when the throttle grip is turned to the front.

Tighten nut 4 .

Turn barrel adjuster cable at the throttle grip.

Guideline 3 so that there is play in the throttle Throttle cable play 3 … 5 mm (0.12 … 0.2 in) – – – Tighten nut 2 .

Slide on sleeve 1 .

Check throttle grip for smooth operation.

– – – – –

Finishing work

– Install the front right fuel tank.

Install the engine guard. (

(

p. 87)

Mount front fairing. (

Mount side cover. (

p. 86)

p. 85)

Mount tool set compartment.

Mount the seat. ( p. 67)

Check throttle cable play. ( p. 114)

p. 74)

17.3

Adjusting the idle speed

A00407-10 – Run the engine until warm.

Danger Danger of poisoning

  Exhaust gases are toxic and inhal ing them may result in unconsciousness and death.

– Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

– Adjust the idle speed by turning the idle speed adjusting screw.

Guideline Idle speed 2,400 ± 200 rpm

Info

Turn counterclockwise to increase the idle speed.

Turn clockwise to decrease the idle speed.

115

17 TUNING THE ENGINE 17.4

Checking basic position of the shift lever Info

When driving, the shift lever must not touch the rider's boot when in the basic position.

When the shift lever keeps touching the boot, the transmission will be subject to an excessive load.

– 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 10 … 20 mm (0.39 … 0.79 in) » If the distance does not meet specifications: – Set basic position of shift lever.

( p. 116)

400692-10

17.5

Adjusting the basic position of the shift lever

– Remove screw lever 2 .

1 with the washers and take off shift 401950-12 401951-10 – – Clean gear teeth A of the shift lever and shift shaft.

Mount shift lever 2 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.

Mount and tighten screw 1 with the washers.

Guideline Screw, shift lever M6 14 Nm (10.3 lbf ft)

Loctite ® 243™ 116

SERVICE WORK ON THE ENGINE 18 18.1

Checking the engine oil level

S03036-11

Preparatory work

– Stand the motorcycle upright on a horizontal surface.

Condition

The engine is at operating temperature.

– Check the engine oil level.

Info

After switching off the engine, wait one minute before checking the level.

The engine oil level is between A and B .

» When the engine oil level is below the –

Add engine oil. ( p. 121)

A marking: » When the engine oil level is at or above the ing: – Correct the engine oil level.

B mark-

18.2

Changing the engine oil and oil filter, cleaning the oil screens

– –

Warning Danger of scalding

  Engine and gear oil get very hot when the motorcycle is ridden.

Wear suitable protective clothing and safety gloves.

In the event of scalding, rinse the area affected immediately with lukewarm water.

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

Drain the engine oil while the engine is at operating temperature.

Preparatory work

– Park motorcycle on a level surface.

Remove engine guard. ( p. 86)

Main work

– Place an appropriate container under the engine.

– Remove oil drain plug 1 with the magnet and seal ring.

S03047-10

117

18 SERVICE WORK ON THE ENGINE

– Remove screw plug rings.

2 with the short oil screen and the O S03046-10 – – – Remove screw plug rings.

3 with the long oil screen 4 and the O Completely drain engine oil.

Thoroughly clean parts and sealing surfaces.

S03045-10 – Mount and tighten screw plug the O-rings.

2 with the short oil screen and Guideline Screw plug, oil screen M20x1.5

15 Nm (11.1 lbf ft) S03044-10 – – – Position oil screen 4 with the O-rings on a pin wrench.

Position pin wrench through the drill hole of the screw plug in the opposite section of the engine case.

Push oil screen all the way into the engine case.

S03043-10 S03042-10 – – Mount and tighten screw plug 3 with the O-ring.

Guideline Screw plug, oil screen M20x1.5

15 Nm (11.1 lbf ft) Mount and tighten oil drain plug new seal ring.

1 with the magnet and a Guideline Oil drain plug with magnet M12x1.5

20 Nm (14.8 lbf ft)

118

SERVICE WORK ON THE ENGINE 18

– Remove screws 5 . Remove oil filter cover with the O-ring.

S03039-10 – – – – Pull oil filter 6 out of the oil filter housing.

Lock ring plier (51012011000) Completely drain engine oil.

Thoroughly clean the parts and sealing surface.

Insert the new oil filter.

S03041-10 – Lubricate the O-ring of the oil filter cover and mount it with the oil filter cover 7 .

S03040-10 – Mount and tighten screws Guideline 5 .

Screw, oil filter cover M6 10 Nm (7.4 lbf ft) S03039-10 – Remove oil filler plug filter cover.

8 with the O-ring from the upper oil S03037-10

119

18 SERVICE WORK ON THE ENGINE

S03038-10 – – Fill oil filter housing at opening bubbles stop rising.

9 with oil and wait until air Total filling level, oil change Engine oil 1.40 l (1.48 qt.)

(

Engine oil (SAE 10W/50)

p. 158)

Total filling level, engine service (with oil radiator) Engine oil 1.80 l (1.9 qt.)

(

Engine oil (SAE 10W/50)

p. 158)

Mount and tighten filler plug 8 .

Guideline Filler plug on the oil filter housing M20x1.5

8 Nm (5.9 lbf ft) S03037-10 L02820-10 – Remove filler plug bk from the clutch cover together with the O-ring, and fill up with engine oil.

Total filling level, oil change Engine oil 1.40 l (1.48 qt.)

(

Engine oil (SAE 10W/50)

p. 158)

Total filling level, engine service (with oil radiator) Engine oil 1.80 l (1.9 qt.)

(

Engine oil (SAE 10W/50)

p. 158)

Info

Too little engine oil or poor-quality engine oil will result in premature wear of the engine.

Mount and tighten the filler plug together with the O-ring.

Danger Danger of poisoning

–   Exhaust gases are toxic and inhal ing them may result in unconsciousness and death.

Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

– Start the engine and check that it is oil-tight.

Finishing work

Check the engine oil level. (

Install the engine guard. (

p. 117)

p. 87)

120

SERVICE WORK ON THE ENGINE 18 18.3

Adding engine oil Info

Too little engine oil or poor-quality engine oil results in premature wear to the engine.

S03036-10 –

Main work

– Remove oil filler plug cover.

– 1 with the O-ring from the clutch Fill engine oil to the middle A of the level viewer.

Add the same engine oil that was used when the motor was changed.

Engine oil (SAE 10W/50) ( p. 158)

Info

For optimal performance of the engine oil, do not mix different types of engine oil.

We recommend making an oil change in this case.

– Install and tighten the oil filler plug with O-ring.

Danger Danger of poisoning

–   Exhaust gases are toxic and inhal ing them may result in unconsciousness and death.

Always make sure there is sufficient ventilation when running the engine.

– Use effective exhaust extraction when starting or running the engine in an enclosed space.

– Start the engine and check that it is oil-tight.

Finishing work

Check the engine oil level. ( p. 117)

121

19 CLEANING, CARE 19.1

Cleaning the motorcycle

– –

Note Material damage

  Components become damaged or destroyed if a pressure cleaner is used incorrectly.

The high pressure forces water into the electrical components, connectors, throttle cables, and bearings, etc.

Pressure which is too high causes malfunctions and destroys components.

Do not direct the water jet directly on to electrical components, connectors, throttle cables or bearings.

Maintain a minimum distance between the nozzle of the pressure cleaner and the component.

Minimum clearance 60 cm (23.6 in)

Note Environmental hazard

  Hazardous substances cause environmental damage.

– Dispose of oils, grease, filters, fuel, cleaning agents, brake fluid, etc., correctly and in compliance with the applicable regulations.

Info

To maintain the value and appearance of the motorcycle over a long period, clean it regularly.

Avoid direct sunshine when cleaning the motorcycle.

401061-01 – – – Close off exhaust system to keep water from entering.

Remove loose dirt first with a soft jet of water.

Spray heavily soiled parts with a normal commercial motorcy cle cleaner and then brush off with a soft brush.

– –

Info

Use warm water containing normal motorcycle cleaner and a soft sponge.

Never apply motorcycle cleaner to a dry vehicle; always rinse the vehicle with water first.

After rinsing the motorcycle with a gentle spray of water, allow it to dry thoroughly.

Remove closure of the exhaust system.

Warning Danger of accidents

  Moisture and dirt impair the brake system.

– Brake carefully several times to dry out and remove dirt from the brake linings and the brake discs.

– After cleaning, ride vehicle a short distance until the engine warms up.

– – –

Info

The heat produced causes water at inaccessible loca tions in the engine and on the brake system to evapo rate.

Push back protection caps of the handlebar controls to allow any water that has penetrated to evaporate.

After the motorcycle has cooled down, lubricate all moving parts and pivot points.

Clean the chain. ( p. 75)

122

CLEANING, CARE 19

– – – Treat bare metal (except for brake discs and the exhaust sys tem) with a corrosion inhibitor.

Treat all plastic parts and powder-coated parts with a mild cleaning and care product.

(

Preserving materials for paints, metal and rubber

p. 160)

Oil steering lock.

Universal oil spray ( p. 160)

19.2

Checks and maintenance steps for winter operation Info

If you use the motorcycle in winter, salt can be expected on the roads. You should therefore take precau tions against aggressive road salt.

If the vehicle was operated in road salt, clean it with cold water after riding. Warm water would enhance the corrosive effects of salt.

401060-01 – –

Clean motorcycle. (

Clean brake system.

p. 122)

Info

After

EVERY

trip on salted roads, thoroughly clean the brake calipers and brake linings, after they have cooled down and without removing them, with cold water and dry them carefully.

After riding on salted roads, thoroughly clean the motorcycle with cold water and dry it well.

Treat engine, link fork, and all other bare or zinc-plated parts (except the brake discs) with a wax-based corrosion inhibitor.

Info

Corrosion inhibitor must not come in contact with the brake discs as this would greatly reduce the braking force.

Clean the chain. ( p. 75)

123

20 STORAGE 20.1

Storage

– – – – – – –

Warning Danger of poisoning

  Fuel is poisonous and a health hazard.

Avoid skin, eye and clothing contact with fuel.

Immediately consult a doctor if you swallow fuel.

Do not inhale fuel vapors.

In case of skin contact, rinse the affected area with plenty of water.

Rinse the eyes thoroughly with water, and consult a doctor in case of fuel contact with the eyes.

Change your clothing in case of fuel spills on them.

Keep fuels correctly in a suitable canister, and out of the reach of children.

Info

If you plan to garage the motorcycle for a longer period, perform the following steps or have them per formed.

Before storing the motorcycle, check all parts for function and wear. If service, repairs, or replacements are necessary, you should do this during the storage period (less workshop overload). In this way, you can avoid long workshop waiting times at the start of the new season.

401058-01 – – – – – – – – – When refueling for the last time before taking the motorcycle out of service, add fuel additive.

Fill up with fuel. ( p. 41)

Clean motorcycle. (

(

Change engine oil and oil filter and clean the oil screens.

p. 117)

Check the antifreeze and coolant level. (

Check tire pressure. (

p. 122)

p. 104)

p. 111)

Remove 12-V battery.

Charge 12-V battery.

Guideline

(

( p. 106)

p. 107)

Storage temperature of the 12-V battery without direct sunlight Charging level of the 12-V battery for storage 0 … 35 °C (32 … 95 °F) 50 … 75 % Store vehicle in a dry location that is not subject to large fluc tuations in temperature.

– –

Info

KTM recommends jacking up the motorcycle.

Raise the motorcycle with a lift stand. ( p. 55)

Cover vehicle with a tarp or similar cover that is permeable to air.

124

STORAGE 20 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. Because the engine will not warm up sufficiently, the water vapor produced during combustion will condense, caus ing engine parts and the exhaust system to rust.

20.2

Preparing for use after storage

– – – –

Remove motorcycle from the lift stand. (

Take a test ride.

p. 55)

Install the 12-V battery.

( p. 106)

Perform checks and maintenance steps when preparing for

use. ( p. 38)

401059-01

125

21 TROUBLESHOOTING Faults

The engine does not turn when the electric starter button is pressed The engine turns but does not start Main fuse blown Starter relay defective Starter motor defective Operating error The coupling of the fuel hose connection is not connected Fuse

8

is blown Idle speed is not set correctly Spark plug oily or wet Electrode distance (plug gap) of spark plug too wide Engine does not speed up Engine has too little power

Possible cause

Operating error 12-V battery discharged Faulty ignition system Short circuit cable in wiring harness frayed, kill switch defective Error in the electronic fuel injection Error in the electronic fuel injection Faulty ignition system Air filter is very dirty Fuel filter is very dirty Error in the electronic fuel injection Exhaust system leaky, deformed or too little glass fiber yarn filling in main silencer Valve clearance too little – – – – – – – –

Action

(

Carry out the start procedure.

p. 38)

Charge 12-V battery.

Check charging voltage.

nator.

( p. 107)

Check the open-circuit current.

Check the stator winding of the alter-

Change the main fuse. (

Check the starter relay.

Check the starter motor.

p. 108)

(

Carry out the start procedure.

p. 38)

Join the fuel hose connection.

– – – – – – – – – – – – – – – – – Change the fuses of individual power

consumers. ( p. 109)

Adjust the idle speed.

( p. 115)

Clean and dry the spark plug, or change it if necessary.

Adjust plug gap.

Guideline Spark plug electrode gap 0.9 mm (0.035 in) Check ignition system.

Check the wiring harness. (visual check) Check the electrical system.

Read out fault memory using the KTM diagnostics tool.

Read out fault memory using the KTM diagnostics tool.

Ignition coil - check the secondary winding.

Check the spark plug connector.

Check the stator winding of the alter nator.

(

Clean the air filter and air filter box.

p. 68)

Change the fuel filter.

Read out fault memory using the KTM diagnostics tool.

Check exhaust system for damage.

Change the glass fiber yarn filling of the main silencer.

( p. 70)

– Adjust the valve clearance.

126

TROUBLESHOOTING 21 Faults

Engine has too little power The engine dies during the trip Engine overheats

FI

warning lamp (

MIL

) lights up/flashes High oil consumption 12-V battery discharged

Possible cause

Faulty ignition system Lack of fuel Too little coolant in cooling sys tem Too little air stream Radiator fins very dirty Foam formation in cooling sys tem Bent radiator hose Thermostat defective Defect in radiator fan system Error in the electronic fuel injection – – – – – – – – – – – – –

Action

– Ignition coil - check the secondary winding.

Check the spark plug connector.

Check the stator winding of the alter nator.

Fill up with fuel. ( p. 41)

Check the cooling system for leaks.

Check the coolant level. (

Switch off the engine when standing.

Clean the radiator fins.

Drain coolant.

Refill the coolant.

(

(

p. 112)

Change the radiator hose.

Check the thermostat.

Check fuse

7

.

Check the radiator fan.

p. 112)

p. 113)

Stop motorcycle and identify faulty component using the blink code.

Engine vent hose bent The engine oil level is too high The engine oil is too thin (low viscosity) Piston and cylinder worn The 12-V battery is not being charged by the alternator Combination instrument values deleted (time, stop watch, lap times) The turn signal and the combi nation instrument are not work ing The brake light is not working Unwanted power consumer The combination instrument battery is empty Fuse

1

is blown Fuse

5

is blown

Info

See blink code – – – – – – – – – – Check cabling for damage and electri cal plug-in connections for corrosion and damage.

Read out fault memory using the KTM diagnostics tool.

Route the vent hose without bends or change it if necessary.

Check the engine oil level. ( p. 117)

Change engine oil and oil filter and clean the oil screens.

( p. 117)

Measure the piston/cylinder mounting clearance.

Check charging voltage.

Check the stator winding of the alter nator.

Check the open-circuit current.

Change combination instrument bat tery.

– Change the fuses of individual power

consumers. ( p. 109)

– Change the fuses of individual power

consumers. ( p. 109)

127

21 TROUBLESHOOTING Faults

The high beam, low beam, position light, tail light, license plate lamp, and horn are not working

Possible cause

Fuse

6

is blown

Action

– Change the fuses of individual power

consumers. ( p. 109)

128

Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition Blink code FI warning lamp (MIL) Error level condition

02

FI

warning lamp (

MIL

) flashes 2x briefly Crankshaft speed sensor – circuit fault 06

FI

warning lamp (

MIL

) flashes 6x briefly Throttle valve position sensor circuit A – input signal too low Throttle valve position sensor circuit A – input signal too high 09

FI

warning lamp (

MIL

) flashes 9x briefly Induction manifold pressure sensor cylinder 1 – input signal too low Induction manifold pressure sensor cylinder 1 – input signal too high 12

FI

warning lamp (

MIL

) flashes 1x long, 2x briefly Coolant temperature sensor – input signal too low Coolant temperature sensor - input signal too high 13

FI

warning lamp (

MIL

) flashes 1x long, 3x briefly Intake air temperature sensor – input signal too low Intake air temperature sensor - input signal too high 15

FI

warning lamp (

MIL

) flashes 1x long, 5x briefly Rollover sensor (A/D type) - input signal too low Rollover sensor (A/D type) - input signal too high 33

FI

warning lamp (

MIL

) flashes 3x long, 3x briefly Injector cylinder 1 - circuit fault 37

FI

warning lamp (

MIL

) flashes 3x long, 7x briefly Ignition coil 1, cylinder 1 - circuit fault 41

FI

warning lamp (

MIL

) flashes 4x long, 1x briefly Fuel pump relay - short circuit to ground or open circuit Open/short circuit to plus

BLINK CODE 22 129

23 TECHNICAL DATA 23.1

Engine

Design Displacement Stroke Bore Compression ratio Idle speed Control Valve diameter, intake Valve diameter, exhaust Valve clearance Intake at: 20 °C (68 °F) Exhaust at: 20 °C (68 °F) Crankshaft bearing Conrod bearing Piston pin bearing Pistons Piston rings Engine lubrication Primary transmission Clutch Gearbox Transmission ratio First gear Second gear Third gear Fourth gear Fifth gear Sixth gear Alternator Ignition Spark plug Spark plug electrode gap Cooling Starting aid 1-cylinder 4-stroke engine, water-cooled 449.3 cm³ (27.418 cu in) 63.4 mm (2.496 in) 95 mm (3.74 in) 12.6:1 2,400 ± 200 rpm OHC, 4 valves controlled via rocker arm 40 mm (1.57 in) 33 mm (1.3 in) 0.10 … 0.15 mm (0.0039 … 0.0059 in) 0.12 … 0.17 mm (0.0047 … 0.0067 in) 2-cylinder roller bearing Slide bearing No bearing bush - DLC coated piston pin Forged light alloy 1 compression ring, 1 oil scraper ring Pressure circulation lubrication with two Eaton pumps 31:76 Multidisc clutch in oil bath, hydraulically activated 6-gear transmission, claw shifted 14:36 17:32 19:28 22:26 23:24 26:21 12 V, 200 W Contactless controlled fully electronic ignition with digital ignition adjustment NGK LKAR8AI ‑ 9 0.9 mm (0.035 in) Water cooling, permanent circulation of coolant by water pump Starter motor

130

23.2

Engine tightening torques

Oil jet, piston cooling M4 Crankshaft speed sensor screw and cable retainer Oil nozzle for clutch lubrication M5 M5 Oil nozzle, piston cooling Oil nozzle, rocker arm lubrication Screw, bearing retainer M5 M5 M5 Screw, clutch spring retainer Screw, gear position sensor Screw, locking lever Screw, stator Screw, suction pump cover Nut, water pump impeller M5 M5 Screw, alternator cover Screw, bearing bolt, torque limiter M6 M6 Screw, camshaft retaining bracket M6 M5 M5 M5 M6 Screw, clutch cover Screw, cylinder head Screw, engine case Screw, EVAP plug Screw, exhaust flange Screw, oil filter cover Screw, pressure pump cover Screw, shift drum locating Screw, shift lever M6 M6 Screw, starter motor Screw, timing chain failure protec tion Screw, timing chain tensioner Screw, timing chain tensioning rail M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6

TECHNICAL DATA 23

2 Nm (1.5 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft)

Loctite ® 243™

2 Nm (1.5 lbf ft)

Loctite ® 243™

2 Nm (1.5 lbf ft)

Loctite ® 243™

2 Nm (1.5 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft) 5 Nm (3.7 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft)

Loctite ® 243™

6 Nm (4.4 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 5 Nm (3.7 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft)

Loctite ® 243™

14 Nm (10.3 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™ 131

23 TECHNICAL DATA

Screw, valve cover Screw, water pump cover Oil nozzle for conrod bearing lubri cation Plug, oil channel M6 M6 M6x0.75

M7 Screw, rocker arm bearing Plug, crankshaft location Plug, timing chain tensioner Plug, oil channel M7 M8 M8 M10 Screw, engine sprocket Spark plug Coolant temperature sensor Screw plug, rocker arm shaft Screw, cylinder head M10 M10x1 M10x1.25

M10x1.25

M10x1.25

Nut, rotor M12x1 Oil drain plug with magnet Screw plug, oil pressure control valve Nut, inner clutch hub Filler plug on the oil filter housing Nut, primary gear wheel M12x1.5

M12x1.5

M18x1.5

M20x1.5

M20LHx1.5

Screw plug, oil screen M20x1.5

23.3

23.3.1

Engine oil

Capacities Engine oil

Total filling level, oil change 1.40 l (1.48 qt.) Total filling level, engine service (with oil radiator) Engine oil 1.80 l (1.9 qt.)

23.3.2

Coolant (

Coolant

p. 158)

10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 2 Nm (1.5 lbf ft) 9 Nm (6.6 lbf ft)

Loctite ® 243™

15 Nm (11.1 lbf ft) 10 Nm (7.4 lbf ft) 8 Nm (5.9 lbf ft) 15 Nm (11.1 lbf ft)

Loctite ® 243™

60 Nm (44.3 lbf ft)

Loctite ® 2701™

10 … 12 Nm (7.4 … 8.9 lbf ft) 12 Nm (8.9 lbf ft) 10 Nm (7.4 lbf ft) 1st stage 10 Nm (7.4 lbf ft) 2nd stage 30 Nm (22.1 lbf ft) 3rd stage 50 Nm (36.9 lbf ft) Collar and thread oiled 60 Nm (44.3 lbf ft) Thread, oiled with engine oil/cone degreased 20 Nm (14.8 lbf ft) 20 Nm (14.8 lbf ft) 80 Nm (59 lbf ft) 8 Nm (5.9 lbf ft) 100 Nm (73.8 lbf ft)

Loctite ® 243™

15 Nm (11.1 lbf ft)

(

Engine oil (SAE 10W/50)

p. 158) (

Engine oil (SAE 10W/50)

p. 158)

1.0 l (1.1 qt.)

132

23.3.3

Fuel

Please observe the labels on EU fuel pumps.

TECHNICAL DATA 23

A00420-10 Front left fuel tank, approx.

Super unleaded (ROZ 95/RON 95/PON 91) (

Front right fuel tank, approx.

Super unleaded (ROZ 95/RON 95/PON 91) (

Rear fuel tank, approx.

Super unleaded (ROZ 95/RON 95/PON 91) (

Total fuel tank capacity, approx.

Super unleaded (ROZ 95/RON 95/PON 91) ( p. 159) p. 159) p. 159) p. 159)

23.4

Frame

Chassis

Suspension travel front rear Brake system Brake discs - diameter front rear Brake discs - wear limit front rear Street tire pressure front rear Offroad tire pressure front rear Secondary drive ratio Rear sprockets available Chain Wheelbase Steering head angle Seat height unloaded Ground clearance unloaded Lattice frame of chromium-molybdenum steel tubes, powder-coated 305 mm (12.01 in) 300 mm (11.81 in) Disc brakes, floating brake calipers 300 mm (11.81 in) 240 mm (9.45 in) 3.4 mm (0.134 in) 3.5 mm (0.138 in) 1.5 bar (22 psi) 1.5 bar (22 psi) 8.0 l (2.11 US gal) 8.0 l (2.11 US gal) 14.0 l (3.7 US gal) 30.0 l (7.93 US gal) 1.0 … 1.5 bar (15 … 22 psi) 1.0 … 1.5 bar (15 … 22 psi) 14:51 50, 51, 52 5/8 x 1/4" 1,520 ± 10 mm (59.84 ± 0.39 in) 62.5° 960 mm (37.8 in) 280 mm (11.02 in)

133

23 TECHNICAL DATA

Weight without fuel, approx.

Maximum permissible front axle load Maximum permissible rear axle load Maximum permissible overall weight

23.5

Electrical system

Lithium-ion battery Fuse Fuse Fuse Fuse High beam Low beam Position light Indicator lamps Turn signal Brake / tail light License plate lamp 139 kg (306 lb.) 161.5 kg (356 lb.) 173.5 kg (382.5 lb.) 335 kg (739 lb.) Battery voltage: 13.2 V Nominal capacity: 4.6 Ah Maintenance-free 58011109105 58011109110 58011109115 58011109130 LED LED LED W1.2W / socket W2x4.6d

RY10W / socket BAU15s LED LED 5 A 10 A 15 A 30 A 12 V 1.2 W 12 V 10 W

23.6

Tires Front tire Rear tire 90/90 - 21 54S TT

Michelin T63

130/80 - 18 66S TT

Michelin T63 The tires specified represent one of the possible series production tires. Additional information is available in the Service section under: http://www.ktm.com

23.7

Fork

Fork article number Fork Compression damping Standard Rebound damping Standard Spring length with preload spacer(s) Spring rate Weight of rider: 55 … 65 kg (121 … 143 lb.) Weight of rider: 65 … 75 kg (143 … 165 lb.) Weight of rider: 75 … 85 kg (165 … 187 lb.) Weight of rider: 85 … 95 kg (187 … 209 lb.) Weight of rider: ≥ 95 kg ( ≥ 209 lb.) 14.18.2S.40

WP Suspension

Up Side Down 4860 MXMA CC 15 clicks 15 clicks 488 mm (19.21 in) 4.6 N/mm (26.3 lb/in) 4.8 N/mm (27.4 lb/in) 5.0 N/mm (28.6 lb/in) 5.2 N/mm (29.7 lb/in) 5.4 N/mm (30.8 lb/in)

134

TECHNICAL DATA 23

Fork length Oil capacity fork leg without car tridge Oil capacity per cartridge 950 mm (37.4 in) 445 ml (15.05 fl. oz.) 165 ml (5.58 fl. oz.)

(

Fork oil (SAE 4) (48601166S1)

p. 159) (

Fork oil (SAE 4) (48601166S1)

p. 159)

23.8

Shock absorber

Shock absorber article number Shock absorber Low-speed compression damping Comfort Standard Sport High-speed compression damping Comfort Standard Sport Rebound damping Comfort Standard Sport Spring preload Standard Spring rate Weight of rider: ≤ 65 kg ( ≤ 143 lb.) Weight of rider: 65 … 75 kg (143 … 165 lb.) Weight of rider: 75 … 85 kg (165 … 187 lb.) Weight of rider: 85 … 95 kg (187 … 209 lb.) Weight of rider: ≥ 95 kg ( ≥ 209 lb.) Spring length Gas pressure Static sag Riding sag Fitted length Shock absorber oil 18.18.0S.40

WP Suspension

5018 DCC Link 24 clicks 20 clicks 16 clicks 45 clicks 40 clicks 30 clicks 24 clicks 20 clicks 16 clicks 11 mm 48 N/mm (274 lb/in) 51 N/mm (291 lb/in) 54 N/mm (308 lb/in) 57 N/mm (325 lb/in) 60 N/mm (343 lb/in) 260 mm (10.24 in) 8 bar (116 psi) 40 mm (1.57 in) 105 mm (4.13 in) 474 mm (18.66 in) Shock absorber fluid (SAE 2.5)

(50180751S1) ( p. 159)

135

23 TECHNICAL DATA 23.9

Chassis tightening torques

Screw, license plate holder, bot tom Screw, license plate lamp Screw, tail light Spoke nipple, front wheel Remaining nuts, chassis Remaining screws, chassis Screw, additional tail light Screw, brake line holder on bottom triple clamp Screw, foot brake lever stub EJOT EJOT PT K50x18 T20 EJOT PT K60x20 M4.5

M5 M5 M5 M5 M5 Screw, shock absorber adjusting ring Spoke nipple, rear wheel Nut, cable on 12-V battery Nut, cable on starter motor Remaining nuts, chassis Remaining screws, chassis Screw connection, foot brake cylin der Screw connection, voltage regula tor Screw, bottom radiator bracket Screw, cable on starter relay Screw, chain sliding guard M5 M5 M6 M6 M6 M6 M6 M6 M6 M6 M6 M6 Screw, engine guard bracket on engine bearer Screw, front brake disc Screw, rear brake disc M6 M6 Screw, seat lock Screw, steering damper Screw, steering damper bracket Silentblock, air filter box Nut, rear sprocket screw Nut, rim lock Remaining nuts, chassis Remaining screws, chassis Screw, bottom triple clamp Screw, chain sliding piece Screw, connection lever on frame M6 M6 M6 M6 M8 M8 M8 M8 M8 M8 M8 3 Nm (2.2 lbf ft) 1.5 Nm (1.11 lbf ft) 2 Nm (1.5 lbf ft) 5 … 6 Nm (3.7 … 4.4 lbf ft) 5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 2 Nm (1.5 lbf ft) 2 Nm (1.5 lbf ft) 6 Nm (4.4 lbf ft) 5 Nm (3.7 lbf ft)

Loctite ® 243™

5 … 6 Nm (3.7 … 4.4 lbf ft) 5 Nm (3.7 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft) 10 Nm (7.4 lbf ft)

Loctite ® 243™

8 Nm (5.9 lbf ft)

Loctite ® 243™

5 Nm (3.7 lbf ft) 5 Nm (3.7 lbf ft) 6 Nm (4.4 lbf ft)

Loctite ® 243™

15 Nm (11.1 lbf ft) 14 Nm (10.3 lbf ft)

Loctite ® 243™

14 Nm (10.3 lbf ft)

Loctite ® 243™

5 Nm (3.7 lbf ft) 15 Nm (11.1 lbf ft) 15 Nm (11.1 lbf ft) 2 Nm (1.5 lbf ft) 35 Nm (25.8 lbf ft)

Loctite ® 243™

10 Nm (7.4 lbf ft) 30 Nm (22.1 lbf ft) 25 Nm (18.4 lbf ft) 12 Nm (8.9 lbf ft) 15 Nm (11.1 lbf ft) 30 Nm (22.1 lbf ft)

Loctite ® 243™ 136

Screw, engine bearer on frame Screw, engine guard Screw, foot brake lever Screw, fork stub Screw, front brake caliper Screw, front fuel tank Screw, fuel tank bracket Screw, handlebar clamp Screw, license plate holder, top Screw, rear fuel tank, top Screw, steering stem, bottom Screw, top steering stem Screw, top triple clamp Fitting, rear fuel tank M8 M8 M10 Remaining nuts, chassis Remaining screws, chassis Screw connection, engine mount ing bracket Screw connection, shock absorber, bottom Screw connection, shock absorber, top Screw, handlebar support M10 M10 M10 M10 M10 M10 Screw, side stand Banjo bolt Nut, turn signal Nut, angle lever to link fork Nut, linkage lever to angle lever Nut, fork pivot Screw, top steering head Screw, front wheel spindle Nut, rear wheel spindle M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M8 M10 M10x1 M10x1.25

M14x1.5

M14x1.5

M16x1.5

M20x1 M24x1.5

M25x1.5

TECHNICAL DATA 23

35 Nm (25.8 lbf ft)

Loctite ® 243™

25 Nm (18.4 lbf ft) 25 Nm (18.4 lbf ft)

Loctite ® 243™

15 Nm (11.1 lbf ft) 30 Nm (22.1 lbf ft)

Loctite ® 243™

8 Nm (5.9 lbf ft) 15 Nm (11.1 lbf ft) 16 Nm (11.8 lbf ft) 20 Nm (14.8 lbf ft) 25 Nm (18.4 lbf ft)

Loctite ® 243™

25 Nm (18.4 lbf ft)

Loctite ® 243™

20 Nm (14.8 lbf ft)

Loctite ® 243™

17 Nm (12.5 lbf ft) 50 Nm (36.9 lbf ft)

Loctite ® 243™

50 Nm (36.9 lbf ft) 45 Nm (33.2 lbf ft) 45 Nm (33.2 lbf ft)

Loctite ® 243™

45 Nm (33.2 lbf ft)

Loctite ® 243™

45 Nm (33.2 lbf ft)

Loctite ® 243™

40 Nm (29.5 lbf ft)

Loctite ® 243™

35 Nm (25.8 lbf ft) 12 Nm (8.9 lbf ft) 8 Nm (5.9 lbf ft) 100 Nm (73.8 lbf ft) 100 Nm (73.8 lbf ft) 160 Nm (118 lbf ft) 12 Nm (8.9 lbf ft) 40 Nm (29.5 lbf ft) 90 Nm (66.4 lbf ft)

Loctite ® 243™ 137

24 WIRING DIAGRAM 24.1

Page 1 of 10

bu-rd wh-rd 4 3 4 3 30A 1 2 1 2 bl bl bl wh-rd wh-rd bl bl wh-rd br br br 1 1 wh-rd 2 2 wh-rd wh-rd br 4 1 4 1 EY/3 EZ/3 2 3 3 wh-bl 5 wh-bl wh-rd wh-rd , wh-rd 1 4 1 4 br br br-pu 2 3 2 3 wh-bl rd , rd br br br-pu wh-bl 2 2 br br br-pu 6 22 6 22 33 33 A00429-01

138

Components:

M10 Electric starter system K10 Starter relay with main fuse G10 12-V battery C10 T20 G20 K30 Capacitor Voltage regulator Alternator Power relay

WIRING DIAGRAM 24 139

24 WIRING DIAGRAM 24.2

Page 2 of 10

bl-gn 7 7 10A 15 15 rd bl-gn 1 1 2 2 wh-bl bl 1 1 2 2 wh-bl bl 1 1 2 2 br br br ye , ye 6 6 15A 14 14 rd gn-or 2 2 1 1 bu-or br ye 1 1 4 4 gn-or br ye 1 1 4 4 2 2 3 3 bu-or , bu-or bu gn-or 2 2 3 3 gn-or , gn-or gn

140

A00430-01

Components:

F7 Fuse R10 Diode M14 Radiator fan B33 F6 R11 K13 K14 Radiator fan temperature switch Fuse Diode High beam relay Low beam relay

WIRING DIAGRAM 24 141

24 WIRING DIAGRAM 24.3

Page 3 of 10

bl-gn 7 7 10A 15 15 rd bl-gn 1 1 2 2 wh-bl bl 1 1 2 2 wh-bl bl 1 1 2 2 br br br ye , ye 6 6 15A 14 14 rd gn-or 2 2 1 1 bu-or br ye 1 1 4 4 gn-or br ye 1 1 4 4 2 2 3 3 bu-or , bu-or bu gn-or 2 2 3 3 gn-or , gn-or gn 3/10

142

A00431-01

Components:

F8 Fuse K41 Relay for rear fuel pump M12 Rear fuel pump K40 M13 Relay for front fuel pump Front fuel pump

WIRING DIAGRAM 24 143

24 WIRING DIAGRAM 24.4

Page 4 of 10

or br-pu 6 1 4 2 3 1 2 1 2 wh-bu bl-bu bl-rd bl-bu wh-bu br-pu or or br-pu bl-rd bl-bu wh-bu 26 13 14 26 13 14 or 1 1 2 2 bl-gr bl-gr 4 4 or or or 1 1 or bl 3 1 3 1 4 2 4 2 lbu rd-gn lbu rd-gn 9 20 9 20 A00432-01

144

Components:

A11 EFI control unit R30 CAN bus terminating resistor M51 Injection valve B51 Lambda sensor

WIRING DIAGRAM 24 145

24 WIRING DIAGRAM 24.5

Page 5 of 10

bu bl bl 2 2 bu bl 1 1 ye-bl 1 1 wh-pu 1 2 1 2 ye-bu ye-wh bu bl 1 3 1 3 bu bl ye-or 3 2 3 2 ye-or bl bu 4 6 4 3 6 2 2 br-gn bu 1 1 bu ye-or 1 5 2 5 ye-gn bu bl 1 3 1 3 2 2 pu bl 1 1 2 2 rd bu bl 12 17 12 17 ye-bl 21 21 wh-pu 11 11 ye-bu ye-wh 23 24 23 24 br-gn 18 18 ye-or ye-gn pu rd 15 16 27 19 15 16 27 19 A00439-01

146

Components:

B21 Coolant temperature sensor R51 Ignition coil B37 Crankshaft speed sensor B34 B43 B26 B41 B12 Shift shaft sensor Throttle valve position sensor Rollover sensor Induction manifold pressure sensor Intake air temperature sensor

WIRING DIAGRAM 24 147

24 WIRING DIAGRAM 24.6

Page 6 of 10 -X57

NZ/16 bl-gr 1 1 10A 9 9 rd bl-rd 2 2 10A 10 10 rd ye-rd 3 3 5A 11 11 wh-rd gn-rd 4 4 5A 12 12 wh-rd ye-bu , ye-bu 5 5 5A 13 13 rd ye-bu 2 2 wh-gn wh-gn , wh-gn ye-gn 3 3 br-pu gn-gr ye-gr 1 1 1 1 2 1 2 1 br-pu ye-gr bu-gr br-pk bl-br wh-gr wh 5 10 32 28 30 7 5 10 32 28 30 7

-X56

LM/12 A00434-01

148

Components:

F1 Fuse F2 Fuse F3 Fuse F4 F5 B77 P36 B35 Fuse Fuse Rear brake light switch Brake/tail light Oil pressure sensor

WIRING DIAGRAM 24 149

24 WIRING DIAGRAM 24.7

Page 7 of 10

LL/12

-X10

1 2 3 4 1 2 3 4 or pk-br bl-br br-pu br 1 1 2 2 rd-br br 1 1 2 2 rd-pu gr-bu 1 1 gr-bu rd-bu rd-bu br gr-wh 1 3 1 2 4 1 gr-wh 2 3 2 3 pu-gn bu-gn gr-bu rd-bu 1 3 1 2 4 1 bl bl ye-bl gr-wh wh wh 2 2 wh 1 1 or

150

A00435-01

Components:

S55 Map switch P20 Rear fuel level warning lamp P24 Front fuel level warning lamp S56 S21 P31 Fuel pump switch Electric starter button Malfunction indicator lamp

WIRING DIAGRAM 24 151

24 WIRING DIAGRAM 24.8

Page 8 of 10

ye-bu 2 2 ye-bu 2 2 1 1 gr-ye NY/16

-X11

1 1 gr-gn ye-bu 1 1 1 2 1 2 1 2 gn-ye br gn-rd br ye-rd br 2 2 wh-gn br ye-bu , ye-bu ye-bl 2 2

-X81

BA/1 BF/1 1 1 or-bu ye-bu , ye-bu br 2 2 ye 5 5 3 4 6 1 3 4 6 1 rd or-bu, or-bu gn-or gn-ye ye gn-ye bu gn br 1 4 3 2 1 4 3 2 2 2 1 1 ye gn-ye bu gn br br br 2 2 2 2 1 1 br 1 1 br

152

A00436-01

Components:

P26 Indicator lamp for coolant temperature P27 Oil pressure warning lamp X36 Intake air temperature sensor X33 X34 B76 Coolant temperature sensor Rollover sensor Crankshaft speed sensor P23 S29 E11 E12 P35 Induction manifold pressure sensor Light switch, horn button, kill switch Low beam High beam Position light

WIRING DIAGRAM 24 153

24 WIRING DIAGRAM 24.9

Page 9 of 10

1 2 1 2 1 2 bl-gr br bl-gr br bl-gr br 1 2 3 4 br bl-rd bu rd 1 2 rd bu rd ye-bu 1 2 3 1 2 3 rd ye-bu ye-bu 2 2 rd 1 1 rd rd

154

A00437-01

Components:

P15 Horn

WIRING DIAGRAM 24 155

24 WIRING DIAGRAM 24.10

Page 10 of 10

OP/2

-X73 -X74

OL/2 CW/2

-X75

bl-gr , bl-gr bl-gr , bl-gr or 2 2 1 1 bl-gr or 1 1 2 3 2 3 pu bl 1 2 1 2 bl pu br 2 2 1 1 bl br 2 2 1 1 pu br 2 2 1 1 bl br 2 2 1 1 pu br br br 2 2 1 1 bl-gr br br 2 3 2 3 bl-gr 3 3 br br 2 1 2 1 A00438-01

156

K20 S25 P21 P42 P41 P46 P45 E60 Turn signal relay Turn signal switch Turn signal indicator lamp Right front turn signal Left front turn signal Right rear turn signal Left rear turn signal License plate lamp

Cable colors:

bl Black br bu gn Brown Blue Green gr lbu or pk Gray Light blue Orange Pink pu rd wh ye Violet Red White Yellow

WIRING DIAGRAM 24 157

25 SUBSTANCES Brake fluid DOT 4 / DOT 5.1

Standard/classification

– DOT

Guideline

– Use only brake fluid that complies with the specified standard (see specifications on the container) and that exhibits the corresponding properties.

Recommended supplier Castrol

REACT PERFORMANCE DOT 4 MOTOREX ®

Brake Fluid DOT 5.1

Coolant Guideline

– Only use high-grade, silicate-free coolant with corrosion inhibitor additive for aluminum motors. Low grade and unsuitable antifreeze causes corrosion, deposits and frothing.

– Do not use pure water as only coolant is able to meet the requirements needed in terms of corrosion protec tion and lubrication properties.

– Only use coolant that complies with the requirements stated (see specifications on the container) and that has the relevant properties.

Antifreeze protection to at least − 25 °C ( − 13 °F) The mixture ratio must be adjusted to the necessary antifreeze protection. Use distilled water if the coolant needs to be diluted.

The use of premixed coolant is recommended.

Observe the coolant manufacturer specifications for antifreeze protection, dilution and miscibility (compatibility) with other coolants.

Recommended supplier MOTOREX ®

COOLANT M3.0

Engine oil (SAE 10W/50) Standard/classification

JASO T903 MA2 (

SAE ( p. 161) p. 161) (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.

Fully synthetic engine oil

Recommended supplier MOTOREX ®

Cross Power 4T 158

SUBSTANCES 25 Fork oil (SAE 4) (48601166S1) Standard/classification

SAE ( p. 161) (SAE 4)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

Shock absorber fluid (SAE 2.5) (50180751S1) Standard/classification

SAE ( p. 161) (SAE 2.5)

Guideline

– Use only oils that comply with the specified standards (see specifications on the container) and that exhibit the corresponding properties.

Super unleaded (ROZ 95/RON 95/PON 91) Standard/classification

– DIN EN 228 (ROZ 95/RON 95/PON 91)

Guideline

– Only use unleaded super fuel that matches or is equivalent to the specified fuel grade.

– Fuel with an ethanol content of up to 10 % (E10 fuel) is safe to use.

Info

Do

not

use fuel containing methanol (e. g. M15, M85, M100) or more than 10 % ethanol (e. g. E15, E25, E85, E100).

159

26 AUXILIARY SUBSTANCES Air filter cleaner Recommended supplier MOTOREX ®

Racing Bio Dirt Remover Chain cleaner Recommended supplier MOTOREX ®

Chain Clean High viscosity grease Recommended supplier SKF ®

LGHB 2 Long-life grease Recommended supplier MOTOREX ®

Bike Grease 2000 Off-road chain spray Recommended supplier MOTOREX ®

Chainlube Offroad Oil for foam air filter Recommended supplier MOTOREX ®

Racing Bio Liquid Power Preserving materials for paints, metal and rubber Recommended supplier MOTOREX ®

Moto Protect Rubber grip adhesive (00062030051) Recommended supplier

KTM AG –

GRIP GLUE Universal oil spray Recommended supplier MOTOREX ®

Joker 440 Synthetic 160

STANDARDS 27 JASO T903 MA2

Different technical development directions required a separate specification for motorcycles – the

JASO T903 MA2

standard.

Earlier, engine oils from the automobile industry were used for motorcycles because there was no separate motor cycle specification.

Whereas long service intervals are demanded for automobile engines, the focus for motorcycle engines is on high performance at high engine speeds.

In most motorcycle engines, the transmission and clutch are lubricated with the same oil.

The

JASO T903 MA2

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.

161

28 INDEX OF SPECIAL TERMS

OBD On-board diagnosis Vehicle system, which monitors the specified parame ters of the vehicle electronics

162

Art. no.

ca.

cf.

e.g.

etc.

i.a.

no.

poss.

Article number circa compare for example et cetera inter alia number possibly

LIST OF ABBREVIATIONS 29 163

30 LIST OF SYMBOLS 30.1

Red symbols

Red symbols indicate an error condition that requires immediate intervention.

The oil pressure warning lamp lights up red engine.

– The oil pressure is too low. Stop immediately, taking care not to endanger yourself or other road users in the process, and switch off the

30.2

Yellow and orange symbols

Yellow and orange symbols indicate an error condition that requires prompt intervention. Active driving aids are also represented by yellow or orange symbols.

Left fuel level warning lamp lights up orange reached the reserve mark.

– The fuel level of the two front fuel tanks has Malfunction indicator lamp lights up/flashes yellow – The OBD has detected an error in the vehicle electronics. Come safely to a halt, and contact an authorized KTM workshop.

30.3

Green and blue symbols

Green and blue symbols reflect information.

Turn signal indicator lamp flashes green – The turn signal is switched on.

The high beam indicator lamp lights up blue – The high beam is switched on.

164

INDEX

1 12-V battery

charging . . . . . . . . . . . . . . . . . . . . . . . . . 107

installing . . . . . . . . . . . . . . . . . . . . . . . . . 106 removing . . . . . . . . . . . . . . . . . . . . . . . . . 106

A Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Air filter

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 68

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 69

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Air filter box

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Antifreeze

checking . . . . . . . . . . . . . . . . . . . . . . . . . 111

Auxiliary substances

. . . . . . . . . . . . . . . . . . . . . . 9

B Basic chassis setting

checking with rider's weight . . . . . . . . . . . . . 45

Blink code

. . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Brake discs

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Brake fluid

front brake, adding . . . . . . . . . . . . . . . . . . . 89

of rear brake, adding . . . . . . . . . . . . . . . . . . 95

Brake fluid level

front brake, checking . . . . . . . . . . . . . . . . . 89

rear brake, checking . . . . . . . . . . . . . . . . . . 94

Brake linings

front brake, changing . . . . . . . . . . . . . . . . . 91

front brake, checking . . . . . . . . . . . . . . . . . 90

of rear brake, changing . . . . . . . . . . . . . . . . 96 rear brake, checking . . . . . . . . . . . . . . . . . . 96

C Capacities

engine oil . . . . . . . . . . . . . . . . . . . . 120, 132

Chain

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 77

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Chain guide

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Chain tension

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 76 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . 122-123

Clutch

fluid level, checking/correcting . . . . . . . . . . . 81

fluid, changing . . . . . . . . . . . . . . . . . . . . . . 83

Clutch lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

basic position, adjusting . . . . . . . . . . . . . . . 81

Cold start button

. . . . . . . . . . . . . . . . . . . . . . . . 20

Combination instrument

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 25

clock, setting . . . . . . . . . . . . . . . . . . . . . . . 26

kilometers or miles, setting . . . . . . . . . . . . . 24 overview . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Compression damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 51

Coolant

draining . . . . . . . . . . . . . . . . . . . . . . . . . 112

refilling . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Coolant level

checking . . . . . . . . . . . . . . . . . . . . . . 111-112

Cooling system

. . . . . . . . . . . . . . . . . . . . . . . . 111

Customer service

. . . . . . . . . . . . . . . . . . . . . . . . 9

E Electric starter button Emergency OFF switch

. . . . . . . . . . . . . . . . . . . . 16

. . . . . . . . . . . . . . . . . . . . 17

Engine

running in . . . . . . . . . . . . . . . . . . . . . . . . . 37

Engine guard

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Engine guards

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Engine number

. . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine oil

adding . . . . . . . . . . . . . . . . . . . . . . . . . . 121

changing . . . . . . . . . . . . . . . . . . . . . . . . . 117

Engine oil level

checking . . . . . . . . . . . . . . . . . . . . . . . . . 117

Engine sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Environment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

F Fender

front, installing . . . . . . . . . . . . . . . . . . . . . 66 front, removing . . . . . . . . . . . . . . . . . . . . . . 66

Figures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Foot brake lever

. . . . . . . . . . . . . . . . . . . . . . . . 21

free travel, adjusting . . . . . . . . . . . . . . . . . . 94

free travel, checking . . . . . . . . . . . . . . . . . . 93

Fork legs

basic setting, checking . . . . . . . . . . . . . . . . 51

bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 55

dust boots, cleaning . . . . . . . . . . . . . . . . . . 56

165 INDEX

INDEX

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 58

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fork protector

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 57

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Frame

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Front fairing

mounting . . . . . . . . . . . . . . . . . . . . . . . . . 86 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Front left fuel tank

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 73

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Front right fuel tank

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 74

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Front wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 99 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Fuel pump switch Fuel tank

. . . . . . . . . . . . . . . . . . . . . . . 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuel tank filler caps

closing . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

opening . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuel, oils, etc.

. . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fuse

individual power consumers, changing . . . . . 109

main fuse, changing . . . . . . . . . . . . . . . . . 108

H Hand brake lever

. . . . . . . . . . . . . . . . . . . . . . . 15

basic position, adjusting . . . . . . . . . . . . . . . 88

Handlebar position

. . . . . . . . . . . . . . . . . . . . . . 52 adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 52

High-speed compression damping

shock absorber, adjusting . . . . . . . . . . . . . . 46

Horn button

. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

I Idle speed

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 115

Idle speed adjusting screw Implied warranty

. . . . . . . . . . . . . . . . . 20

. . . . . . . . . . . . . . . . . . . . . . . . . 9

Intended use

. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

K Key number Kill switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . 13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

L Light switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Link fork

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Lower triple clamp

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 60

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Low-speed compression damping

shock absorber, adjusting . . . . . . . . . . . . . . 45

M Main fuse

changing . . . . . . . . . . . . . . . . . . . . . . . . . 108

Main silencer

glass fiber yarn filling, changing . . . . . . . . . . 70 installing . . . . . . . . . . . . . . . . . . . . . . . . . . 70

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Manufacturer warranty

. . . . . . . . . . . . . . . . . . . . . 9

Motorcycle

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 122

lift stand, raising with . . . . . . . . . . . . . . . . . 55 lift stand, removing from . . . . . . . . . . . . . . . 55

O Oil filter

changing . . . . . . . . . . . . . . . . . . . . . . . . . 117

Oil screens

cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 117

Overview of indicator lamps Owner's Manual

. . . . . . . . . . . . . . . . 17

. . . . . . . . . . . . . . . . . . . . . . . . . 8

P Preparing for use

advice on preparing for first use . . . . . . . . . . 36

after storage . . . . . . . . . . . . . . . . . . . . . . 125

checks and maintenance when preparing for use 38

Protective clothing

. . . . . . . . . . . . . . . . . . . . . . . 7

R Rear hub damping rubber pieces

checking . . . . . . . . . . . . . . . . . . . . . . . . . 103

Rear sprocket

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Rear wheel

installing . . . . . . . . . . . . . . . . . . . . . . . . . 102

removing . . . . . . . . . . . . . . . . . . . . . . . . . 100

Rebound damping

fork, adjusting . . . . . . . . . . . . . . . . . . . . . . 51

shock absorber, adjusting . . . . . . . . . . . . . . 47

Refueling

fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Riding sag

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 50

166

Rubber grip

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 81

S Safe operation

. . . . . . . . . . . . . . . . . . . . . . . . . . 7

Seat

mounting . . . . . . . . . . . . . . . . . . . . . . . . . 67 removing . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service schedule

. . . . . . . . . . . . . . . . . . . . . 43-44

Shift lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

basic position, adjusting . . . . . . . . . . . . . . 116 basic position, checking . . . . . . . . . . . . . . 116

Shock absorber

compression damping, general . . . . . . . . . . . 45

installing . . . . . . . . . . . . . . . . . . . . . . . . . . 65

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 64

riding sag, checking . . . . . . . . . . . . . . . . . . 48

spring preload, adjusting . . . . . . . . . . . . . . . 49

static sag, checking . . . . . . . . . . . . . . . . . . 48

Shock absorber article number

. . . . . . . . . . . . . . 14

Side cover

mounting . . . . . . . . . . . . . . . . . . . . . . . . . 85

removing . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Side stand Spare parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Spoke tension

checking . . . . . . . . . . . . . . . . . . . . . . . . . 105

Starting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Steering

locking . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 unlocking . . . . . . . . . . . . . . . . . . . . . . . . . 23

Steering head bearing

greasing . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Steering head bearing play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 62 checking . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Steering lock Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . 22

. . . . . . . . . . . . . . . . . . . . . . . . . 124-125

T Technical data

capacities . . . . . . . . . . . . . . . . . . . . . . . . 132

chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 133

chassis tightening torques . . . . . . . . . . . . . 136

electrical system . . . . . . . . . . . . . . . . . . . 134

engine . . . . . . . . . . . . . . . . . . . . . . . . . . 130

engine tightening torques . . . . . . . . . . . . . 131

fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

shock absorber . . . . . . . . . . . . . . . . . . . . . 135

tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Throttle cable play

adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 114 checking . . . . . . . . . . . . . . . . . . . . . . . . . 114

Throttle cable routing

checking . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Throttle grip

. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Tire condition

checking . . . . . . . . . . . . . . . . . . . . . . . . . 103

Tire pressure

checking . . . . . . . . . . . . . . . . . . . . . . . . . 104

Tool set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Transporting

. . . . . . . . . . . . . . . . . . . . . . . . . . 41

Troubleshooting

. . . . . . . . . . . . . . . . . . . . 126-128

Turn signal switch

. . . . . . . . . . . . . . . . . . . . . . . 16

Type label

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

U Use definition

. . . . . . . . . . . . . . . . . . . . . . . . . . 6

V Vehicle identification number

. . . . . . . . . . . . . . . 13

View of vehicle

front left . . . . . . . . . . . . . . . . . . . . . . . . . . 11

rear right . . . . . . . . . . . . . . . . . . . . . . . . . . 12

W Winter operation

checks and maintenance steps . . . . . . . . . . 123

Wiring diagram

Page 1 of 10 . . . . . . . . . . . . . . . . . . . . . . 138

Page 10 of 10 . . . . . . . . . . . . . . . . . . . . . 156

Page 2 of 10 . . . . . . . . . . . . . . . . . . . . . . 140

Page 3 of 10 . . . . . . . . . . . . . . . . . . . . . . 142

Page 4 of 10 . . . . . . . . . . . . . . . . . . . . . . 144

Page 5 of 10 . . . . . . . . . . . . . . . . . . . . . . 146

Page 6 of 10 . . . . . . . . . . . . . . . . . . . . . . 148

Page 7 of 10 . . . . . . . . . . . . . . . . . . . . . . 150

Page 8 of 10 . . . . . . . . . . . . . . . . . . . . . . 152

Page 9 of 10 . . . . . . . . . . . . . . . . . . . . . . 154

Work rules

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

167 INDEX

*3213863en*

3213863en 10/2018

KTM Sportmotorcycle GmbH

5230 Mattighofen/Austria

http://www.ktm.com

Photo: Mitterbauer/KTM

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